Dodge - Grand Caravan - Workshop Manual - 1989 - 1989

Factory Workshop Manual Make Dodge Model Grand Caravan Engine and year V6-181 3.0L SOHC (1989) 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 Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine compartment. The CAB uses the wheel speed information from the wheel speed sensors to control the ABS system function. The CAB also monitors ABS operation and detects system faults. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 7 Electronic Brake Control Module: Description and Operation The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine compartment. The CAB uses the wheel speed information from the wheel speed sensors to control the ABS system function. The CAB also monitors ABS operation and detects system faults. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 8 Electronic Brake Control Module: Service and Repair 1. Turn ignition Off. 2. Remove speed control servo. 3. Disconnect wiring harness 60-way connector from anti-lock brake controller. 4. Remove controller mounting bolts, then the controller. 5. Reverse procedure to install. 6. Torque controller attaching bolts to 40 in. lbs. and electrical connector screw to 105 in. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Lower Instrument Panel Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 17 Cruise Control Module: Testing and Inspection Fig. 5 Engine Controller 60-Way Connector, Shown From Terminal End 1. Set voltmeter to read 12 volts, then connect negative lead to chassis ground. 2. Connect positive lead to pin 7 of module connector then drive vehicle at speeds between 40 - 50 mph. 3. Turn speed control switch to the On position. Voltmeter should read 12 volts. 4. Press and release the speed control Set button. The voltmeter should indicate from 5 - 9 volts and fluctuate 1 - 2 volts at a rapid rate. 5. Speed control system should be performing throttle control at this time, maintaining set speed. If not, replace control module. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > A/C Compressor Clutch Cut-Out Relay Compressor Clutch Relay: Locations A/C Compressor Clutch Cut-Out Relay Engine Compartment Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > A/C Compressor Clutch Cut-Out Relay > Page 23 Compressor Clutch Relay: Locations A/C Wide Open Throttle Cut-Out Relay Engine Compartment Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 24 Compressor Clutch Relay: Description and Operation The A/C clutch relay is connected to the A/C damped pressure switch and the A/C switch. This relay is in the On position during normal engine operation, but is closed when the SMEC senses low idle speeds or wide open throttle conditions, preventing A/C clutch engagement. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Engine Compartment Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations Audible Warning Device Control Module: Locations Center Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Low Fuel Indicator Relay > Component Information > Locations Low Fuel Indicator Relay: Locations Low Fuel Relay The low fuel relay is located on the back of the instrument cluster, behind the message center. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Malfunction Indicator Lamp Driver Module > Component Information > Locations Malfunction Indicator Lamp Driver Module: Locations Upper I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > 4 Speed A/T Backup Lamp Relay: Locations 4 Speed A/T Engine Compartment. The Backup Lamp Relay is located in the right rear corner of the engine compartment, on the side shield. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 47 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 48 Interior Lighting Module: Electrical Diagrams Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 49 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Relay: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 54 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 55 Interior Lighting Relay: Electrical Diagrams Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 56 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Trailer Lighting Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 61 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 62 Trailer Lighting Module: Electrical Diagrams Rear Lighting & Trailer Tow Wiring Circuit SH-68 - Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 63 Rear Lighting & Trailer Tow Wiring Circuit SH-79 - Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 70 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Engine Control Module: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 79 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds Engine Control Module: Customer Interest ECM - Engine Die Out at Low Speeds NO.: 18-11-91 GROUP: DRIVEABILITY DATE: Aug. 26, 1991 SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L & 3.3L Engines MODELS: 1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON (AQ) CHRYSLER'S TC (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY (AY) IMPERIAL/NEW YORKER FIFTH AVENUE THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH >> ARROWS <<. SYMPTOM/CONDITION: Vehicle may exhibit either or both of the following conditions: Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine dies out when throttle is closed. Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM but fail to continue idling. Engine will run normally if throttle is held open. These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on for extended periods of time and only when the ambient temperature is above 40~ F (4~ C). DIAGNOSIS: Connect a DRB II tester to the vehicle diagnostic connector. 1. With the engine at normal operating temperature and with the AC on, record the AIS position while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following repair procedure. PARTS REQUIRED: 1 Single Module Engine Controller (SMEC) 1989 3.0L Engine AS Body, Federal 4639386 AS Body, California 4639001 AC Body, Federal 4639382 AC Body, California 4639384 1990 3.0L Engine >> AS Body, Federal (except Town & Country) 4639422 << >> AS Body, California (except Town & Country) 4639424 << AC & AY Bodies, Federal 4639398 AC & AY Bodies, California 4639400 AQ Body, Federal 4650386 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds > Page 84 AQ Body, California 4650388 >> AS Body, Federal (except Town & Country) 4639386 << >> AS Body, California (except Town & Country) 4639001 << 1990 3.3L Engine AS Body, Federal 4672435 AS Body, California 4672438 AC & AY Bodies, Federal 4672440 AC & AY Bodies, California 4672431 1 Authorized Modification Label 4275086 REPAIR PROCEDURE: This repair involves the replacement of the engine controller with a revised one. 1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS REQUIRED. Figure 1 2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1, and attached near the VECI label. * INSERT PART NUMBER USED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Engine Control Module: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 90 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds Engine Control Module: All Technical Service Bulletins ECM - Engine Die Out at Low Speeds NO.: 18-11-91 GROUP: DRIVEABILITY DATE: Aug. 26, 1991 SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L & 3.3L Engines MODELS: 1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON (AQ) CHRYSLER'S TC (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY (AY) IMPERIAL/NEW YORKER FIFTH AVENUE THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH >> ARROWS <<. SYMPTOM/CONDITION: Vehicle may exhibit either or both of the following conditions: Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine dies out when throttle is closed. Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM but fail to continue idling. Engine will run normally if throttle is held open. These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on for extended periods of time and only when the ambient temperature is above 40~ F (4~ C). DIAGNOSIS: Connect a DRB II tester to the vehicle diagnostic connector. 1. With the engine at normal operating temperature and with the AC on, record the AIS position while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following repair procedure. PARTS REQUIRED: 1 Single Module Engine Controller (SMEC) 1989 3.0L Engine AS Body, Federal 4639386 AS Body, California 4639001 AC Body, Federal 4639382 AC Body, California 4639384 1990 3.0L Engine >> AS Body, Federal (except Town & Country) 4639422 << >> AS Body, California (except Town & Country) 4639424 << AC & AY Bodies, Federal 4639398 AC & AY Bodies, California 4639400 AQ Body, Federal 4650386 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds > Page 95 AQ Body, California 4650388 >> AS Body, Federal (except Town & Country) 4639386 << >> AS Body, California (except Town & Country) 4639001 << 1990 3.3L Engine AS Body, Federal 4672435 AS Body, California 4672438 AC & AY Bodies, Federal 4672440 AC & AY Bodies, California 4672431 1 Authorized Modification Label 4275086 REPAIR PROCEDURE: This repair involves the replacement of the engine controller with a revised one. 1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS REQUIRED. Figure 1 2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1, and attached near the VECI label. * INSERT PART NUMBER USED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations Engine Control Module: Component Locations Single Module Engine Controller The Single Module Engine Controller is located on the front left hand side of the engine compartment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 98 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 101 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 102 Engine Control Module: Connector Views 14-Way Connector (1989 3.0) Single Module Engine Controller Connector(14-Way) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 103 Single Module Engine Controller Connector(60-Way) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 104 60 Way (SMEC) Wiring Connector Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 105 Engine Control Module: Description and Operation Fig. 2 Single Module Engine Controller (SMEC) The SMEC, Fig. 2, is mounted in the engine compartment and contains circuits necessary to energize the ignition coil, fuel injectors and alternator field in order to minimize electrical noise in the passenger compartment. The SMEC contains a voltage converter which converts battery voltage into a regulated 8 volt output to energize the ignition pick up coil. The externally mounted Automatic Shut Down (ASD) relay which interrupts power to the fuel pump, ignition coil and injector when necessary is controlled by the SMEC. The ASD relay is turned on and off by the SMEC in response to distributor reference pulses. When distributor reference pulses are transmitted to the SMEC, the SMEC activates the ASD relay. However, when no reference pulse is transmitted to the SMEC, the ASD relay is deactivated and power is shut off to the fuel control system and ignition coil. The SMEC has been programmed to monitor several different circuits of the fuel injection system in order to provide a self-diagnosis function. In conjunction with the self-diagnosis function, a check engine lamp is wired into the system to indicate a failure in the monitored circuits. The check engine lamp is illuminated for 3 seconds whenever the engine is started as a `bulb test.' However, if the SMEC detects a malfunction in one of the monitored circuits the check engine lamp will be illuminated and will remain on as long as the ignition key remains in the on position. Illumination of the check engine lamp indicates that the system has entered the `limp-in' mode and signals an immediate need for system service. If vehicle performance or the check engine lamp indicate fuel injection system malfunctions, certain procedures should be followed. Prior to suspecting the fuel injection service as the cause for complaints, ensure that the engine and all related systems are in proper operating condition. After checking related systems, inspect fuel injection components and connecting harnesses as outlined in Visual Inspection, repair system as indicated, then road test vehicle to check system operation. If service performed during visual inspection does not correct observed malfunctions, or if check engine lamp remains illuminated, refer to `Obtaining fault codes' to call up fault codes stored in the SMEC memory and correct as needed. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 106 Engine Control Module: Service and Repair 1. Remove air cleaner duct from SMEC. 2. Remove battery. 3. Remove two SMEC mounting screws. 4. Remove SMEC electrical connectors. 5. Remove SMEC. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Relay Locations--next To Battery The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the inner fender. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 111 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions Main Relay (Computer/Fuel System): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions > Page 114 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Page 115 Main Relay (Computer/Fuel System): Description and Operation Relay Locations--next To Battery The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel injectors, and electric fuel pump at all times when the ignition switch is in the START position. When the ignition switch is in the RUN position and the engine control module is receiving reference signals from the distributor, power will also be supplied. If there is no reference signal after two seconds the engine control module will de-energize the ASD and no power will be supplied to the ignition coil, fuel injectors, or electric fuel pump. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay Relay Terminal Identification ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with circuit codes, and color codes, and their function: Circuit No. Terminal No. Color Code Description J1 30 Red Has battery input voltage supplied through fusible link. Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output voltage to fuel pump, O2 sensor, fuel injectors, and coil. K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine Controller (SMEC). The SMEC provides input voltage to relay. K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when distributor signal is present. N/A 87A N/A Not used in these applications. ASD RELAY TEST NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent. Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no scanner is available proceed with the following test. 1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage. If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present proceed to step 2. 2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to the START position and crank the engine. If Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 118 output voltage is present during cranking, the ASD relay is functioning normally and no further testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3. 3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86) wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD relay, and test operation. 4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning, and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14 (terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists replace and ASD relay and test operation. 5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58 of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Polarity Protection Relay, ECM > Component Information > Locations Polarity Protection Relay: Locations Relay Identification The ASD relay is found on the left inner fender apron near the left strut tower and the diagnostic connector. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Engine Compartment Components This vehicle utilizes the Automatic Shutdown (ASD) Relay to control the Fuel Pump operation. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Relay Locations--next To Battery The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the inner fender. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 130 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions Main Relay (Computer/Fuel System): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions > Page 133 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Page 134 Main Relay (Computer/Fuel System): Description and Operation Relay Locations--next To Battery The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel injectors, and electric fuel pump at all times when the ignition switch is in the START position. When the ignition switch is in the RUN position and the engine control module is receiving reference signals from the distributor, power will also be supplied. If there is no reference signal after two seconds the engine control module will de-energize the ASD and no power will be supplied to the ignition coil, fuel injectors, or electric fuel pump. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay Relay Terminal Identification ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with circuit codes, and color codes, and their function: Circuit No. Terminal No. Color Code Description J1 30 Red Has battery input voltage supplied through fusible link. Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output voltage to fuel pump, O2 sensor, fuel injectors, and coil. K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine Controller (SMEC). The SMEC provides input voltage to relay. K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when distributor signal is present. N/A 87A N/A Not used in these applications. ASD RELAY TEST NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent. Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no scanner is available proceed with the following test. 1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage. If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present proceed to step 2. 2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to the START position and crank the engine. If Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 137 output voltage is present during cranking, the ASD relay is functioning normally and no further testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3. 3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86) wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD relay, and test operation. 4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning, and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14 (terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists replace and ASD relay and test operation. 5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58 of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 143 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Fig. 45 Airbag system diagnostic module Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Engine Compartment & Front End Components. On Left Fenderwell Applicable to: 4-153/2.5L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 152 Engine Compartment Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 153 Engine Compartment & Transaxle Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 164 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 165 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 166 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 167 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 168 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 169 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift Control Module: Customer Interest A/T - 41TE Harsh 2nd - 1st Gear Downshift NO.: 21-16-93 Rev. A GROUP: Transmission DATE: Oct 8, 1993 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED. CHANGES ARE HIGHLIGHTED BY **ASTERISKS**. MODELS: 1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue 1992 (AP) Shadow/Sundance SYMPTOM/CONDITION: Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service Manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > 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: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 174 TIME ALLOWANCE: Labor Operation No. **08-19-05-99** 0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift Control Module: Customer Interest A/T - 41TE Harsh 2-1 Gear Downshift NO.: 21-16-92 GROUP: Transmission DATE: Nov. 2, 1992 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle MODELS: 1989-1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990-1992 (AY) Imperial/New Yorker Fifth Avenue SYMPTOM/CONDITION: Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 179 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting Control Module: Customer Interest A/T - A604 Excessive Upshifting/Downshifting Models 1989-90 AA, AC, AG, AJ, AS, & AY Bodies Subject A-604 Transmission Excessive Upshifting/ Downshifting Index TRANSMISSION Date April 9, 1990 No. 21-12-90 (C21-06-0) P-1042 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY AY - IMPERIAL/NEW YORKER FIFTH AVENUE SYMPTOM/CONDITION Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition when the vehicle is fully loaded, driving up a grade or into a head wind. This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior (1989) model year A-604 controllers. A new A-604 controller, PN 4557585, entered production late March 1990. The new controller allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle torque load changes. DIAGNOSIS Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does not apply. Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain Diagnostic Procedure Manual. If no fault codes are present, perform the following repair procedure. If fault codes are present, they must be corrected and the corrections verified before performing the following repair procedure. PARTS REQUIRED 1. 1 - Controller PN 4557585 REPAIR PROCEDURE This repair involves the replacement of the transaxle controller. 1. Disconnect the negative battery cable. 2. Disconnect the 60-way connector from the controller. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > 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: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 184 3. Remove the controller. 4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds. 5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds. 6. Reconnect the negative battery cable. 7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-05-96 0.6 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 190 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 191 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 192 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 193 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 194 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 195 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2nd - 1st Gear Downshift NO.: 21-16-93 Rev. A GROUP: Transmission DATE: Oct 8, 1993 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED. CHANGES ARE HIGHLIGHTED BY **ASTERISKS**. MODELS: 1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue 1992 (AP) Shadow/Sundance SYMPTOM/CONDITION: Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service Manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 200 TIME ALLOWANCE: Labor Operation No. **08-19-05-99** 0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2-1 Gear Downshift NO.: 21-16-92 GROUP: Transmission DATE: Nov. 2, 1992 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle MODELS: 1989-1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990-1992 (AY) Imperial/New Yorker Fifth Avenue SYMPTOM/CONDITION: Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 205 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting Control Module: All Technical Service Bulletins A/T - A604 Excessive Upshifting/Downshifting Models 1989-90 AA, AC, AG, AJ, AS, & AY Bodies Subject A-604 Transmission Excessive Upshifting/ Downshifting Index TRANSMISSION Date April 9, 1990 No. 21-12-90 (C21-06-0) P-1042 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY AY - IMPERIAL/NEW YORKER FIFTH AVENUE SYMPTOM/CONDITION Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition when the vehicle is fully loaded, driving up a grade or into a head wind. This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior (1989) model year A-604 controllers. A new A-604 controller, PN 4557585, entered production late March 1990. The new controller allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle torque load changes. DIAGNOSIS Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does not apply. Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain Diagnostic Procedure Manual. If no fault codes are present, perform the following repair procedure. If fault codes are present, they must be corrected and the corrections verified before performing the following repair procedure. PARTS REQUIRED 1. 1 - Controller PN 4557585 REPAIR PROCEDURE This repair involves the replacement of the transaxle controller. 1. Disconnect the negative battery cable. 2. Disconnect the 60-way connector from the controller. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > 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: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 210 3. Remove the controller. 4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds. 5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds. 6. Reconnect the negative battery cable. 7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-05-96 0.6 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision Technical Service Bulletin # 210889 Date: 890403 A/T Reaction Shaft Support - Revision Models 1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle Subject Revised Reaction Shaft Support Index TRANSMISSION Date April 3, 1989 No. 21-08-89 P-1408 (C21-16-9) Description BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER SYMPTOM/CONDITION NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE AUTOMATIC TRANSAXLE, PART NUMBER 4446659. The procedure outlined in this bulletin should be followed if removal and disassembly of the transaxle is required. DIAGNOSIS 1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual (#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A) to determine if disassembly is required. Use the following procedure when the transaxle is disassembled for repair. PARTS REQUIRED 1 Repair package P/N 4549248 1 Gasket Package P/N 4504558 1 Controller (AS REQUIRED) P/N 5234678 NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT CLUTCH HUB IS REQUIRED. Input Clutch Retainer P/N 4431609 REPAIR PROCEDURE 1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the following guidelines. 2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or subsequent) controller. Always check input shaft end play before disassembling the transaxle. Step A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 215 FIGURE 1 - FRONT PUMP REACTION SHAFT 1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves, replace it with the four ring reaction support supplied in the repair package (Figure 1). If the reaction support that is removed from the transaxle has four ring grooves, the repair package is not needed. Step B FIGURE 2 - INPUT CLUTCH RETAINER 1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer as shown. If the bump is present, replace the retainer with a new one (P/N 4431609). 2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package. When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the compression of the Orings. 3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is no difference in any of the O-rings. The color was added to facilitate assembly. 4. Inspect and replace any distressed (burned) clutch components as required. Step C 1. Remove and discard the steel separator plate from the valve body. 2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow to the overdrive clutch circuit. Step D Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 216 1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play to the service preferred setting of .005" to .015". The actual total end play specification is .005" to .025" and is acceptable if the service preferred setting cannot be obtained. Other Recommendations 1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not use other kinds of petroleum based greases such as chassis grease that could plug critical orifices or might be incompatible with transmission fluid. 2. Replace the torque convertor if a clutch failure has occurred. 3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY. Replace it if necessary. 4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has occurred. 5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be used if ATF Plus is not available. POLICY: Reimbursable within the limits of the warranty. TIME ALLOWANCE: Labor Operation No. 21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs. FAILURE CODE: 7H - Reaction shaft/supt. assy. failed Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 217 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision Technical Service Bulletin # 210889 Date: 890403 A/T Reaction Shaft Support - Revision Models 1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle Subject Revised Reaction Shaft Support Index TRANSMISSION Date April 3, 1989 No. 21-08-89 P-1408 (C21-16-9) Description BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER SYMPTOM/CONDITION NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE AUTOMATIC TRANSAXLE, PART NUMBER 4446659. The procedure outlined in this bulletin should be followed if removal and disassembly of the transaxle is required. DIAGNOSIS 1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual (#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A) to determine if disassembly is required. Use the following procedure when the transaxle is disassembled for repair. PARTS REQUIRED 1 Repair package P/N 4549248 1 Gasket Package P/N 4504558 1 Controller (AS REQUIRED) P/N 5234678 NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT CLUTCH HUB IS REQUIRED. Input Clutch Retainer P/N 4431609 REPAIR PROCEDURE 1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the following guidelines. 2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or subsequent) controller. Always check input shaft end play before disassembling the transaxle. Step A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 223 FIGURE 1 - FRONT PUMP REACTION SHAFT 1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves, replace it with the four ring reaction support supplied in the repair package (Figure 1). If the reaction support that is removed from the transaxle has four ring grooves, the repair package is not needed. Step B FIGURE 2 - INPUT CLUTCH RETAINER 1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer as shown. If the bump is present, replace the retainer with a new one (P/N 4431609). 2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package. When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the compression of the Orings. 3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is no difference in any of the O-rings. The color was added to facilitate assembly. 4. Inspect and replace any distressed (burned) clutch components as required. Step C 1. Remove and discard the steel separator plate from the valve body. 2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow to the overdrive clutch circuit. Step D Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 224 1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play to the service preferred setting of .005" to .015". The actual total end play specification is .005" to .025" and is acceptable if the service preferred setting cannot be obtained. Other Recommendations 1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not use other kinds of petroleum based greases such as chassis grease that could plug critical orifices or might be incompatible with transmission fluid. 2. Replace the torque convertor if a clutch failure has occurred. 3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY. Replace it if necessary. 4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has occurred. 5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be used if ATF Plus is not available. POLICY: Reimbursable within the limits of the warranty. TIME ALLOWANCE: Labor Operation No. 21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs. FAILURE CODE: 7H - Reaction shaft/supt. assy. failed Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 225 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 228 Control Module: Locations Power Distribution Center Power Distribution Center Fuse Block Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 229 Control Module: Diagrams Part 1 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 230 Part 2 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 231 Part 3 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 232 Part 4 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 233 Part 5 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 234 Part 6 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 235 Part 7 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 236 Part 8 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 237 Part 9 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 238 Part 10 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 239 Part 11 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 Control Module: Description and Operation A604 DESCRIPTION This computer is dedicated to the control of the A-604 Transaxle. It has a connector shaped similarly to the one on the Engine Controller. It contains on-board diagnostics and fault code memory which is accessed by the DRBII Diagnostic Tool through Chrysler's C2D Bus. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 > Page 242 Control Module: Description and Operation 41TE Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 > Page 243 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 - Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 246 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 250 Back Up Lamp Relay / Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 251 Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 252 Transmission Control System Relay: Description and Operation DESCRIPTION This relay is operated by the A-604 controller. Its purpose is to make operating voltage available to the solenoids and switches located in the Solenoid Pack. When the Controller opens the relay, voltage is taken away from the solenoids and the transmission goes into a limp-in mode. While in this mode, only second gear, reverse and neutral are available. This relay may also be referred to as the Safety Shutdown Relay. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations Transmission Position Relay: Component Locations Back Up Lamp Relay / Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page 257 Back Up Lamp Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations I/P, Cowl & Steering Column Components Center Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Front Door Components In Front Door Armrest Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Sliding Door Circuit Test Power Door Lock Switch: Testing and Inspection Sliding Door Circuit Test Sliding Side Door Power Lock Assembly 1. Connect one lead of a test light to the upper contact of the pillar, and place the other lead to the lower contact. 2. If the test light illuminates when the lock switch is depressed, the wiring circuit to the contacts is good. If the test light does not illuminate, check the electrical connectors at the right side cowl, check for a broken wire, or see Circuit Breaker Test. 3. With the sliding door partially open, connect jumper wires across contacts on pillar to contacts on the door. The door should lock or unlock when Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 269 these jumper wires are connected and the switch is depressed. 4. If the door locks and unlocks, the problem is in the door and pillar contacts (check for proper shim at the door contact plate). If lock and unlock does not occur, remove trim panel and check for voltage at the lock motor. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 270 Power Door Lock Switch: Testing and Inspection Switch Voltage Test NOTE: The following test determines whether voltage is continuous through the wiring harness to the power door lock switch. 1. Remove the door lock switch from the door trim panel. 2. Separate the multiple terminal block on the wiring harness from the door lock switch. 3. Connect one lead of a test light to the black wire terminal and the other lead to the red wire terminal. If the test light illuminates, the wiring circuit between the battery and switch is functioning properly. If the test light does not illuminate, check the 30 amp main fuse (circuit breaker) or check for an open in the wiring harness. 4. If the wiring circuit is functioning properly, See: Body and Frame/Locks/Power Locks/Power Door Lock Actuator/Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 271 Power Door Lock Switch: Testing and Inspection Door Lock Switch Test Door Lock Switch Continuity Remove each door lock switch from the door trim panel. Connect an ohmmeter to the switch and check that there is continuity in lock and unlock positions (refer to the image shown). If these results are not obtained, replace the switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Page 272 Power Door Lock Switch: Service and Repair 1. Pry up rear of switch bezel releasing it from clips. Pull bezel out of door trim. 2. Disconnect wiring harness. 3. Remove switch screws and switch. 4. Reverse removal sequence to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Front Door Components In Center Of Door Panel Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations Power Seat Components Outboard Side Of Seat Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations Power Trunk / Liftgate Lock Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Lower I/P Components Center Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Front Body Components Front Center Of Headliner Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Brake Fluid Pressure Sensor/Switch: Locations Engine Compartment Components. LH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 295 Engine Compartment & Transaxle Components. LH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 296 Brake Fluid Pressure Sensor/Switch: Description and Operation The switch activates a light on the dash panel to indicate that one of the hydraulic systems has failed. There are two basic types of switches. In some earlier models, as pressure falls in one system, the normal pressure of the other system forces the piston to the inoperative side where it contacts the switch terminal, causing the warning lights to illuminate. On most models, the brake warning switch is of the latching type. If a pressure loss occurs in one side of the system, the piston in the valve is forced toward the failed side where it latches in position and illuminates the warning light. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations I/P, Cowl & Steering Column Components LH Kickpanel On Park Brake Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations Wheel Speed Sensor: Locations The wheel speed sensors are located at each wheel and transmit wheel speed information to the Controller Anti-Lock Brake. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 303 Wheel Speed Sensor: Description and Operation The wheel speed sensors are located at each wheel and transmit wheel speed information to the Controller Anti-Lock Brake (CAB). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Fig. 66 Front Speed Sensor Assembly 1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove screw from clip that retains sensor wiring grommet, then pull sensor grommet from fenderwell. 3. Disconnect electrical connector, then remove two screws retaining sensor wiring routing tube. 4. Remove sensor head screw, then the sensor head from steering knuckle. CAUTION: If sensor head is seized, use a punch and gently rock sensor back and forth until free. Do not use pliers on sensor head. 5. Reverse procedure to install. Coat sensor with suitable high temperature E.P. grease and Torque mounting bolt to 60 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 306 Wheel Speed Sensor: Service and Repair Rear 1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove sensor wiring grommet retainer bracket, then pull sensor grommet from underbody. 3. Disconnect electrical connector, then remove wiring to frame rail attaching bracket. 4. Remove rear axle U-bolt nuts, then the sensor assembly mounting bracket. 5. Remove sensor head screw, then the sensor head from steering knuckle. If sensor head is seized, use a punch and gently rock sensor back and forth until free. Do not use pliers on sensor head. 6. Reverse procedure to install. Torque sensor mounting bolt to 60 inch lbs. and U-bolt nuts to 65 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Top RH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 314 Engine Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 315 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 5 Coolant & charge temperature sensors The coolant temperature sensor, Fig. 5, is mounted in the thermostat housing and allows the SMEC to monitor engine operating temperature in order to provide proper air/fuel mixtures. The sensor provides a variable resistance which is proportional to coolant temperature. When the engine is cold and sensor resistance is low, the SMEC provides richer air/fuel mixtures and increases engine idle speed to provide acceptable cold engine performance and allow quick warm up. When coolant temperature and sensor resistance increase, the SMEC provides leaner air/fuel mixtures and lowers engine idle speed to provide proper exhaust emission control and increased fuel economy. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Top RH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions Temperature Sensor (Gauge): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 321 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 322 Oil Pressure & Temperature System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 323 Temperature Sensor (Gauge): Testing and Inspection When a malfunction occurs with a cluster gauge, before disassembling the cluster to check the gauge, check for a defective sending unit or wiring as follows: 1. Ground sending unit connector leads, at the sending unit, in the vehicle. 2. With ignition in On position, a grounded input will cause the fuel or temperature gauge to read maximum or above. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection 1. Disconnect six cavity connector from stop lamp switch pigtail. 2. Using an ohmmeter, check continuity at switch side of connector. 3. With brake pedal released, there should be continuity between the dark blue/red and yellow/red wires, and between white/pink and white wires. There should be no continuity between pink and white wires. 4. With brake pedal depressed, there should be continuity between pink and white wires. There should be no continuity between the dark blue/red and yellow/red wires, or between white/pink and white wires. 5. If the above results are not obtained the stop lamp switch is defective or out of adjustment. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Clutch Switch: Locations I/P, Cowl & Steering Column Components Top Of Clutch Pedal Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations I/P, Cowl & Steering Column Components Top Of Brake pedal Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 334 Cruise Control Switch: Testing and Inspection Fig. 6 Speed Control Continuity Chart. 1988-90 Rear Wheel Drive Models Fig. 7 Speed Control Continuity Chart. 1988-90 Front Wheel Drive Models Fig. 8 Speed Control Connector Terminal Identification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 335 Fig. 9 Speed Control Continuity Chart. 1991 Models 1. Disconnect the blade type four wire electrical connector from base of steering column. 2. Using a continuity tester, or an ohmmeter, check for continuity at connector wires. Do not use a test light. 3. Results should be obtained according to the charts. If these results are not obtained, replace switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 336 Cruise Control Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove lower steering column cover. 3. Remove four plastic retaining clips from underside of steering column, then the trough. 4. Disconnect speed control switch electrical connector from instrument panel harness connector. 5. Remove wiper control knob from end of turn signal lever, then the silencer from lever. 6. Remove two screws attaching speed control switch to column. 7. On tilt columns, remove steering wheel, then attach a flexible guide wire to lower end of speed control switch harness. 8. Remove switch and harness from column by gently pulling wires through lock housing between lock plate and side of housing. 9. On standard columns, remove attaching screws and the upper steering lock housing cover, then pull harness up through column. 10. On tilt columns, insert harness connector through turn signal lever opening in column, then pull upward through upper housing. 11. Attach guide wire to switch wiring harness, then gently pull downward through column opening, between lock plate and side of housing. 12. On standard columns, insert harness and connector through turn signal lever opening in column, then pull down and out lower end. 13. On all models, remove slack from all wires. 14. On tilt column, remove guide wires. 15. On all models, install wiring trough with plastic clips. 16. Connect speed control switch electrical connector to instrument panel harness connector. 17. Secure speed control switch to column with two screws. 18. Position silencer on lever, then push wiper control knob in place on end of lever. 19. On tilt columns, replace steering wheel. 20. On standard columns, install upper steering column lock housing cover. 21. On all models, install lower steering column cover. 22. Connect battery ground cable, then test operation of speed control. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 345 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 351 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Lower LH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 358 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 359 Oil Pressure & Temperature System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations Air Conditioning Switch: Locations Lower I/P Components Center Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Front End Components Behind Center Of Grill Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations Engine Components. A/C High Pressure Switch located at rear Of A/C Clutch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Engine Compartment Components. RH Rear Corner Of Engine Compartment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Dome Lamp Switch Door Switch: Locations Dome Lamp Switch Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Dome Lamp Switch > Page 379 Door Switch: Locations Door Ajar Switches Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Top Of Fuel Tank Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 383 Fuel Gauge Sender: Testing and Inspection Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by clamps, check to see whether the insulation has been severed thereby grounding the wire. In the case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of the tank unit. 1. Disconnect wiring from fuel tank sending unit. 2. Connect wiring to a known good sending unit. 3. Connect a jumper wire between sending unit pick up tube and ground. Fuel Tank Sending Unit (Typical) 4. Check fuel gauge as follows: Allow at least two minutes for gauge to settle at each test point. a. Move and clip float arm to its empty stop and turn ignition to the On position, gauge should read Empty or below. b. Move and clip float arm to the Full position, gauge should read Full or above. 5. If gauge does not meet specifications, check the following items for possible malfunction: a. Wiring and connections between gauge sending unit and multiple connector behind left kick panel. b. Wiring and connections between multiple connector and printed circuit board terminals. c. Circuit continuity between printed circuit board terminals and gauge terminals. If the above items are satisfactory, the gauge is defective and must be replaced. 6. If fuel gauge meets specifications check original fuel tank sending unit as follows: a. Remove fuel tank sending unit from fuel tank and connect a jumper wire between sending unit pick up tube and ground. 7. Repeat step 4. 8. If fuel gauge is now within specifications, check the following as possible cause: a. Ground wire from sending unit to left side cowl for continuity. b. Sending unit deformed. Ensure float arm moves freely and pick up tube is not bent. c. Inspect float. d. Sending unit improperly installed. Install correctly. e. Mounting flange on fuel tank for sending unit deformed. f. Fuel tank bottom deformed causing improper positioning of pick-up tube. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations I/P, Cowl & Steering Column Components LH Kickpanel On Park Brake Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > 3 Speed A/T Backup Lamp Switch: Locations 3 Speed A/T Neutral/Park Safety Switch Neutral Starting And Back-Up Lamp Switch The neutral starting switch is the center terminal of the 3 terminal switch. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 394 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 395 Backup Lamp Switch: Electrical Diagrams 3 Speed A/T Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at the vehicle level. See: Diagrams/Electrical Diagrams 4 Speed A/T Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 396 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 397 Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at the vehicle level. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > 3 Speed A/T Backup Lamp Switch: Description and Operation 3 Speed A/T Neutral Starting And Back-Up Lamp Switch The neutral starting switch is the center terminal of the 3 terminal switch. - It provides ground for the starter solenoid circuit through the selector lever in only Park and Neutral positions. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Testing and Inspection > 3 Speed A/T Backup Lamp Switch: Testing and Inspection 3 Speed A/T Neutral Starting And Back-Up Lamp Switch Replacement And Test 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in Park or Neutral. 2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to Park and then to Neutral positions, and inspect to see that the switch operating lever fingers are centered in switch opening in the case. 4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 8. Continuity should exist only with transaxle in Reverse position. 9. No continuity should exist from either pin to the case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > 3 Speed A/T Backup Lamp Switch: Service and Repair 3 Speed A/T Neutral Starting And Back-Up Lamp Switch Replacement And Test 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in Park or Neutral. 2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to Park and then to Neutral positions, and inspect to see that the switch operating lever fingers are centered in switch opening in the case. 4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 8. Continuity should exist only with transaxle in Reverse position. 9. No continuity should exist from either pin to the case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations I/P, Cowl & Steering Column Components Top Of Brake pedal Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Light Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 409 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 410 Speed Control & Stop Lamp Switch Wiring Circuit SH-25 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 411 Brake Light Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect stop light switch electrical connector, then remove switch assembly. 3. Install new switch and connect switch electrical connector. If adjustment of switch is required, proceed as follows: a. Push switch forward until fully seated. This will move brake pedal slightly forward. b. Pull back on brake pedal until it will go back no further. This will cause switch to ratchet backward into correct position. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Dome Lamp Switch > Component Information > Locations Dome Lamp Switch: Locations Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Dome Lamp Switch Door Switch: Locations Dome Lamp Switch Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Dome Lamp Switch > Page 419 Door Switch: Locations Door Ajar Switches Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair Hazard Warning Switch: Service and Repair 1. If equipped, disarm airbag system refer to MAINTENANCE PROCEDURES. 2. Remove steering wheel. Steering column cover, silencer & reinforcement removal 3. Remove steering column cover and silencer. 4. Remove shift indicator operating cable from slot in shift housing. 5. Pry off wiring trough from steering column, then disconnect control lever electrical connectors. 6. On models equipped with standard column, proceed as follows: a. Remove screws attaching turn signal lever cover to lock housing, then lever cover. b. Remove washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch. e. Remove turn signal/hazard switch attaching screws. 7. On models equipped with tilt column, proceed as follows: a. Remove tilt lever, then hazard warning knob. Push knob in and unscrew to remove. b. Remove ignition key lamp assembly, then knob off washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch. Lock plate removal. Models w/tilt column e. Depress lock plate using lock plate compressor No. C-4156 or equivalent and pry retaining ring out of groove with a suitable screwdriver. The full load of upper bearing spring should not be relieved. If full load is relieved, retaining ring will turn too easily and make removal difficult. f. Remove lock plate, cancelling cam and upper bearing spring. g. Remove turn signal/hazard switch actuator screws and arm. h. Remove turn signal/hazard switch attaching screws, Place shift bowl in Low position. Turn signal switch replacement Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Page 423 8. On all models, remove turn signal/hazard warning switch assembly by gently pulling switch up from column while straightening and guiding wires up through column opening. 9. Reverse procedure to install. Rearm airbag system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations I/P, Cowl & Steering Column Components Top Of Steering Column Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 429 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 430 Headlamp Dimmer Switch: Electrical Diagrams Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 431 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 432 Headlamp Dimmer Switch: Service and Repair Dimmer switch replacement 1. Disconnect battery ground cable. 2. Remove left lower instrument panel cover, then tape dimmer switch rod to steering column to prevent rod from falling out of notch in actuator lever. 3. Remove switch to column attaching screws. 4. Disconnect switch electrical connector, then remove switch from steering column. 5. Reverse procedure to install. During installation, gently push up on switch to take up slack on rod. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 438 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 439 Headlamp Switch: Electrical Diagrams Headlamp Switch & Horn System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 440 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 441 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 442 Headlamp Switch: Service and Repair Headlamp switch removal 1. Disconnect battery ground cable. 2. Remove headlight and accessory switch trim bezel. 3. Remove four screws attaching switch plate to lower panel. 4. Pull switch assembly rearward, then disconnect switch electrical connectors. 5. Remove switch knob and stem by depressing button on switch. 6. Remove two headlight switch plate to switch plate assembly attaching screws, then the headlight switch retainer and switch. 7. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > Turn Signal Switch - Canceling Pin Indexing Turn Signal Switch: Technical Service Bulletins Turn Signal Switch - Canceling Pin Indexing Models 1988 & 1989 AA-, AB-, AC-, AD-, AG-, AH-, AJ-, AK-, AL-, AM-, AN-, & AP-Body Equipped With Non-tilt Steering Column Subject Turn Signal Switch Canceling Index ELECTRICAL Date January 30, 1989 No. 08-03-89 P-196 (C08-03-9) BODY CODE LEGEND AA - Spirit/Acclaim AK - Aries/Reliant AB - Dodge Ram/Van Wagon AL - Omni/Horizon AC - Dynasty/New Yorker/Landau AM - Diplomat/Gran Fury/ AD - Dodge Ram Pickup/ Fifth Avenue Ramcharger Sport Utility AN - Dodge Dakota/ AG - Daytona Dakota/Sport AH - Lancer/LeBaron GTS AP - Shadow/Sundance AJ - Lebaron SYMPTOM/CONDITION Turn signals do not cancel properly after the steering wheel has been removed and reinstalled. REPAIR PROCEDURE Anytime the steering wheel is removed and replaced on nontilt columns, there is the possibility that the turn signals will not cancel properly until the pin in the steering wheel is properly indexed with respect to the turn signal switch. The following procedure should be used to ensure the turn signal cancel feature operates correctly. 1. Engage the turn signal lever in either the right turn or the left turn position. 2. While holding the turn signal lever to prevent movement, rotate the steering wheel two complete turns (or until the wheel stops) in the direction opposite the direction of the turn signal lever. Example: If the turn signal lever is moved downward to the left, rotate the steering wheel to the right. If the turn signal lever was moved upward to the right, then rotate the steering wheel to the left. 3. Release the turn signal lever and then return the steering wheel to the straight ahead position. 4. To check for proper canceling operation, engage the turn signal lever and then turn the steering wheel at least one-half revolution in the same direction in which the turn signal switch is engaged. 5. Return the steering wheel to the straight ahead position. The turn signal switch should cancel at this time. 6. Repeat Steps 4 and 5 to check the cancel feature in the opposite direction. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > Page 447 Turn Signal Switch: Service and Repair Turn Signal/Hazard Warning Switch 1. If equipped, disarm airbag system refer to MAINTENANCE PROCEDURES. 2. Remove steering wheel. Steering column cover, silencer & reinforcement removal 3. Remove steering column cover and silencer. 4. Remove shift indicator operating cable from slot in shift housing. 5. Pry off wiring trough from steering column, then disconnect control lever electrical connectors. 6. On models equipped with standard column, proceed as follows: a. Remove screws attaching turn signal lever cover to lock housing, then lever cover. b. Remove washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch. e. Remove turn signal/hazard switch attaching screws. 7. On models equipped with tilt column, proceed as follows: a. Remove tilt lever, then hazard warning knob. Push knob in and unscrew to remove. b. Remove ignition key lamp assembly, then knob off washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch. Lock plate removal. Models w/tilt column e. Depress lock plate using lock plate compressor No. C-4156 or equivalent and pry retaining ring out of groove with a suitable screwdriver. The full load of upper bearing spring should not be relieved. If full load is relieved, retaining ring will turn too easily and make removal difficult. f. Remove lock plate, cancelling cam and upper bearing spring. g. Remove turn signal/hazard switch actuator screws and arm. h. Remove turn signal/hazard switch attaching screws, Place shift bowl in Low position. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > Page 448 Turn signal switch replacement 8. On all models, remove turn signal/hazard warning switch assembly by gently pulling switch up from column while straightening and guiding wires up through column opening. 9. Reverse procedure to install. Rearm airbag system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Absolute Pressure Sensor: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 459 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 Absolute Pressure Sensor: Customer Interest Check Engine Lamp Comes On and Fault Code 13 NO.: 18-09-91 GROUP: DRIVEABILITY DATE: Sept. 23, 1991 SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine MODELS: 1989 (AA) SPIRIT/ACCLAIM 1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON 1989 (AG) DAYTONA 1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE 1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER SYMPTOM/CONDITION: The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic Change" is set into the diagnostic system. DIAGNOSIS: Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the diagnostic manual to verify that the MAP sensor is operating properly. PARTS REQUIRED: 1 MAP Sensor Relocation Package 4638458 Package Contents: 1 Cap Plug (1987-88 vehicles) 3580172 1 Cap Plug (1989 vehicles) 4241618 1 Purge Jumper Assembly 4669038 Consisting of: 1 In-Line Vacuum Connector 4201275 1 Vacuum Tee 33000227 1 11" Vacuum Hose 4104272 1 Bleed/Hose Assembly 4669042 Consisting of: 1 Vent 53007494 1 1" Vacuum Hose 4713956 1 Vacuum Tee 4669041 2 Vacuum Hose With 90 Degree Bend 4669044 1 Bracket 4686013 1 Wiring Harness 4687141 5 Tie Wraps 6015756 REPAIR PROCEDURE: This repair involves relocation of the MAP sensor. 1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable. 2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its present location. 3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug (3580172 for 1987 and 1988 vehicles or 4241618 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 464 for 1989 vehicles) in its place. 4. Loosen clamps and remove throttle body/air filter intake hose. 5. Wiring Harness Installation Procedure: If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted on the right side shock tower or on the bulkhead follow Step B. A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor connector. Route the harness along the backside of the intake manifold toward the throttle body. The harness should be secured to the fuel line and to the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps. B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length. Connect the FEMALE end of the harness to the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the harness to the right side of the motor mount and the two rear engine wiring support brackets. Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the supplied tie wraps. 6. Attach original MAP sensor to the bracket (4686013) supplied in the package. Figure 1 7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to slide over throttle body stud. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 465 Figure 2 8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque nut to 25 N-m (225 in.lbs.). 9. Disconnect the intake manifold end of the formed purge hose that extends from the intake manifold nipple to the "F" shaped connector (Figure 2). Figure 3 10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to nipple on intake manifold. Position the MAP bleed valve as close to vertical as possible. Figure 4 11. Cut the existing PVC hose as shown in Figure 2. 12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the formed purge hose (disconnected in Step 9) and the PVC hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed purge hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 466 Figure 5 NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE IT OVER THE TOP OF THROTTLE LINKAGE. 13. Connect vacuum hose to MAP sensor. 14. Connect wiring harness connector to MAP sensor. 15. Install throttle body/air filter intake hose and tighten clamps. 16. Use the DRB II to erase any fault codes and perform the applicable verification tests. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-14-15-94 . . . . . . . . . . . . . . . . . 0.8 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set Absolute Pressure Sensor: Customer Interest MAP Sensor - DTC's 13 or 14 Set Models 1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies Subject MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines Index DRIVEABILITY Date January 29, 1990 No. 18-03-90 (C18-20-9) P-164 BODY CODE LEGEND AA - ACCLAIM/,SPIRIT LEBARON LANDAU C/AC - DYNASTY/NEW YORKER LANDAU/SALON E - CARAVELLE/600 G/AG - DAYTONA H/AH - LANCER/LEBARON GTS J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE K/AK - ARIES/RELIANT P/AP - SHADOW/SUNDANCE S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle diagnostic memory. PARTS REQUIRED 1 MAP Sensor PN 5227351 1 Sensor Hose (3.0L Engine Only) PN 4557138 REPAIR PROCEDURE When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service Manual for replacement procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption Absolute Pressure Sensor: Customer Interest Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 475 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Absolute Pressure Sensor: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 481 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 Absolute Pressure Sensor: All Technical Service Bulletins Check Engine Lamp Comes On and Fault Code 13 NO.: 18-09-91 GROUP: DRIVEABILITY DATE: Sept. 23, 1991 SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine MODELS: 1989 (AA) SPIRIT/ACCLAIM 1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON 1989 (AG) DAYTONA 1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE 1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER SYMPTOM/CONDITION: The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic Change" is set into the diagnostic system. DIAGNOSIS: Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the diagnostic manual to verify that the MAP sensor is operating properly. PARTS REQUIRED: 1 MAP Sensor Relocation Package 4638458 Package Contents: 1 Cap Plug (1987-88 vehicles) 3580172 1 Cap Plug (1989 vehicles) 4241618 1 Purge Jumper Assembly 4669038 Consisting of: 1 In-Line Vacuum Connector 4201275 1 Vacuum Tee 33000227 1 11" Vacuum Hose 4104272 1 Bleed/Hose Assembly 4669042 Consisting of: 1 Vent 53007494 1 1" Vacuum Hose 4713956 1 Vacuum Tee 4669041 2 Vacuum Hose With 90 Degree Bend 4669044 1 Bracket 4686013 1 Wiring Harness 4687141 5 Tie Wraps 6015756 REPAIR PROCEDURE: This repair involves relocation of the MAP sensor. 1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable. 2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its present location. 3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug (3580172 for 1987 and 1988 vehicles or 4241618 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 486 for 1989 vehicles) in its place. 4. Loosen clamps and remove throttle body/air filter intake hose. 5. Wiring Harness Installation Procedure: If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted on the right side shock tower or on the bulkhead follow Step B. A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor connector. Route the harness along the backside of the intake manifold toward the throttle body. The harness should be secured to the fuel line and to the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps. B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length. Connect the FEMALE end of the harness to the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the harness to the right side of the motor mount and the two rear engine wiring support brackets. Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the supplied tie wraps. 6. Attach original MAP sensor to the bracket (4686013) supplied in the package. Figure 1 7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to slide over throttle body stud. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 487 Figure 2 8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque nut to 25 N-m (225 in.lbs.). 9. Disconnect the intake manifold end of the formed purge hose that extends from the intake manifold nipple to the "F" shaped connector (Figure 2). Figure 3 10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to nipple on intake manifold. Position the MAP bleed valve as close to vertical as possible. Figure 4 11. Cut the existing PVC hose as shown in Figure 2. 12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the formed purge hose (disconnected in Step 9) and the PVC hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed purge hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 488 Figure 5 NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE IT OVER THE TOP OF THROTTLE LINKAGE. 13. Connect vacuum hose to MAP sensor. 14. Connect wiring harness connector to MAP sensor. 15. Install throttle body/air filter intake hose and tighten clamps. 16. Use the DRB II to erase any fault codes and perform the applicable verification tests. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-14-15-94 . . . . . . . . . . . . . . . . . 0.8 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set Absolute Pressure Sensor: All Technical Service Bulletins MAP Sensor - DTC's 13 or 14 Set Models 1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies Subject MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines Index DRIVEABILITY Date January 29, 1990 No. 18-03-90 (C18-20-9) P-164 BODY CODE LEGEND AA - ACCLAIM/,SPIRIT LEBARON LANDAU C/AC - DYNASTY/NEW YORKER LANDAU/SALON E - CARAVELLE/600 G/AG - DAYTONA H/AH - LANCER/LEBARON GTS J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE K/AK - ARIES/RELIANT P/AP - SHADOW/SUNDANCE S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle diagnostic memory. PARTS REQUIRED 1 MAP Sensor PN 5227351 1 Sensor Hose (3.0L Engine Only) PN 4557138 REPAIR PROCEDURE When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service Manual for replacement procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption Absolute Pressure Sensor: All Technical Service Bulletins Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 497 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Barometric Pressure Sensor: Locations Engine Compartment Components. RH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 505 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Top RH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 511 Engine Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 512 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 5 Coolant & charge temperature sensors The coolant temperature sensor, Fig. 5, is mounted in the thermostat housing and allows the SMEC to monitor engine operating temperature in order to provide proper air/fuel mixtures. The sensor provides a variable resistance which is proportional to coolant temperature. When the engine is cold and sensor resistance is low, the SMEC provides richer air/fuel mixtures and increases engine idle speed to provide acceptable cold engine performance and allow quick warm up. When coolant temperature and sensor resistance increase, the SMEC provides leaner air/fuel mixtures and lowers engine idle speed to provide proper exhaust emission control and increased fuel economy. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Senior 105 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 518 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 519 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect distributor lead wire at wiring harness connector. 2. Remove distributor cap retaining screws and remove distributor cap. 3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum. Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when reinstalling the distributor. 4. Remove the distributor hold down nut and remove the distributor from the engine. DISASSEMBLY 1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and remove lead wire. 2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or damaged slots. 3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing. 4. Remove 2 bearing retainer screws. 5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the distributor drive gear roll pin. 6. Remove distributor drive gear, remove distributor shaft and bearing assembly. REASSEMBLY 1. Install shaft and bearing assembly in distributor housing. 2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference marks made during disassembly, and install roll pin. 3. Install distributor shaft bearing retaining screws. 4. Install the photo optic sensing unit and bushing and tighten with 3 screws. 5. Install disk spacers and disk. Install disk assembly screw. 6. Install lead wire, and lead wire clamp screw. 7. Install protective cover on distributor housing. INSTALLATION 1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If engine has been cranked with distributor removed proceed to step 3 for installation. 2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the distributor is installed, the rotor will be in line with the previously scribed line on the air intake plenum. Proceed to step 4. 3. If the engine has been cranked with the distributor removed perform the following procedure: a. Rotate the crankshaft until the number one piston is at the top of its compression stroke. Distributor Cap Terminal Routing b. Rotate the distributor shaft until the rotor points to number one terminal. c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam shaft. With the distributor fully seated the rotor should be under the number one terminal. 4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers. Install hold down nut finger tight. 5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to ADJUSTMENT PROCEDURES for timing adjustment. . Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Engine Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 523 Intake Air Temperature Sensor: Description and Operation Fig. 5 Coolant & charge temperature sensors The charge temperature switch, Fig. 5, is mounted in the intake manifold and measures the temperature of the air/fuel mixture. This information is used by the SMEC to modify the air/fuel mixture. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Switch > Component Information > Locations Intake Air Temperature Switch: Locations RH Side Of Air Cleaner Assembly Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations Engine Compartment Components. RH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 531 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 532 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 3 Manifold Absolute Pressure (MAP) sensor location The MAP sensor, Fig. 3, is mounted in the engine compartment on the dash panel and monitors intake manifold vacuum through a line connected to the intake plenum. The sensor converts manifold vacuum (negative pressure) and barometric pressure into electrical signals and transmits these signals to the SMEC. The SMEC uses these signals to monitor engine load and atmospheric conditions in order to determine the correct air/fuel mixture for vehicle operating conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 533 Manifold Pressure/Vacuum Sensor: Service and Repair 1. Remove vacuum hose from sensor. 2. Remove sensor attaching screws, then the sensor. 3. Reverse procedure to install. Ensure proper installation of vacuum hose to sensor and sensor to dash panel. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations On Exhaust Manifold Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 539 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 540 Oxygen Sensor: Description and Operation Fig. 4 Oxygen sensor The oxygen sensor, Fig. 4, produces voltage signals when exposed to oxygen in the exhaust gasses. The oxygen content in the exhaust gasses is directly proportional to the air/fuel mixture entering the engine, and the voltage signal produced by the sensor is inversely proportional to the amount of oxygen remaining in the exhaust gasses. The SMEC uses these signals to determine air/fuel mixtures entering the engine. The oxygen sensor is mounted in the rear exhaust manifold, and the sensing element must be heated by exhaust gasses before the sensor begins to produce voltage signals. When exhaust gas oxygen content is high (lean mixtures), the sensor produces a low voltage. When oxygen content is low (rich mixtures), the sensor produces a higher voltage. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 541 Oxygen Sensor: Service and Repair The oxygen sensor is to be removed using tool No. C-4907 or equivalent. After removal, clean threads in exhaust manifold using an 18mm x 1.5 x 6E tap. If reinstalling the same sensor, apply a suitable anti-seize to threads of sensor. New sensors are packaged with an anti-seize compound already applied to the threads and no further application is required. When installing sensor, torque to 20 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure Revision Models 1989 AS Subject Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI Index MISCELLANEOUS Date December 29, 1989 No. 26-34-89 P-13 (C26-34-9) BODY CODE LEGEND AS - 1989 RAM VAN, CARAVAN, VOYAGER Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 546 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 547 DIAGNOSTIC MANUAL REVISION Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH. 1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No. 81-699-9017. Pages 136 and 137. Please affix these revised pages in your manual. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 548 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 549 Throttle Position Sensor: Locations LH Rear Corner Of Cylinder Head Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 552 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 553 Throttle Position Sensor: Description and Operation The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The sensor produces a voltage signal which increases and decreases according to throttle position. The SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide open throttle, acceleration and deceleration. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 554 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle body mounting screws. 3. Lift TPS from throttle shaft, then remove O-ring. 4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw to 20 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 563 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 564 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 565 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and 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 571 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and 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 572 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 577 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 578 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 579 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 585 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 586 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 589 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 590 Transmission Position Switch/Sensor: Locations 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 591 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 594 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 597 Transmission Position Switch/Sensor: Description and Operation PRNDL The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. It may have been replaced by a transmission range sensor (TRS). Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 600 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 601 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 602 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations LH Side Of Engine Compartment. Upper LH Corner Of Transaxle Applicable to: 1989 w/Electronic Transaxle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 608 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 609 Vehicle Speed Sensor: Description and Operation The distance sensor is located in the transaxle extension housing and signals vehicle motion to the SMEC by generating eight pulses per axle shaft revolution. The SMEC uses this signal along with signals from the throttle position sensor to determine between a closed throttle deceleration and a normal idle condition, thereby allowing the SMEC to maintain desired control of the AIS motor. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure Revision Models 1989 AS Subject Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI Index MISCELLANEOUS Date December 29, 1989 No. 26-34-89 P-13 (C26-34-9) BODY CODE LEGEND AS - 1989 RAM VAN, CARAVAN, VOYAGER Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 615 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 616 DIAGNOSTIC MANUAL REVISION Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH. 1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No. 81-699-9017. Pages 136 and 137. Please affix these revised pages in your manual. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 617 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 618 Throttle Position Sensor: Locations LH Rear Corner Of Cylinder Head Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 621 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 622 Throttle Position Sensor: Description and Operation The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The sensor produces a voltage signal which increases and decreases according to throttle position. The SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide open throttle, acceleration and deceleration. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 623 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle body mounting screws. 3. Lift TPS from throttle shaft, then remove O-ring. 4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw to 20 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 629 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Senior 105 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 635 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 636 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect distributor lead wire at wiring harness connector. 2. Remove distributor cap retaining screws and remove distributor cap. 3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum. Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when reinstalling the distributor. 4. Remove the distributor hold down nut and remove the distributor from the engine. DISASSEMBLY 1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and remove lead wire. 2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or damaged slots. 3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing. 4. Remove 2 bearing retainer screws. 5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the distributor drive gear roll pin. 6. Remove distributor drive gear, remove distributor shaft and bearing assembly. REASSEMBLY 1. Install shaft and bearing assembly in distributor housing. 2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference marks made during disassembly, and install roll pin. 3. Install distributor shaft bearing retaining screws. 4. Install the photo optic sensing unit and bushing and tighten with 3 screws. 5. Install disk spacers and disk. Install disk assembly screw. 6. Install lead wire, and lead wire clamp screw. 7. Install protective cover on distributor housing. INSTALLATION 1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If engine has been cranked with distributor removed proceed to step 3 for installation. 2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the distributor is installed, the rotor will be in line with the previously scribed line on the air intake plenum. Proceed to step 4. 3. If the engine has been cranked with the distributor removed perform the following procedure: a. Rotate the crankshaft until the number one piston is at the top of its compression stroke. Distributor Cap Terminal Routing b. Rotate the distributor shaft until the rotor points to number one terminal. c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam shaft. With the distributor fully seated the rotor should be under the number one terminal. 4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers. Install hold down nut finger tight. 5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to ADJUSTMENT PROCEDURES for timing adjustment. . Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations Ignition Switch: Locations I/P, Cowl & Steering Column Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations > Page 640 Steering Column Components Top Of Steering Column Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations > Page 641 Ignition Switch: Service and Repair Fig. 10 Ignition switch replacement 1. If equipped, disarm airbag system, refer to MAINTENANCE PROCEDURES. 2. Remove left lower instrument panel cover. 3. Position gear selector to D and disconnect indicator cable, if equipped with automatic transaxle. 4. Remove lower panel reinforcement, then five steering column to support bracket attaching nuts. 5. Lower column and disconnect ignition switch electrical connector. 6. Position ignition lock cylinder in Lock position. 7. Tape ignition switch rod to steering column to prevent rod from falling out of lock cylinder assembly. 8. Remove two ignition switch attaching screws, then the switch. 9. Reverse procedure to install. Rearm airbag system, refer to MAINTENANCE PROCEDURES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Clutch (Inhibitor) Switch Test 1. Disconnect double connector at switch pigtail, then connect a 12 volt power source to either end of switch terminal. 2. Connect a test light to remaining terminal end and ground. 3. Test light should be on when pedal is in normal position and off when pedal is depressed. 4. If above step is not as specified, replace clutch switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Locations Ignition Switch: Locations I/P, Cowl & Steering Column Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Locations > Page 649 Steering Column Components Top Of Steering Column Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Locations > Page 650 Ignition Switch: Service and Repair Fig. 10 Ignition switch replacement 1. If equipped, disarm airbag system, refer to MAINTENANCE PROCEDURES. 2. Remove left lower instrument panel cover. 3. Position gear selector to D and disconnect indicator cable, if equipped with automatic transaxle. 4. Remove lower panel reinforcement, then five steering column to support bracket attaching nuts. 5. Lower column and disconnect ignition switch electrical connector. 6. Position ignition lock cylinder in Lock position. 7. Tape ignition switch rod to steering column to prevent rod from falling out of lock cylinder assembly. 8. Remove two ignition switch attaching screws, then the switch. 9. Reverse procedure to install. Rearm airbag system, refer to MAINTENANCE PROCEDURES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > 3 Speed A/T Neutral Safety Switch: Locations 3 Speed A/T Neutral/Park Safety Switch Neutral Starting And Back-Up Lamp Switch The neutral starting switch is the center terminal of the 3 terminal switch. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > 3 Speed A/T > Page 655 Neutral Safety Switch: Locations 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > 3 Speed A/T > Page 656 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 659 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 660 Neutral Safety Switch: Electrical Diagrams 3 Speed A/T Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at the vehicle level. See: Diagrams/Electrical Diagrams 4 Speed A/T The Neutral Safety Switch wiring is part of the starting system circuit. See: Starting and Charging/Starting System/Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Description and Operation > 3 Speed A/T Neutral Safety Switch: Description and Operation 3 Speed A/T Neutral Starting And Back-Up Lamp Switch The neutral starting switch is the center terminal of the 3 terminal switch. - It provides ground for the starter solenoid circuit through the selector lever in only Park and Neutral positions. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Description and Operation > 3 Speed A/T > Page 663 Neutral Safety Switch: Description and Operation 4 Speed A/T The Neutral Safety Switch sends a signal to the EATX control module and the engine control module, controlling starter relay operation when the transaxle is in any gear other than Park or Neutral. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Testing and Inspection > 3 Speed A/T Neutral Safety Switch: Testing and Inspection 3 Speed A/T Neutral Starting And Back-Up Lamp Switch Replacement And Test 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in Park or Neutral. 2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to Park and then to Neutral positions, and inspect to see that the switch operating lever fingers are centered in switch opening in the case. 4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 8. Continuity should exist only with transaxle in Reverse position. 9. No continuity should exist from either pin to the case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Testing and Inspection > 3 Speed A/T > Page 666 Neutral Safety Switch: Testing and Inspection 4 Speed A/T The 4 speed Automatic Transaxle is computer controlled, if troubleshooting this system, extract codes. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair > 3 Speed A/T Neutral Safety Switch: Service and Repair 3 Speed A/T Neutral Starting And Back-Up Lamp Switch Replacement And Test 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in Park or Neutral. 2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to Park and then to Neutral positions, and inspect to see that the switch operating lever fingers are centered in switch opening in the case. 4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 8. Continuity should exist only with transaxle in Reverse position. 9. No continuity should exist from either pin to the case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair > 3 Speed A/T > Page 669 Neutral Safety Switch: Service and Repair 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair > 3 Speed A/T > Page 670 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation A604 (41TE) 4 Speed Transaxle DESCRIPTION The PRNDL switch is similar in appearance to the Neutral Safety Switch. Its purpose is to help the transaxle controller sense the shifter position (manual valve), and help operate the reverse lamps. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 684 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 685 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 686 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 692 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 693 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 698 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 699 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 700 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 706 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 707 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 710 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 711 Transmission Position Switch/Sensor: Locations 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 712 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 715 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 718 Transmission Position Switch/Sensor: Description and Operation PRNDL The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. It may have been replaced by a transmission range sensor (TRS). Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 721 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 722 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 723 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 732 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 737 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 738 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 739 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 745 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 750 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 751 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 752 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 753 Input / Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Transmission Speed Sensor: Description and Operation Output Speed Sensor DESCRIPTION This is a two wire, magnetic pick-up device used to sense the output speed of the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor > Page 756 Transmission Speed Sensor: Description and Operation Turbine Speed Sensor A604 (41TE) 4 Speed Transaxle DESCRIPTION This is a two wire, magnetic pick-up device used to sense the input speed of the transaxle (torque convertor turbine). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 757 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations Heated Glass Element Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Front Door Components In Front Door Armrest Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Switch Test Power Window Switch: Testing and Inspection Power Window Switch Test Left Power Window Switch Continuity Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Switch Test > Page 770 Right Power Window Switch Continuity 1. If the failure is in the right side door, remove the right power window switch from the door trim panel. 2. Connect jumper wires to the right power window switch connector as shown. The jumper wires take the place of a good switch in the inactive position. 3. Using the drivers side power window switch, activate the windows up and down. If the power windows now operate properly, replace the passenger side switch. If the power windows still do not operate, go to step 4. 4. Remove the drivers side power window switch from the door trim panel. 5. Connect jumper wires to the power window switch electrical connector as shown. If the power window system operates with the jumper wires connected, the power window switch is defective and needs to be replaced. If the power window system doesn't work with the jumper wires connected, check the wiring harness from the switch to the window lift motor for an open circuit. See: Windows and Glass/Windows/Power Window Motor/Testing and Inspection/Window Lift Motor Test Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Switch Test > Page 771 Power Window Switch: Testing and Inspection Switch Voltage Test Left Power Window Switch Continuity Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Switch Test > Page 772 Right Power Window Switch Continuity NOTE: The following test determines whether voltage is continuous through the wiring harness to the power window switch. 1. Remove the power window switch from the door trim panel. 2. Separate the multiple terminal block on the wiring harness from the power window switch. 3. Connect one lead of a test light to the black wire terminal and the other lead to the tan wire terminal. If the test light illuminates, the wiring circuit between the battery and switch is functioning properly. If the test light does not illuminate, check the 30 amp main fuse (circuit breaker) or check for an open in the wiring harness. 4. If the wiring circuit is functioning properly, See: Windows and Glass/Windows/Power Window Motor/Testing and Inspection/Window Lift Motor Test Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 773 Power Window Switch: Service and Repair 1. Pry up rear of switch bezel releasing it from clips. Pull bezel out of door trim. 2. Disconnect wiring harness. 3. Remove switch screws and switch. 4. Reverse removal sequence to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Engine Compartment Components. LH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair Windshield Washer Switch: Service and Repair Fig. 2 Ignition lock removal. Models w/tilt column FRONT Standard Column Refer to Vehicle Lighting/Turn Signals/Turn Signal Switch/Service and Repair for washer/wiper switch replacement procedure. Tilt Column 1. If equipped, disarm airbag system. Refer to MAINTENANCE PROCEDURES. 2. Remove turn signal/hazard warning switch as described under "Turn Signal/Hazard Warning Switch, Replace." 3. Remove ignition key lamp. 4. Position ignition lock cylinder in Lock position, then insert a small diameter screwdriver into lock cylinder release holes and push inward until spring loaded lock cylinder retainers release. 5. Remove buzzer/chime switch by inserting a bent piece of stiff wire into exposed loop of wedge spring and pulling straight out. Use caution not to drop switch into steering column. 6. Remove three switch housing cover attaching screws, then the housing cover. 7. Remove washer/wiper switch. Remove washer/wiper switch pivot pin using a suitable punch, if necessary. 8. Reverse procedure to install. Rearm airbag system. REAR 1. Disconnect battery ground cable. 2. Remove switch plate bezel. 3. Remove four screws attaching switch plate to lower panel. 4. Pull switch assembly rearward, then disconnect switch electrical connectors. 5. Remove switch retaining screw. Depress locking tabs to remove switch from switch plate. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 784 Wiper Switch: Testing and Inspection Fig. 11 Two Speed Wiper Switch Continuity Chart Fig. 12 Intermittent Wiper Switch Continuity Chart 1. Disconnect electrical connector to switch at body wiring harness connector. 2. Operate switch in all positions, and check continuity between terminals with an ohmmeter. The first (clockwise) position is the Off position. Next is the slide for the Delay wipe, with counterclockwise rotation, reducing the delay. Low is the next detent position. High is the full counterclockwise detent position. In any wiper mode, if the knob is pushed in all the way, the washer circuit will be completed. 3. If continuity is not as specified in charts, replace switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 785 Wiper Switch: Service and Repair Fig. 2 Ignition lock removal. Models w/tilt column FRONT Standard Column Refer to Vehicle Lighting/Turn Signals/Turn Signal Switch/Service and Repair for washer/wiper switch replacement procedure. Tilt Column 1. If equipped, disarm airbag system. Refer to MAINTENANCE PROCEDURES. 2. Remove turn signal/hazard warning switch as described under "Turn Signal/Hazard Warning Switch, Replace." 3. Remove ignition key lamp. 4. Position ignition lock cylinder in Lock position, then insert a small diameter screwdriver into lock cylinder release holes and push inward until spring loaded lock cylinder retainers release. 5. Remove buzzer/chime switch by inserting a bent piece of stiff wire into exposed loop of wedge spring and pulling straight out. Use caution not to drop switch into steering column. 6. Remove three switch housing cover attaching screws, then the housing cover. 7. Remove washer/wiper switch. Remove washer/wiper switch pivot pin using a suitable punch, if necessary. 8. Reverse procedure to install. Rearm airbag system. REAR 1. Disconnect battery ground cable. 2. Remove switch plate bezel. 3. Remove four screws attaching switch plate to lower panel. 4. Pull switch assembly rearward, then disconnect switch electrical connectors. 5. Remove switch retaining screw. Depress locking tabs to remove switch from switch plate. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear Alignment: Customer Interest Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Fig. 1-Shim Installation for Toe-Out Fig. 2-Shim Installation for Toe-in Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 795 Fig. 3-Shim Installation for Positive Camber Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 796 completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear Alignment: All Technical Service Bulletins Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Fig. 1-Shim Installation for Toe-Out Fig. 2-Shim Installation for Toe-in Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 802 Fig. 3-Shim Installation for Positive Camber Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 803 completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 804 Alignment: By Symptom Technical Service Bulletin # 020790 Date: 901105 Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Fig. 1-Shim Installation for Toe-Out Fig. 2-Shim Installation for Toe-in Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 805 Fig. 3-Shim Installation for Positive Camber Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 806 completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Technical Service Bulletin # 020790 Date: 901105 Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 807 Fig. 1-Shim Installation for Toe-Out Fig. 2-Shim Installation for Toe-in Fig. 3-Shim Installation for Positive Camber Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 808 Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 809 The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Technical Service Bulletin # 020790 Date: 901105 Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Fig. 1-Shim Installation for Toe-Out Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 810 Fig. 2-Shim Installation for Toe-in Fig. 3-Shim Installation for Positive Camber Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 811 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Technical Service Bulletin # 020790 Date: 901105 Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 812 reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Fig. 1-Shim Installation for Toe-Out Fig. 2-Shim Installation for Toe-in Fig. 3-Shim Installation for Positive Camber Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 813 Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 814 The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Alignment Specifications Front Wheel Alignment Specifications Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Alignment Specifications > Page 817 Rear Wheel Alignment Specifications Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment Alignment: Service and Repair Front Alignment Camber Fig. 1 Camber adjustment To adjust camber, loosen cam and through bolts. Rotate upper cam bolt to move top of wheel in or out to achieve specified camber angle. Torque cam bolt nut to 75 ft. lbs. plus an additional 1/4 turn. Caster The caster angle on these vehicles cannot be adjusted. Preliminary Inspection Prior to wheel alignment, ensure tires are at recommended pressure, are of equal size and have approximately the same wear pattern. Check front wheel and tire assembly for radial runout and inspect lower ball joints and steering linkage for looseness. Check front and rear springs for sagging or damage. Front suspension inspections should be performed on a level floor or alignment rack with fuel tank at capacity and vehicle free of luggage and passenger compartment load. Before each alignment reading, the vehicle should be bounced an equal number of times from the center of the bumper alternating first from the rear, then the front, and releasing at bottom of down cycle. Toe Adjustment Fig. 2 Toe-in adjustment To adjust toe-in, center steering wheel and hold in position with a suitable tool. Loosen tie rod locknuts and rotate rod, to adjust toe-in to specifications. Use care not to twist steering gear rubber boots. Torque tie rod locknuts to 55 ft. lbs. Adjust position of steering gear rubber boots. Remove steering wheel holding tool. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment > Page 820 Alignment: Service and Repair Rear Alignment Rear wheel alignment is not adjustable. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations System not equipped with fuel pressure test port. (To test fuel pressure tee into system with adapter.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle mixture using this screw! Idle mixture is electronically controlled by the Powertrain Control Module (PCM), and is not adjustable. If an idle mixture problem is suspected, check oxygen sensor and feedback system. SEE Computers and Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications IDLE SPEED Idle speed adjustment is electronically controlled by the Automatic Idle Speed (AIS) Motor and is not adjustable. For diagnosis of incorrect idle speed, refer to COMPUTERIZED ENGINE CONTROLS. IDLE SPEED Automatic ............................................................................................................................................. .................................................................. 800 RPM Manual .............................................................. ...................................................................................................................................................... 800 RPM Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 832 Idle Speed: Testing and Inspection 1. Remove air cleaner assembly, then plug heated air door vacuum hose. 2. With vehicle in PARK for A/T, or NEUTRAL for M/T, START engine and warm until cooling fan cycles ON and OFF at least once. STOP engine. 3. Connect suitable timing light, then disconnect coolant temperature sensor. START engine, and ensure basic timing is set to 12° BTDC. 4. STOP engine and reconnect coolant temperature sensor wire. 5. Disconnect PCV valve hose from intake manifold nipple. 6. Attach tool No. C-5004 or equivalent (.125 inch orifice in attached hose) to intake manifold PCV nipple. 7. Connect DRB II or equivalent scanner, then START engine and allow to idle for at least 1 minute. 8. Using scanner, place read/hold switch in read position and depress ATM button until code 70 appears. 9. Place read/hold switch to hold position, then the following should occur: a. AIS motor will fully close. b. Idle spark advance will become fixed. c. Idle fuel will become enriched. d. Engine rpm will be displayed on diagnostic read-out tool in units of rpm x 10. For example, display 95 equals 95 x 10 which indicates 950 rpm. 10. Check idle rpm. If idle rpm is within 850-1250 rpm then throttle body minimum air flow is satisfactory. If idle rpm is not as specified, clean or replace throttle body, refer to MAINTENANCE PROCEDURES. Retest minimum air flow after throttle body cleaning. 11. STOP engine, then remove tool No. C-5004 (orifice) from intake manifold PCV nipple. Install PCV valve hose. 12 Erase fault codes. Remove scanner, then install air cleaner assembly and heated air door vacuum hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 833 Idle Speed: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle speed using this screw, unless directed to do so in a service procedure. Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air Control (IAC) motor, and is not adjustable. If idle is outside of specified RPM, or is rough, or unstable, inspect and clean throttle body if deposits are visible. Perform Minimum Idle Air Flow Test if applicable. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair 1. Loosen gas cap and allow tank pressure to release. 2. Remove wiring harness connector from any injector, then ground one injector terminal. 3. Connect a suitable jumper wire to a second terminal, then touch the positive post of the battery for approximately 10 seconds and release system pressure. 4. Remove jumper wires and service fuel system as required. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Cylinder Location 1988-1996 3.0L (182) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Cylinder Location > Page 842 Distributor Cap From The Top - Includes Connections Inside The Cap. (Round Terminals Are Plug Wire Connections On The Top Of The Cap.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations 1988-1996 3.0L (182) 3.0L Except Stealth Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Marks and Indicators: Diagrams TIMING MARK 3.0L Timing Scale Above Crank Pulley--Viewed From Front Of Car Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications Distributor: Specifications Distributer Adapter ............................................................................................................................... .......................................... 14 Nm (120 in lbs) Distributer Housing Bolt ............................................. .................................................................................................................... 15 Nm (130 in lbs) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications > Page 856 Distributor: Locations Distributor Hold-Down The Optical Distributor is located at the back of the engine, behind the right-hand cylinder head. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications > Page 857 Distributor: Service and Repair REMOVAL 1. Disconnect distributor lead wire at wiring harness connector. 2. Remove distributor cap retaining screws and remove distributor cap. 3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum. Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when reinstalling the distributor. 4. Remove the distributor hold down nut and remove the distributor from the engine. DISASSEMBLY 1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and remove lead wire. 2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or damaged slots. 3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing. 4. Remove 2 bearing retainer screws. 5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the distributor drive gear roll pin. 6. Remove distributor drive gear, remove distributor shaft and bearing assembly. REASSEMBLY 1. Install shaft and bearing assembly in distributor housing. 2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference marks made during disassembly, and install roll pin. 3. Install distributor shaft bearing retaining screws. 4. Install the photo optic sensing unit and bushing and tighten with 3 screws. 5. Install disk spacers and disk. Install disk assembly screw. 6. Install lead wire, and lead wire clamp screw. 7. Install protective cover on distributor housing. INSTALLATION 1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If engine has been cranked with distributor removed proceed to step 3 for installation. 2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the distributor is installed, the rotor will be in line with the previously scribed line on the air intake plenum. Proceed to step 4. 3. If the engine has been cranked with the distributor removed perform the following procedure: a. Rotate the crankshaft until the number one piston is at the top of its compression stroke. Distributor Cap Terminal Routing b. Rotate the distributor shaft until the rotor points to number one terminal. c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam shaft. With the distributor fully seated the rotor should be under the number one terminal. 4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers. Install hold down nut finger tight. 5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to ADJUSTMENT PROCEDURES for timing adjustment. . Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. .................... 0.9 to 1.1 mm (0.039 to 0.044 in) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 862 Spark Plug: Specifications Tightening Specifications Spark Plug Torque ............................................................................................................................... ...................................................... 28 Nm (20 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications SERVICE SPECIFICATIONS Compression pressure ..................................................................................................................... 840 kPa (178 psi) +/- 100 kPa (14 psi) @ 250-400 rpm Maximum variation ....................................... .............................................................................................................................................................. .... 25% Manifold vacuum .................................................................................................................... ........................................................... 520 mmHg (20 in.Hg.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 866 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. NOTE: Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. NOTE: Correct engine compression pressures should be 178 psi +/- 14 psi, Maximum cylinder deviation 25% Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 870 Valve Clearance: Adjustments This engine uses hydraulic lash adjusters. No provision for adjustment is provided. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Testing and Inspection Timing Belt: Testing and Inspection ABNORMAL NOISES FROM TIMING BELT Incorrect Belt Tension Timing belts which are too loose or too tight are prone to making a humming sound, especially on heavy deceleration. Inspect the timing belt and re-adjust the tension. Pulley or Belt Rubbing on Cover A rubbing or whining sound can occur when the pulleys (or belt) are rubbing against the timing covers. Remove the covers and inspect for wear. If the timing belt shows any signs of wear or fraying along the outer edge it should be replaced. - Inspect the pulleys for proper alignment. An incorrectly placed washer or spacer may move one pulley out of alignment with the rest. - Verify all pulleys have no lateral movement (wobble) . Replace any pulley which wobbles. - Verify the timing cover is not warped. The cover should be replaced if warped. - Verify the timing cover rubber gasket is properly installed. Incorrect Type of Timing Belt Timing belt teeth are available in several different types. Compare the new belt to the old one and verify the teeth are the same shape. Timing belt types are not interchangeable. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks Timing Belt: Service and Repair Initial Checks INITIAL CHECKS (PRIOR TO REMOVAL) PURPOSE Checking and recording the ignition timing and manifold vacuum level before and after the timing belt replacement allows for two assurances: Initial conditions are correct. - Verifies the quality of the job after the belt has been installed. WHY Ignition Timing Ignition timing is the position of the piston on its compression stroke when the ignition coil fires the associated sparkplug. Ignition timing is affected by two sources. Physical rotation of the distributor. - Alignment of the camshaft and crankshaft via the timing belt. Prior to replacing the timing belt it is very important to verify that this relationship is correct. If the timing belt is installed correctly the after-repairs timing check should be within 2 degrees of the pre-repairs timing check. NOTE: Minor differences, +/- 2 degrees may result from original belt stretching as it aged. If the timing belt is initially installed incorrectly, the prerepairs ignition timing may not be correct, and the after-repairs timing will differ greatly from the initial. Checking the timing before and after the job will help prevent confusion and verify the job was done correctly. Notes on Timing: An ignition timing of 0 degrees BTDC (Before Top Dead Center) implies that the ignition coil fires the spark exactly as the piston reaches its highest position (top dead center). - An ignition timing of 10 degrees BTDC implies that the spark is triggered 10 degrees of crankshaft rotation Before to the piston reaching top dead center. - An ignition timing of 10 degrees IT'D implies that the spark is triggered 10 degrees of crank shaft rotation After the piston reaches top dead center. Manifold Vacuum If the camshaft is out of alignment with the crankshaft, the intake and exhaust valves will not open and close at the optimum times. This will reduce the volumetric efficiency of the engine and thus reduce the manifold vacuum level. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 876 NOTE: The ignition timing will also affect the manifold vacuum levels, verify the timing is correct prior to measuring the vacuum. If the after-repair vacuum level is lower than the pre-repairs level this would be an indication that the timing belt may not be installed correctly. NOTE: The vacuum checks should be made at similar engine speeds and temperatures. - Check "manifold vacuum" at a source downstream of the throttle plates. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 877 Timing Belt: Service and Repair Pre-Installation Inspection PRE-INSTALLATION INSPECTION - Prior to installing the timing belt inspect the teeth of the crank and cam pulleys for burrs or damage. Light burrs may be removed, but any damage which permanently mars the teeth/belt mating surface will require the pulley to be replaced. - Inspect the inside of the timing belt covers for rubbing or wear. The plastic covers may warp, causing the pulleys or belts to rub against the inside of the cover. - Inspect the tensioner and water pump pulleys for wobble or looseness. The pulleys should spin freely with no rough spots or lateral (side-to-side) movement. - Inspect the tensioner and water pump pulley surfaces. They should be clean and free of nicks and burrs. If any damage is noted the pulleys should be replaced. - Inspect the camshaft and crankshaft oil seals for leakage. Any seal which shows signs of leakage should be replaced. WARNING: Oil leakage will damage the new timing belt. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 878 Timing Belt: Service and Repair Timing Belt Removal and Installation Removal NOTE: Always carefully inspect the Water Pump when replacing the Timing Belt, as the pump is timing belt driven. Fig. 5 Accessories & mounting brackets removal & installation 1. Disconnect battery ground cable. Air Conditioning Belt Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 879 Alternator/Power Steering Belt 2. Remove accessory drive belts. a Loosen adjusting lock nut on A/C belt adjuster, Turn adjusting jack screw counterclockwise to reduce belt tension. b Install breaker bar into 1/2 square opening in tensioner on Alternator/Power Steering belt. Rotate tensioner counterclockwise to remove belt. 3. Remove A/C compressor, alternator, power steering pump, tensioners and mounting brackets as shown in Fig. 5, and set aside. Right Inner Splash Shield - Typical 4. Raise and support vehicle, then remove right inner splash shield. Fig. 6 Crankshaft pulley removal Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 880 5. Remove crankshaft drive pulleys and torsional damper, Fig. 6, then lower vehicle and position a suitable jack under engine. Fig. 7 Engine mount removal - Typical 6. Remove engine mount insulator from engine mount bracket, raise engine slightly, then remove engine mount bracket as shown in Fig. 7. Fig. 8 Timing belt cover removal 7. Remove timing belt covers as shown in Fig. 8. 8. If belt is to be reused, mark belt running direction for reassembly reference. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 881 Fig. 9 Timing Belt Routing 9. Loosen timing belt tensioner, Fig. 9, then remove timing belt. 10. Remove crankshaft sprocket flange, if necessary. 11. Remove camshaft sprocket attaching bolts, then the sprockets, if necessary. Camshaft Sprockets 12. Install camshaft sprockets, then using camshaft sprocket holder tool MB990775, torque bolts to 73 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 882 Fig. 10 Positioning timing belt tensioner 13. Install timing belt tensioner and spring. Rotate tensioner counterclockwise, Fig. 10, then temporarily tighten bolt. 14. Install timing belt on crankshaft sprocket first, while keeping belt tight on tension side, then position belt over front camshaft sprocket, Fig. 9. 15. Then, install belt on water pump pulley and rear camshaft sprocket and finally on the timing belt tensioner, Fig. 9. 16. Rotate front camshaft sprocket in opposite direction and check that all timing marks align, Fig. 9. 17. Install crankshaft sprocket flange, then loosen tensioner bolt to allow spring to tension belt. Rotate crankshaft two complete revolutions, in direction of normal rotation and check timing marks. 18. Tighten tensioner bolt to 23 ft. lbs. 19. Install timing belt covers as shown in Fig. 8. 20. Install engine brackets, pulleys, and accessories as shown in Fig. 5, then the drive belts. Installation NOTE: Always carefully inspect the Water Pump when replacing the Timing Belt, as the pump is timing belt driven. Camshaft Sprockets 1. Install camshaft sprockets, then using camshaft sprocket holder tool MB990775, torque bolts to 73 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 883 Fig. 10 Positioning timing belt tensioner 2. Install timing belt tensioner and spring. Rotate tensioner counterclockwise, Fig. 10, then temporarily tighten bolt. Fig. 9 Timing Belt Routing 3. Install timing belt on crankshaft sprocket first, while keeping belt tight on tension side, then position belt over front camshaft sprocket, Fig. 9. 4. Then, install belt on water pump pulley and rear camshaft sprocket and finally on the timing belt tensioner, Fig. 9. 5. Rotate front camshaft sprocket in opposite direction and check that all timing marks align, Fig. 9. 6. Install crankshaft sprocket flange, then loosen tensioner bolt to allow spring to tension belt. Rotate crankshaft two complete revolutions, in direction of normal rotation and check timing marks. 7. Tighten tensioner bolt to 23 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 884 Fig. 8 Timing belt cover removal 8. Install timing belt covers as shown in Fig. 8. Fig. 5 Accessories & mounting brackets removal & installation Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 885 Air Conditioning Belt Alternator/Power Steering Belt Fig. 7 Engine mount removal - Typical 9. Install engine brackets, pulleys, and accessories as shown in Fig. 5, then the drive belts. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Page 886 Timing Belt: Tools and Equipment RECOMMENDED TOOLS - Floor jack (for supporting the engine while removing the front engine mount). - Timing light (for measuring timing before and after). - Vacuum gauge (for measuring engine vacuum levels before and after). Crankshaft Pulley Removal - Crankshaft Holding Tool MD998784 (used in conjunction with an old drive belt), or an air powered impact gun (for removing the crankshaft bolt). Timing Belt Tensioner Release - Large flat blade screw driver (for moving timing belt tensioner). - Torque Wrenches: Low Range (0-50 ft-lb) for covers and brackets. - High Range (0-150 ft-lb) for crankshaft pulley bolt. - Full set of Metric sockets and wrenches. - Fender covers. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General Information Timing Belt: Fundamentals and Basics General Information TIMING BELT, GENERAL INFORMATION PURPOSE The timing belt synchronizes (times) the opening and closing of the intake and exhaust valves with the movement/stroke of the pistons. The timing belt also matches the rotation of the distributor with the movement of the pistons. OPERATION The crankshaft represents the movement of the pistons while the camshaft controls the opening and closing of the valves. The timing belt connects the crankshaft to the camshaft and uses the rotation of the crankshaft to drive the camshaft in a 2 to 1 relationship. For every two revolutions of the crankshaft the camshaft is rotated only once. Why 2:1 In 4 stoke engine each piston must complete 4 separate strokes (intake, compression, power, and exhaust) to complete a cycle. For a single piston to complete all four strokes the crankshaft must rotate two full revolutions. The camshaft controls the opening and closing of the valves. During the four piston strokes of an engine cycle the intake and exhaust valves (for each cylinder) will open and close only once. This requires only one revolution of the camshaft. NOTE: The intake valves will open and close only during the intake stroke and the exhaust valves will open and close only during the exhaust stroke. During the compression and power strokes the valves remain closed. How This 2 to 1 reduction is accomplished by making the circumference of the camshaft pulley twice as large as the crankshaft pulley. This allows the smaller crankshaft to complete two revolutions while the larger camshaft completes only one revolution. NOTE: The distributor also requires only one rotation for every two rotations of the crankshaft. FIRST INDICATIONS OF A BROKEN BELT 1. The engine will immediately die or fail to start. 2. When attempting to restart the engine, the cranking speed (rpm) will be unusually fast. 3. The sound of the engine while attempting to restart will be different than normal. Instead of the usual rhythmic "Rir. . .Rir. . .Rir..." cranking sound it will sound more like "RirRirRirRir" with no detectable rhythm. Why When the timing belt brakes the camshaft and distributor quit rotating. - Without distributor rotation the ignition system stops producing spark and the engine immediately dies or fails to start. - Without the rotation of the camshaft the intake and exhaust valves stop opening and closing. This prevents the pistons from developing compression which also causes the engine to die. This lack of compression also produces the unusually fast and non- rhythmic cranking speed when attempting to restart the engine. NOTE: The normal rhythmic cranking sound is a result of the starter having to work harder as each piston begins its compression stroke. VERIFYING TIMING BELT IS BROKEN Check for camshaft rotation while cranking the engine (with the starter or by hand, using the crankshaft bolt). WARNING: When rotating the crankshaft by hand always disconnect the battery. Camshaft rotation can be verified by: Remove oil filler cap and check if camshaft is visible. - Remove valve cover and directly observe camshaft. - Remove distributor cap and check for rotor rotation (the rotor is driven by the camshaft) - Remove upper timing belt cover and check camshaft pulley rotation and belt integrity. Other Indications the Timing Belt may be broken. No ignition spark. - Very low compression (<15 psi) on all cylinders. Due to the low compression the following additional symptoms may be present. While attempting to start the car, the battery strength remains high for an unusually long length of time. - The sound of the engine while attempting to restart will be different than normal. Instead of the usual rhythmic "Rir.. .Rir. . .Rir..." cranking sound it will sound more like "RirRirRirRir" with no detectable rhythm. NOTE: For an experienced technician this unique sound will often be the initial symptom that leads to a more in-depth check of the timing belt. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 889 OTHER RELATED PROBLEMS The Timing Belt has Jumped Teeth If the belt is excessively worn, loose, or missing teeth it is possible for the belt to jump teeth on the crankshaft. - A belt which is off by just one tooth will cause an engine to run very poorly or not run at all. A belt which is off by more than one tooth will generally prevent the engine from starting. To verify the problem, remove the timing belt covers and check the crankshaft and camshaft alignment marks. The Camshaft is Seized - A seized camshaft will produce the same symptoms as a broken timing belt. WARNING: Rotating the camshaft with the timing belt removed on an interference engine can result in additional valve damage. INTERFERENCE/FREE RUNNING Interference - Upon reaching Top Dead Center a piston will impact a valve which is fully open. This situation occurs when the timing belt breaks and a valve is left fully open while the pistons continue to operate. NOTE: This engine is an Interference design. Free Running - The engine has been designed such that should the timing belt break there will still be clearance between a fully open valve and a piston at TDC. Valve Damage - Interference engines will generally bend intake or exhaust valves when a timing belt is broken. When a timing belt breaks the rotational momentum of the camshaft will cause several valves to open and close out of sequence with the movement of the pistons. Any valve which is left open when the associated piston reaches TDC will be struck and bent. Bent valves will generally stick in a partially open position, resulting in a loss of vacuum and compression on that cylinder. If a timing belt breaks during normal city or highway driving the probability that an interference engine will bend at least one valve is very high. NOTE: If a timing belt breaks, an interference type engine will not always bend or damage valves. If the timing belt breaks during start-up with camshaft remaining in a position where no valve is fully open there will be no valve damage. Free running engines will generally not bend or damage valves when a timing belt is broken. However the design clearance between a fully open valve and a piston at TDC may be quite small (<0.020 inches) . A build up of carbon on top of the piston in conjunction with improperly adjusted valve clearances can result in a free running engine bending valves when the timing belt breaks. VERIFYING VALVE DAMAGE Install a new timing belt with the camshaft and crankshaft aligned properly and attempt to start the engine. If the engine starts and runs smoothly with steady high vacuum levels, the valves are not damaged. WARNING: Rotating the camshaft with the timing belt removed on an interference engine can result in additional valve damage. If the engine fails to start or runs roughly with the manifold vacuum reading rapidly oscillating over a 4-6 inch range there may be valve damage. NOTE: Verify that the crankshaft and camshaft are aligned properly. A timing belt which is off Dust one tooth may produce similar performance symptoms. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 890 Remove the valve cover and inspect the valve clearances. A valve which is bent will be stuck in the open position or will have an excessively larger clearance. Perform a compression check or a cylinder leak down check. Cylinders with bent valves will have very low compression (<50.0 psi) and will not hold pressure. If valve damage is detected the cylinder head will have to be removed and the damaged valves replaced. Also inspect top of the pistons for damage. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 891 Timing Belt: Fundamentals and Basics Initial Preparations INITIAL PREPARATIONS Disconnect Battery When working near or around the crankshaft/camshaft pulleys, accidentally engaging the starter can result in serious personal injury and major engine damage. The negative battery terminal should be disconnected prior to commencing work and should not be reconnected until the timing belt is re-installed and the engine is ready to start. Remove Front Tire Access to lower timing belt components can be gained by removing the associated front tire and working through the wheel well. Fender Covers Fender covers will prevent damage to the vehicles finish while performing the job. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 892 Timing Belt: Fundamentals and Basics Positioning Crankshaft to Number 1 TDC POSITIONING CRANKSHAFT TO #1 TDC, Compression NOTE: If the timing belt is broken, pre-position only the crankshaft and ignore references in this article to compression stroke, camshaft, and distributor position. Rotating the camshaft with a broken timing belt may damage the valves. WHY Timing belt installation alignment marks correspond to the crankshaft positioned at #1 Top Dead Center (TDC), during the compression stroke. Moving the crankshaft to this point prior to removing the belt allows you to verify the original alignment of the crankshaft and camshaft. This also reduces crank/cam pulley movement once the belt is removed which helps to minimize any possible confusion. The alignment marks may be dirty and difficult to locate. Pre-positioning the crankshaft will make it easier to locate the marks. HOW - Remove the distributor cap and observe the position of the rotor. - Using the crankshaft bolt, rotate the crankshaft until the distributor rotor is nearly pointing towards the #1 cylinder position. - Then slowly rotate the crankshaft until the timing indicator is pointing at the "0"/TDC degree mark. NOTE: Remember that the crankshaft rotates twice for every rotation of the camshaft. The rotor must be pointing towards #1 cylinder terminal when the timing mark reaches 0 degrees. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 893 Timing Belt: Fundamentals and Basics Removal and Installation Tips and Hints (Maintenance) TIMING BELT REMOVAL - Prior to removing the timing belt, inspect all drive belts. Since the drive belts will need to be removed to replace the timing belt it would be convenient to have any necessary replacement belts on hand should any the drive belts show excessive wear. - After the timing belt covers are removed, verify the camshaft and crankshaft are properly aligned. - Verify that all timing belt cover gaskets and inspection hole covers are intact. Any missing gaskets or covers could allow moisture and debris to enter the covers and damage the belt. NOTE: In cold climates, any moisture which enters the covers may eventually freeze on the timing belt or between the belt and the pulley, resulting in the belt skipping teeth. - When removing the engine mount, Slightly raise the engine with a floor jack. This will take the weight of the engine off of engine mount bolts and will ease in removal. CAUTION: Never apply the lifting surface of the floor jack directly to the oil pan. Use a block of wood or other soft material to prevent puncturing the oil pan. TIMING BELT INSTALLATION - When positioning or removing the camshaft and crankshaft pulleys, do not grasp the teeth of the pulleys with pliers or any other metal object. CAUTION: Any nick or burr left on the pulleys may result in premature belt failure. - When installing the timing belt: Do not use any device to pry the belt over a pulley - Do not lubricate the pulleys with any type of fluid or penetrating oil to ease in slipping the belt on. - Always install the belt such that the initial slack is on the tensioner side of the pulleys. If any slack is left on the opposite side, when the tensioner is released the pulleys will turn and the belt alignment will be incorrect. - After installing and tensioning the belt, recheck the alignment of the camshafts and crankshaft. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 894 Timing Belt: Fundamentals and Basics General Information TIMING BELT, GENERAL INFORMATION PURPOSE The timing belt synchronizes (times) the opening and closing of the intake and exhaust valves with the movement/stroke of the pistons. The timing belt also matches the rotation of the distributor with the movement of the pistons. OPERATION The crankshaft represents the movement of the pistons while the camshaft controls the opening and closing of the valves. The timing belt connects the crankshaft to the camshaft and uses the rotation of the crankshaft to drive the camshaft in a 2 to 1 relationship. For every two revolutions of the crankshaft the camshaft is rotated only once. Why 2:1 In 4 stoke engine each piston must complete 4 separate strokes (intake, compression, power, and exhaust) to complete a cycle. For a single piston to complete all four strokes the crankshaft must rotate two full revolutions. The camshaft controls the opening and closing of the valves. During the four piston strokes of an engine cycle the intake and exhaust valves (for each cylinder) will open and close only once. This requires only one revolution of the camshaft. NOTE: The intake valves will open and close only during the intake stroke and the exhaust valves will open and close only during the exhaust stroke. During the compression and power strokes the valves remain closed. How This 2 to 1 reduction is accomplished by making the circumference of the camshaft pulley twice as large as the crankshaft pulley. This allows the smaller crankshaft to complete two revolutions while the larger camshaft completes only one revolution. NOTE: The distributor also requires only one rotation for every two rotations of the crankshaft. FIRST INDICATIONS OF A BROKEN BELT 1. The engine will immediately die or fail to start. 2. When attempting to restart the engine, the cranking speed (rpm) will be unusually fast. 3. The sound of the engine while attempting to restart will be different than normal. Instead of the usual rhythmic "Rir. . .Rir. . .Rir..." cranking sound it will sound more like "RirRirRirRir" with no detectable rhythm. Why When the timing belt brakes the camshaft and distributor quit rotating. - Without distributor rotation the ignition system stops producing spark and the engine immediately dies or fails to start. - Without the rotation of the camshaft the intake and exhaust valves stop opening and closing. This prevents the pistons from developing compression which also causes the engine to die. This lack of compression also produces the unusually fast and non- rhythmic cranking speed when attempting to restart the engine. NOTE: The normal rhythmic cranking sound is a result of the starter having to work harder as each piston begins its compression stroke. VERIFYING TIMING BELT IS BROKEN Check for camshaft rotation while cranking the engine (with the starter or by hand, using the crankshaft bolt). WARNING: When rotating the crankshaft by hand always disconnect the battery. Camshaft rotation can be verified by: Remove oil filler cap and check if camshaft is visible. - Remove valve cover and directly observe camshaft. - Remove distributor cap and check for rotor rotation (the rotor is driven by the camshaft) - Remove upper timing belt cover and check camshaft pulley rotation and belt integrity. Other Indications the Timing Belt may be broken. No ignition spark. - Very low compression (<15 psi) on all cylinders. Due to the low compression the following additional symptoms may be present. While attempting to start the car, the battery strength remains high for an unusually long length of time. - The sound of the engine while attempting to restart will be different than normal. Instead of the usual rhythmic "Rir.. .Rir. . .Rir..." cranking sound it will sound more like "RirRirRirRir" with no detectable rhythm. NOTE: For an experienced technician this unique sound will often be the initial symptom that leads to a more in-depth check of the Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 895 timing belt. OTHER RELATED PROBLEMS The Timing Belt has Jumped Teeth If the belt is excessively worn, loose, or missing teeth it is possible for the belt to jump teeth on the crankshaft. - A belt which is off by just one tooth will cause an engine to run very poorly or not run at all. - A belt which is off by more than one tooth will generally prevent the engine from starting. - To verify the problem, remove the timing belt covers and check the crankshaft and camshaft alignment marks. The Camshaft is Seized - A seized camshaft will produce the same symptoms as a broken timing belt. WARNING: Rotating the camshaft with the timing belt removed on an interference engine can result in additional valve damage. INTERFERENCE/FREE RUNNING Interference - Upon reaching Top Dead Center a piston will impact a valve which is fully open. This situation occurs when the timing belt breaks and a valve is left fully open while the pistons continue to operate. NOTE: This engine is an Interference design. Free Running - The engine has been designed such that should the timing belt break there will still be clearance between a fully open valve and a piston at TDC. Valve Damage - Interference engines will generally bend intake or exhaust valves when a timing belt is broken. When a timing belt breaks the rotational momentum of the camshaft will cause several valves to open and close out of sequence with the movement of the pistons. Any valve which is left open when the associated piston reaches TDC will be struck and bent. Bent valves will generally stick in a partially open position, resulting in a loss of vacuum and compression on that cylinder. If a timing belt breaks during normal city or highway driving the probability that an interference engine will bend at least one valve is very high. NOTE: If a timing belt breaks, an interference type engine will not always bend or damage valves. If the timing belt breaks during start-up with camshaft remaining in a position where no valve is fully open there will be no valve damage. Free running engines will generally not bend or damage valves when a timing belt is broken. However the design clearance between a fully open valve and a piston at TDC may be quite small (<0.020 inches) . A build up of carbon on top of the piston in conjunction with improperly adjusted valve clearances can result in a free running engine bending valves when the timing belt breaks. VERIFYING VALVE DAMAGE Install a new timing belt with the camshaft and crankshaft aligned properly and attempt to start the engine. If the engine starts and runs smoothly with steady high vacuum levels, the valves are not damaged. WARNING: Rotating the camshaft with the timing belt removed on an interference engine can result in additional valve damage. If the engine fails to start or runs roughly with the manifold vacuum reading rapidly oscillating over a 4-6 inch range there may be valve damage. NOTE: Verify that the crankshaft and camshaft are aligned properly. A timing belt which is off Dust one tooth may produce similar Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 896 performance symptoms. Remove the valve cover and inspect the valve clearances. A valve which is bent will be stuck in the open position or will have an excessively larger clearance. Perform a compression check or a cylinder leak down check. Cylinders with bent valves will have very low compression (<50.0 psi) and will not hold pressure. If valve damage is detected the cylinder head will have to be removed and the damaged valves replaced. Also inspect top of the pistons for damage. Initial Preparations INITIAL PREPARATIONS Disconnect Battery When working near or around the crankshaft/camshaft pulleys, accidentally engaging the starter can result in serious personal injury and major engine damage. The negative battery terminal should be disconnected prior to commencing work and should not be reconnected until the timing belt is re-installed and the engine is ready to start. Remove Front Tire Access to lower timing belt components can be gained by removing the associated front tire and working through the wheel well. Fender Covers Fender covers will prevent damage to the vehicles finish while performing the job. Positioning Crankshaft to Number 1 TDC POSITIONING CRANKSHAFT TO #1 TDC, Compression NOTE: If the timing belt is broken, pre-position only the crankshaft and ignore references in this article to compression stroke, camshaft, and distributor position. Rotating the camshaft with a broken timing belt may damage the valves. WHY Timing belt installation alignment marks correspond to the crankshaft positioned at #1 Top Dead Center (TDC), during the compression stroke. Moving the crankshaft to this point prior to removing the belt allows you to verify the original alignment of the crankshaft and camshaft. This also reduces crank/cam pulley movement once the belt is removed which helps to minimize any possible confusion. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 897 The alignment marks may be dirty and difficult to locate. Pre-positioning the crankshaft will make it easier to locate the marks. HOW - Remove the distributor cap and observe the position of the rotor. - Using the crankshaft bolt, rotate the crankshaft until the distributor rotor is nearly pointing towards the #1 cylinder position. - Then slowly rotate the crankshaft until the timing indicator is pointing at the "0"/TDC degree mark. NOTE: Remember that the crankshaft rotates twice for every rotation of the camshaft. The rotor must be pointing towards #1 cylinder terminal when the timing mark reaches 0 degrees. Removal and Installation Tips and Hints (Maintenance) TIMING BELT REMOVAL - Prior to removing the timing belt, inspect all drive belts. Since the drive belts will need to be removed to replace the timing belt it would be convenient to have any necessary replacement belts on hand should any the drive belts show excessive wear. - After the timing belt covers are removed, verify the camshaft and crankshaft are properly aligned. - Verify that all timing belt cover gaskets and inspection hole covers are intact. Any missing gaskets or covers could allow moisture and debris to enter the covers and damage the belt. NOTE: In cold climates, any moisture which enters the covers may eventually freeze on the timing belt or between the belt and the pulley, resulting in the belt skipping teeth. - When removing the engine mount, Slightly raise the engine with a floor jack. This will take the weight of the engine off of engine mount bolts and will ease in removal. CAUTION: Never apply the lifting surface of the floor jack directly to the oil pan. Use a block of wood or other soft material to prevent puncturing the oil pan. TIMING BELT INSTALLATION - When positioning or removing the camshaft and crankshaft pulleys, do not grasp the teeth of the pulleys with pliers or any other metal object. CAUTION: Any nick or burr left on the pulleys may result in premature belt failure. - When installing the timing belt: Do not use any device to pry the belt over a pulley - Do not lubricate the pulleys with any type of fluid or penetrating oil to ease in slipping the belt on. - Always install the belt such that the initial slack is on the tensioner side of the pulleys. If any slack is left on the opposite side, when the tensioner is released the pulleys will turn and the belt alignment will be incorrect. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 898 - After installing and tensioning the belt, recheck the alignment of the camshafts and crankshaft. Removal and Installation Tips and Hints (Broken Belt) TIMING BELT REMOVAL - Prior to removing the timing belt, inspect all drive belts. Since the drive belts will need to be removed to replace the timing belt it would be convenient to have any necessary replacement belts on hand should any the drive belts show excessive wear. - After the timing belt covers are removed, align the camshaft and crankshaft. 1. Position the crankshaft to a safe position (approaching #1 Top Dead Center (TDC) with no cylinder at or near top dead center) 2. Align the camshaft with its timing marks. 3. Rotate the crankshaft to #1 TDC WARNING: Valve damage will occur if any cylinder reaches Top Dead Center, while an associated valve is at or near its fully open position. NOTES When positioning the camshaft or crankshaft always rotate the shafts slowly and in small increments, while frequently stopping to observe the relationship of the valves and pistons. - With the spark plugs removed the crankshaft should rotate easily. If any resistance is felt, immediately stop and verify that a piston is not striking a valve. - Verify that all timing belt cover gaskets and inspection hole covers are intact. Any missing gaskets or covers could allow moisture and debris to enter the covers and damage the belt. NOTE: In cold climates, any moisture which enters the covers may eventually freeze on the timing belt or between the belt and the pulley, resulting in the belt skipping teeth. - When removing the engine mount, slightly raise the engine with a floor jack. This will take the weight of the engine off of engine mount bolts and will ease in removal. CAUTION: Never apply the lifting surface of the floor jack directly to the oil pan. Use a block of wood or other soft material to prevent puncturing the oil pan. INSPECTION - Prior to installing the timing belt inspect the teeth of the crank and cam pulleys for burrs or damage. Light burrs may be removed, but any damage which permanently mars the teeth/belt mating surface will require the pulley to be replaced. - Inspect the inside of the timing belt covers for rubbing or wear. The plastic covers may warp, causing the pulleys or belts to rub against the inside of the cover. - Inspect the tensioner/idler/water-pump pulleys for wobble or looseness. The pulleys should spin freely with no rough spots or lateral (side-to-side) movement. - Inspect the tensioner/idler/water pump pulley surfaces. They should be clean and free of nicks and burrs. If any damage is noted the pulleys should be replaced. - Inspect the water pump for signs of leakage, replace if necessary. - Inspect the camshaft and crankshaft oil seals for leakage. Any seal which shows signs of leakage should be replaced. CAUTION: Oil leakage will damage the new timing belt. TIMING BELT INSTALLATION - When positioning or moving the camshaft and crankshaft pulleys, do not grasp the teeth of the pulleys with pliers or any other metal object. CAUTION: Any nick or burr left on the pulleys may result in premature belt failure. - When installing the timing belt: Do not use any device to pry the belt over a pulley - Do not lubricate the pulleys with any type of fluid or penetrating oil to ease in slipping the belt on. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 899 - Always install the belt such that the initial slack is on the tensioner side of the pulleys. If any slack is left on the opposite side, when the tensioner is released the pulleys will turn and the belt alignment will be incorrect. - After installing and tensioning the belt, recheck the alignment of the camshafts and crankshafts. Checking Engine Vacuum CHECKING ENGINE VACUUM Manifold vacuum readings (taken at a vacuum port downstream of the throttle plate) should be steady and smooth. If valve damage has occurred the needle will rapidly fluctuate back and forth. NOTE: Prior to checking vacuum, the ignition timing should be checked and adjusted. Ignition timing will affect the vacuum levels. To verify valve, perform a compression check or leak down check on all cylinders. Cylinders with damaged valves will not develop compression and will not hold pressure. If valve damage is detected the cylinder head will need to be removed. Recommended Parts RECOMMENDED PARTS - New Timing Belt - Compare length, width, and shape of teeth to the old belt. They should match exactly. OPTIONAL, PENDING INSPECTION Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 900 - Water Pump - Replacing the water pump requires removing the timing belt. A thorough examination of the water pump while the timing belt is removed is highly recommended. - Gasket Sealant - When removing the timing belt covers the gaskets may come unglued from the covers. - Camshaft and Crankshaft Seals - These seals are located behind the timing belt gears. Leakage from these seals can rapidly deteriorate a new timing belt. - Drive Belts - Drive belt removal is required to access the timing belt. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications Drive Belt: Specifications Fig. 23 Belt deflection check points AIR CONDITIONING BELT Belt deflection under a ten pound push or pull should be between 1/4 to 5/16 at locations shown in Fig. 23. Measure deflection while applying tension to accessory, then tighten mounting mounts to specification. Deflection on a new belt should be between 1/4 to 1/2; a belt is considered used after 15 minutes of engine operation, tension on a used belt should be 1/4 and 5/16 under a tension pound load. ACCESSORY BELT Correct belt tension is 5/16 deflection between pulleys. Fig. 24 Serpentine drive belt SERPENTINE DRIVE BELT ROUTINGS Refer to Fig. 24, for serpentine belt routing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 904 Fig. 24 Serpentine drive belt Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 905 Drive Belt: Adjustments Fig. 23 Belt deflection check points AIR CONDITIONING BELT Belt deflection under a ten pound push or pull should be between 1/4 to 5/16 at locations shown in Fig. 23. Measure deflection while applying tension to accessory, then tighten mounting mounts to specification. Deflection on a new belt should be between 1/4 to 1/2; a belt is considered used after 15 minutes of engine operation, tension on a used belt should be 1/4 and 5/16 under a tension pound load. ACCESSORY BELT Correct belt tension is 5/16 deflection between pulleys. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Belt Drive Belt: Service and Repair A/C Belt Fig. 27 A/C Pulley Removal 1. Loosen adjusting locknut, then turn jack-screw, Fig. 27, counterclockwise to reduce belt tension and remove belt. 2. When reinstalling belt, adjust belt tension to 5/16 inch deflection between pulleys. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Belt > Page 908 Drive Belt: Service and Repair Accessory Drive Belt WARNING: Belts must be checked with engine not running. ACCESSORY DRIVE BELTS Fig. 2 Air Conditioning Belt A/C Belt 1. Loosen Adjusting Lock Nut Fig. 2. 2. Turn adjusting "jack" screw counterclockwise to reduce belt tension. Remove belt. 3. Reinstall. 4. Adjust belt tension. A small spring scale can be used to establish the ten-pound belt load. Belt deflection under a ten-pound push or pull should be between 6 mm (1/4 in.) to 8mm (5/16 in.). Tighten pulley nut to 57 Nm (40 ft. lbs.) after adjustment. Fig. 3 Alternator/Power Steering Belt Alternator/Power Steering Belt 1. Install breaker bar into 1/2 square opening in tensioner. 2. Rotate tensioner counterclockwise to remove (and install) belt Fig. 3. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Belt > Page 909 Drive Belt: Service and Repair Alternator & Power Steering Belt Fig. 29 Alternator & Power Steering Belt Removal. 1989-90 Models Fig. 30 Alternator & Power Steering Belt Removal. 1990-92 Models 1. Install breaker bar into square opening in tensioner, Figs. 29 and 30. 2. ^ On 1990 and earlier models, rotate tensioner counterclockwise to remove or install belt. ^ On 1991 and later models, rotate tensioner counterclockwise to remove or install belt. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid Filter - A/T: Customer Interest A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 919 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 920 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 921 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid Filter - A/T: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 927 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 928 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 929 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Absolute Pressure Sensor: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 935 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 Absolute Pressure Sensor: All Technical Service Bulletins Check Engine Lamp Comes On and Fault Code 13 NO.: 18-09-91 GROUP: DRIVEABILITY DATE: Sept. 23, 1991 SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine MODELS: 1989 (AA) SPIRIT/ACCLAIM 1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON 1989 (AG) DAYTONA 1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE 1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER SYMPTOM/CONDITION: The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic Change" is set into the diagnostic system. DIAGNOSIS: Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the diagnostic manual to verify that the MAP sensor is operating properly. PARTS REQUIRED: 1 MAP Sensor Relocation Package 4638458 Package Contents: 1 Cap Plug (1987-88 vehicles) 3580172 1 Cap Plug (1989 vehicles) 4241618 1 Purge Jumper Assembly 4669038 Consisting of: 1 In-Line Vacuum Connector 4201275 1 Vacuum Tee 33000227 1 11" Vacuum Hose 4104272 1 Bleed/Hose Assembly 4669042 Consisting of: 1 Vent 53007494 1 1" Vacuum Hose 4713956 1 Vacuum Tee 4669041 2 Vacuum Hose With 90 Degree Bend 4669044 1 Bracket 4686013 1 Wiring Harness 4687141 5 Tie Wraps 6015756 REPAIR PROCEDURE: This repair involves relocation of the MAP sensor. 1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable. 2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its present location. 3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug (3580172 for 1987 and 1988 vehicles or 4241618 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 940 for 1989 vehicles) in its place. 4. Loosen clamps and remove throttle body/air filter intake hose. 5. Wiring Harness Installation Procedure: If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted on the right side shock tower or on the bulkhead follow Step B. A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor connector. Route the harness along the backside of the intake manifold toward the throttle body. The harness should be secured to the fuel line and to the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps. B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length. Connect the FEMALE end of the harness to the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the harness to the right side of the motor mount and the two rear engine wiring support brackets. Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the supplied tie wraps. 6. Attach original MAP sensor to the bracket (4686013) supplied in the package. Figure 1 7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to slide over throttle body stud. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 941 Figure 2 8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque nut to 25 N-m (225 in.lbs.). 9. Disconnect the intake manifold end of the formed purge hose that extends from the intake manifold nipple to the "F" shaped connector (Figure 2). Figure 3 10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to nipple on intake manifold. Position the MAP bleed valve as close to vertical as possible. Figure 4 11. Cut the existing PVC hose as shown in Figure 2. 12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the formed purge hose (disconnected in Step 9) and the PVC hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed purge hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 942 Figure 5 NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE IT OVER THE TOP OF THROTTLE LINKAGE. 13. Connect vacuum hose to MAP sensor. 14. Connect wiring harness connector to MAP sensor. 15. Install throttle body/air filter intake hose and tighten clamps. 16. Use the DRB II to erase any fault codes and perform the applicable verification tests. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-14-15-94 . . . . . . . . . . . . . . . . . 0.8 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set Absolute Pressure Sensor: All Technical Service Bulletins MAP Sensor - DTC's 13 or 14 Set Models 1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies Subject MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines Index DRIVEABILITY Date January 29, 1990 No. 18-03-90 (C18-20-9) P-164 BODY CODE LEGEND AA - ACCLAIM/,SPIRIT LEBARON LANDAU C/AC - DYNASTY/NEW YORKER LANDAU/SALON E - CARAVELLE/600 G/AG - DAYTONA H/AH - LANCER/LEBARON GTS J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE K/AK - ARIES/RELIANT P/AP - SHADOW/SUNDANCE S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle diagnostic memory. PARTS REQUIRED 1 MAP Sensor PN 5227351 1 Sensor Hose (3.0L Engine Only) PN 4557138 REPAIR PROCEDURE When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service Manual for replacement procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 091689 > Oct > 89 > Engine - Oil Consumption Absolute Pressure Sensor: All Technical Service Bulletins Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 951 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 957 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 962 for 1989 vehicles) in its place. 4. Loosen clamps and remove throttle body/air filter intake hose. 5. Wiring Harness Installation Procedure: If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted on the right side shock tower or on the bulkhead follow Step B. A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor connector. Route the harness along the backside of the intake manifold toward the throttle body. The harness should be secured to the fuel line and to the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps. B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length. Connect the FEMALE end of the harness to the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the harness to the right side of the motor mount and the two rear engine wiring support brackets. Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the supplied tie wraps. 6. Attach original MAP sensor to the bracket (4686013) supplied in the package. Figure 1 7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to slide over throttle body stud. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 963 Figure 2 8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque nut to 25 N-m (225 in.lbs.). 9. Disconnect the intake manifold end of the formed purge hose that extends from the intake manifold nipple to the "F" shaped connector (Figure 2). Figure 3 10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to nipple on intake manifold. Position the MAP bleed valve as close to vertical as possible. Figure 4 11. Cut the existing PVC hose as shown in Figure 2. 12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the formed purge hose (disconnected in Step 9) and the PVC hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed purge hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 964 Figure 5 NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE IT OVER THE TOP OF THROTTLE LINKAGE. 13. Connect vacuum hose to MAP sensor. 14. Connect wiring harness connector to MAP sensor. 15. Install throttle body/air filter intake hose and tighten clamps. 16. Use the DRB II to erase any fault codes and perform the applicable verification tests. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-14-15-94 . . . . . . . . . . . . . . . . . 0.8 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 973 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill Fluid Filter - A/T: Service and Repair Fluid Drain and Refill 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body. 4. Clean the oil pan and magnet. Reinstall pan using new MOPAR RTV sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill tube. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark. CAUTION: Do not overfill transaxle. Do not acid oil if level is between: Lower holes for warm oil (100°F). Upper holes for hot oil (180°F). 8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill tube. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill > Page 976 Fluid Filter - A/T: Service and Repair Fluid & Filter Change 3 Speed Automatic Fluid and filter changes are not required for average vehicle use. Severe usage such as commercial type usage or prolonged operation in city traffic requires that fluid be changed and bands adjusted every 15,000 miles. 1. Raise vehicle and support vehicle. Place a suitable drain pan below transmission oil pan. 2. Loosen transmission oil pan attaching bolts and allow fluid to drain, then remove oil pan. 3. Replace filter and adjust bands, if necessary. 4. Install oil pan and gasket. Torque attaching bolts to 40 inch lbs. 5. Add four quarts of approved automatic transmission fluid. 6. Start engine and allow to idle for approximately six minutes, then with parking brake applied, move selector lever momentarily to each position. Place selector lever in Park and check fluid level. Add fluid to bring level to Add mark. 7. Recheck fluid level after transmission has reached normal operating temperature. 4 Speed Automatic When the factory fill fluid is changed, only fluids labeled MOPAR ATF Plus 4 (Automatic Transmission fluid) Type 7176, or equivalent should be used. A filter change should be made at the time of the oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a clean, dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair 1. Loosen gas cap and allow tank pressure to release. 2. Remove wiring harness connector from any injector, then ground one injector terminal. 3. Connect a suitable jumper wire to a second terminal, then touch the positive post of the battery for approximately 10 seconds and release system pressure. 4. Remove jumper wires and service fuel system as required. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Locations Water Pump And Coolant Tube Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 240395 > Jan > 95 > A/C System - Poor Cooling Performance Hose/Line HVAC: Customer Interest A/C System - Poor Cooling Performance NO: 24-03-95 GROUP: Heater & A/C DATE: Jan. 27, 1995 SUBJECT: Revised Underbody Refrigerant Line Gasket MODELS: 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1995 (ES) Chrysler Voyager (European Market) 1989 (S) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE (LWB) VEHICLES EQUIPPED WITH AUXILIARY REAR A/C OPTION. SYMPTOM/CONDITION: Poor A/C system cooling performance. DIAGNOSIS: Check for low refrigerant charge and inspect the connection of the A/C underbody refrigerant lines to the rear auxiliary A/C unit. If refrigerant is detected at the connection, perform the repair procedure. PARTS REQUIRED: 1 4798270 Gasket, Underbody Refrigerant Line REPAIR PROCEDURE: This bulletin involves installing a revised underbody refrigerant line gasket. 1. Recover any residual refrigerant in the A/C system. 2. Disconnect the A/C underbody refrigerant lines from the rear auxiliary A/C unit. 3. Inspect and clean the A/C plumbing surfaces that contact the gasket. Do not scratch the surfaces. 4. Install the revised gasket, P/N 4798270. This gasket is rubber coated stainless steel. 5. Evacuate and recharge the A/C system using the procedure outlined in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-45-62-90 ....................................................................................................... ................................................................ 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 240490 > Sep > 90 > Air Conditioning System - Moaning/Growling Noise Hose/Line HVAC: Customer Interest Air Conditioning System - Moaning/Growling Noise NO.: 24-04-90 GROUP: HEATER & A/C DATE: Sept. 10, 1990 SUBJECT: Air Conditioning System Noise - 3.OL Engine MODELS: 1989 Dodge Caravan, Grand Caravan, Caravan C/V, Plymouth Voyager, Grand Voyager, Chrysler Town & Country SYMPTOM/CONDITION Some vehicles equipped with the 3.OL engine may exhibit a moaning or growling noise when the air conditioning system is on. This noise is caused by refrigerant gas pulsation being transmitted through the A/C discharge line. This noise is NOT the fault of the A/C compressor. DIAGNOSIS Verify that the vehicle has a moaning or growling noise when the air conditioning is on. Inspect the entire length of the discharge, suction and liquid lines for grounding. These lines should not touch any sheet metal or underhood component. Also inspect these lines for grounding during engine roll and where the lines go through the bulkhead. Inspect for proper foam or rubber isolation at all brackets and the radiator support and correct as necessary. If the noise persists, proceed to the following repair procedure. Remember, the compressor should not be replaced unless it has failed the output test outlined in TSB 24-03-89 Revision A or is making metallic noises. REPLACING THE COMPRESSOR FOR THE A/C DISCHARGE LINE NOISE WILL NOT CORRECT THE PROBLEM. PARTS REQUIRED 1 4419464 A/C Discharge Line Assembly REPAIR PROCEDURE This procedure involves inspection and replacement of the A/C discharge line assembly with a revised discharge line. 1. Check to see if the A/C discharge line muffler is approximately two inches from the condenser. If so, remove the discharge line according to the procedure outlined in the service manual. A/C systerns should be evacuated using an approved recovery station. 2. Install a new discharge line assembly (PN 4419464) that has a muffler located near the compressor attachment flange. 3. Verify A/C operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 24-45-25-91 . . . . . . . . . . . . . . . . 1.2 Hrs. Replace A/C Discharge Line Assembly 24-01-10-01 . . . . . . . . . . . . . . . . 0.2 Hrs. Additional Time Required When R12 Recovery Station Is Used FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 240395 > Jan > 95 > A/C System - Poor Cooling Performance Hose/Line HVAC: All Technical Service Bulletins A/C System - Poor Cooling Performance NO: 24-03-95 GROUP: Heater & A/C DATE: Jan. 27, 1995 SUBJECT: Revised Underbody Refrigerant Line Gasket MODELS: 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1995 (ES) Chrysler Voyager (European Market) 1989 (S) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE (LWB) VEHICLES EQUIPPED WITH AUXILIARY REAR A/C OPTION. SYMPTOM/CONDITION: Poor A/C system cooling performance. DIAGNOSIS: Check for low refrigerant charge and inspect the connection of the A/C underbody refrigerant lines to the rear auxiliary A/C unit. If refrigerant is detected at the connection, perform the repair procedure. PARTS REQUIRED: 1 4798270 Gasket, Underbody Refrigerant Line REPAIR PROCEDURE: This bulletin involves installing a revised underbody refrigerant line gasket. 1. Recover any residual refrigerant in the A/C system. 2. Disconnect the A/C underbody refrigerant lines from the rear auxiliary A/C unit. 3. Inspect and clean the A/C plumbing surfaces that contact the gasket. Do not scratch the surfaces. 4. Install the revised gasket, P/N 4798270. This gasket is rubber coated stainless steel. 5. Evacuate and recharge the A/C system using the procedure outlined in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-45-62-90 ....................................................................................................... ................................................................ 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 240490 > Sep > 90 > Air Conditioning System Moaning/Growling Noise Hose/Line HVAC: All Technical Service Bulletins Air Conditioning System - Moaning/Growling Noise NO.: 24-04-90 GROUP: HEATER & A/C DATE: Sept. 10, 1990 SUBJECT: Air Conditioning System Noise - 3.OL Engine MODELS: 1989 Dodge Caravan, Grand Caravan, Caravan C/V, Plymouth Voyager, Grand Voyager, Chrysler Town & Country SYMPTOM/CONDITION Some vehicles equipped with the 3.OL engine may exhibit a moaning or growling noise when the air conditioning system is on. This noise is caused by refrigerant gas pulsation being transmitted through the A/C discharge line. This noise is NOT the fault of the A/C compressor. DIAGNOSIS Verify that the vehicle has a moaning or growling noise when the air conditioning is on. Inspect the entire length of the discharge, suction and liquid lines for grounding. These lines should not touch any sheet metal or underhood component. Also inspect these lines for grounding during engine roll and where the lines go through the bulkhead. Inspect for proper foam or rubber isolation at all brackets and the radiator support and correct as necessary. If the noise persists, proceed to the following repair procedure. Remember, the compressor should not be replaced unless it has failed the output test outlined in TSB 24-03-89 Revision A or is making metallic noises. REPLACING THE COMPRESSOR FOR THE A/C DISCHARGE LINE NOISE WILL NOT CORRECT THE PROBLEM. PARTS REQUIRED 1 4419464 A/C Discharge Line Assembly REPAIR PROCEDURE This procedure involves inspection and replacement of the A/C discharge line assembly with a revised discharge line. 1. Check to see if the A/C discharge line muffler is approximately two inches from the condenser. If so, remove the discharge line according to the procedure outlined in the service manual. A/C systerns should be evacuated using an approved recovery station. 2. Install a new discharge line assembly (PN 4419464) that has a muffler located near the compressor attachment flange. 3. Verify A/C operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 24-45-25-91 . . . . . . . . . . . . . . . . 1.2 Hrs. Replace A/C Discharge Line Assembly 24-01-10-01 . . . . . . . . . . . . . . . . 0.2 Hrs. Additional Time Required When R12 Recovery Station Is Used FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Use new brake fluid only, to top off the master cylinder or refill system. Never use reclaimed fluid, unmarked or unspecified fluid, fluid not meeting SAE/DOT standards, fluid marked 70R1, or fluid from a container that has been left open. Brake Fluid Type DOT 3 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1010 Brake Fluid: Testing and Inspection Indications of fluid contamination: Swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination: Put small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil contamination. If contaminated: Drain and thoroughly flush system, and replace all rubber parts. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1011 Brake Fluid: Service and Repair Aluminum Master Cylinder NOTES: - Check master cylinder fluid level twice annually. - Master cylinder reservoirs are marked with the words "fill to bottom of rings". - Add DOT 3 fluid to bring the level to the bottom of the primary split ring. CAUTION: Use of brake fluid with a lower boiling point than DOT 3 fluid could result in brake failure during long, hard braking. CAUTION: Do not use fluid which has been stored in an unsealed container. Brake fluid stored in this manner will absorb moisture which could result in brake failure during long, hard braking. CAUTION: Use of petroleum based fluids will result in seal damage. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1016 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1017 Coolant: Technical Service Bulletins Engine Coolant - Recycling Recommendations SUBJECT: Engine Coolant Recycling NO.: 07-03-90 GROUP: COOLING DATE: Dec. 21, 1990 MODELS: All Domestic & Import Vehicles DISCUSSION: A number of systems are being marketed to "recycle" or "reconstitute" used ethylene glycol antifreeze/coolant in the dealership. Some of the systems have been advertised as producing a recycled antifreeze "as good as" original and suggest the recycled product is suitable for use in Chrysler Corporation vehicles. Tests, so far, indicate most of these systems merely remove suspended solids from the used antifreeze/coolant through the use of various size filters. These systems do not remove glycol degradation products, or dissolved solids, which can cause water pump seal wear. These systems use a universal "reinhibitor package". The "reinhibitor package" can not restore every type antifreeze/coolant inhibitor system to a like new condition. Tests results indicate these "recycled" products do not consistently provide the protection required in Chrysler Corporation engines and cooling systems. The use of these "reconstituted" antifreeze/coolants is not authorized in the performance of any repair covered under the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Page 1018 Coolant: Specifications COOLING SYSTEM CAPACITY 1988-89 Caravan / Voyager / Grand Caravan / Grand Voyager 2.5L Engine ......................................................................................................................................... ........................................................ 8.1 L (8.5 qts) 3.0L Engine without rear heater ............................................................................................................................... ............................................... 9.5 L (10.0 qts) with rear heater .......................................................... ....................................................................................................................... 10.5 L (11.0 qts) NOTES: - Includes 0.47 L (1.0 pt) for the heater and coolant reserve bottle. - Includes 0.95 L (1.0 qt) for rear heater systems, if equipped. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Page 1019 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid - A/T: Customer Interest A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1028 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1029 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1030 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid - A/T: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1036 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1037 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1038 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Page 1039 Fluid - A/T: Specifications CAPACITY, Initial Refill*: ..................................................................................................................... ....................................................................AP** All ......................................................................................................................................................... .............................................3.8 Liters 4.0 Quarts *With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed **May use AF or MA when AP is not available only for "Topping off". Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check Fluid - A/T: Service and Repair Fluid Level & Condition Check Fluid Level The transmission and differential sump have a common oil sump with a opening between the two. The torque converter fills in both the "P" Park and "N" Neutral positions. Place the selector lever in "P" Park to check fluid level. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. This will assure complete oil level stabilization between differential and transmission. The fluid should be at normal operating temperature (approximately 82 C. or 180 F). The fluid level is correct if it is in the "HOT" region (cross-hatched area) on the oil level indicator. Fluid Condition Along with fluid level, it is important to check the condition of the fluid. - When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle overhaul is needed. Be sure to examine the fluid on the dipstick closely. - If there is any doubt about its condition, drain out a sample for a double check. Note: After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Low Fluid Level Symptoms Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. in any hydraulic system, air bubbles will make the fluid spongy, therefore pressures will be low and build up slowly. Improper Filling Level Symptoms Improper filling can also raise the fluid level too high. - When the transaxle has too much fluid, the gears churn up foam and cause the same conditions which occur with a low fluid level. In either case the air bubbles can cause over heating, fluid oxidation, and varnishing, which can interfere with normal valve, clutch and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent, where it may be mistaken for a leak. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 1042 Fluid - A/T: Service and Repair Fluid and Filter Change Fluid and Filter Change When the factory fill fluid is changed, only fluids labeled Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a clean dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 1043 Fluid - A/T: Service and Repair Fluid Drain and Refill Procedure 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body. 4. Clean the oil pan and magnet. Reinstall pan using Mopar RTV Sealant. Tighten oil pan bolts to 19 Nm (165 in-lbs). 5. Pour four quarts of Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill tube. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark on the dipstick. CAUTION: Do not over fill transaxle. Do not add oil if level is between: Lower holes for warm oil (100F). Upper holes for hot oil (180F). 8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill tube. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications Fluid - M/T: Specifications All.......................................................................................................................................................... .........................5W-30 SF/CC, SF/CD, SG/CD, SG CAPACITY, Refill: 5-speed A525......................................................................................................... ................................................................................2.1 Liters 4.6 Pints 5-speed A520, A555, A569 ................................................................................................................. .................................................2.3 Liters 4.8 Pints Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - New `SG' Level Oil Engine Oil: Technical Service Bulletins Engine Oil - New `SG' Level Oil Models All 1989 And Earlier Domestic & Import Vehicles Subject New "SG" Quality Engine Oil Index LUBRICATION Date April 24, 1989 No. 10-01-89 (C10-01-9) BODY CODE LEGEND ALL 1989 AND EARLIER CHRYSLER/PLYMOUTH & DODGE DOMESTIC & IMPORT VEHICLES "SG" QUALITY ENGINE OIL The quality of engine oil recommended for use in all Chrysler Motors' vehicles has been upgraded to an "SG" level. The new "SG" quality engine oils can provide significant improvements concerning sludge, varnish and wear control. These new quality oils may also be used in older vehicles where lower quality oils (SE, SF, SF/CC) were recommended. Specific recommendations for all 1989 vehicles may be found in the vehicle "Owners Manual". The new "SG" engine oils are currently being introduced into the MOPAR product line in addition to being commercially available through many automotive supply outlets. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Page 1051 Engine Oil: Specifications Oil Capacity Oil Capacity Crankcase Only With Filter Change 4.0 Quarts 4.5 Quarts Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > A/C System Refrigerant: Specifications A/C System REFRIGERANT CAPACITIES DODGE/PLYMOUTH TRUCKS 1992 Ram 50 pickup ............................................................................................................................ .............................................. 0.8 kg (30 oz.) Ramcharger .................................................................. ............................................................................................................. 1.3 kg (44 oz.) 1992-91 Dakota ................................................................................................................................... ................................................... 1.2 kg (40 oz.) B-Series van ............................................................ .................................................................................................................. 1.3 kg (44 oz.) with rear unit ....................................................................................................................................................... ...................... 1.8 kg (62 oz.) 1992-90 Caravan, Mini Ram, Voyager ................................................................................................................................................... 0.9 kg (32 oz.) with rear unit ........................................................................................................................... .................................................. 1.2 kg (43 oz.) 1992-88 D/W-Series pickup ................................................................................................................. .................................................. 1.3 kg (44 oz.) 1990-87 Dakota ................................................................................................................................... ................................................... 1.3 kg (44 oz.) 1990-83 B-Series van .......................................................................................................................... .................................................... 1.4 kg (48 oz.) with rear unit ........................................................... .................................................................................................................. 1.8 kg (62 oz.) 1989-84 Caravan, Mini-Ram, Voyager ................................................................................................................................................... 1.1 kg (38 oz.) with rear AC ............................................................................................................................ ................................................. 1.3 kg (44 oz.) 1987-83 D/W-Series pickup ................................................................................................................. .................................................. 1.1 kg (40 oz.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > A/C System > Page 1056 Refrigerant: Specifications Capacities Capacities Capacity 2.38 lb (US) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > A/C System > Page 1057 Refrigerant: Specifications Capacities Capacities Capacity 2.70 lb (US) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications Fig. 10 A/C Component Oil Capacity Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Oil Charge Additions Refrigerant Oil: Service and Repair Oil Charge Additions If there are no signs of external oil leakage, proceed as follows to add oil to system during component replacement. 1. Discharge system refer to, Heating and Air Conditioning/Service and Repair and measure amount of oil collected in discharge container. The amount of oil collected when discharging system must be replaced with new refrigeration oil to maintain proper oil charge. 2. Remove defective components. Measure amount of oil remaining in compressor, if removed. 3. Add correct amount of oil to components. Refer to Air Conditioning/Specifications/Capacities. 4. Install replacement components, then evacuate and recharge system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Oil Charge Additions > Page 1063 Refrigerant Oil: Service and Repair Refrigerant Oil Level Check Compressor oil level need only be checked when there is evidence of oil loss from the system as in the case of a broken line, leaking fitting or component, defective compressor seal or collision damage to system. A wet, shiny surface around a leak point is evidence of oil loss. These compressors must be removed from vehicle and drained to check the oil level, proceed as follows: 1. Discharge system refer to, DISCHARGING & EVACUATING SYSTEM, and repair leak as necessary. 2. Disconnect suction and discharge lines from compressor, then remove compressor and clutch assembly from vehicle. 3. Invert compressor and drain oil through suction and discharge ports. 4. Determine the correct amount of oil to add to compressor by subtracting the amount of oil remaining in other components. Refer to . 5. On all models, add oil to compressor through suction port. 6. Reinstall compressor using new gaskets on refrigerant line fittings, then evacuate and recharge system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding WHEN BLEEDING BRAKES REMEMBER... - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always flush and bleed the brake hydraulic sys. when servicing the brakes, because: Brake fluid absorbs moisture from the air, after 3-4 years of service the water content of the brake fluid may be as high as 6-7%. This significantly reduces the boiling point of the brake fluid which may result in a soft pedal or brake failure during prolonged or severe braking. Corrosion deposits and other contaminants gradually build up inside of the brake hydraulic sys. Check the bottom of the master-cylinder reservoir for a build up of fine black silt. If any is present the brake fluid should be flushed. - Never reuse brake fluid that has been drained from the brake system. DOT 3,4 or DOT 5 As a general rule DOT 5 brake fluid should not be used in vehicles recommending DOT 3 or 4 type fluid. DOT 5 brake fluid is silicone based. DOT 3 (standard) and DOT 4 (heavy-duty) are glycol-based. DOT 5 can be distinguished from conventional brake fluids by its purple color (which comes from a dye). DOT 5 silicone brake fluid won't mix with glycol-based brake fluid (creating concern over sludging if all old fluid isn't removed when a system is refilled with silicone). Silicone does not absorb moisture. DOT 5 brake fluid does not become contaminated with moisture over time as conventional DOT 3 and 4 brake fluids do. Silicone is also chemically inert, nontoxic and won't damage paint like conventional brake fluid. It also has a higher boiling point. Because of this, it is often marketed as a premium "lifetime" brake fluid. It is often used to preserve brake systems in antique vehicles and those that sit for long periods of time between use. Silicone also has slightly different physical properties and compressibility, making it unsuitable for ABS systems calibrated to work with DOT 3 or 4 brake fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 1068 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures When bleeding ABS systems use only diaphragm type bleed pressure bleeder. 1. Turn ignition switch to Off position, then pump brake pedal a minimum of 40 times to de-pressurize hydraulic accumulator. 2. Attach bleeding equipment to brake reservoir. 3. Connect a suitable transparent hose to bleeder valve on left rear wheel cylinder and submerge other end in a glass container partially filled with clean brake fluid. 4. Turn pressure bleeder On, open brake bleed screw 3/4 to one turn. Allow brake fluid to flow until clear and bubble free. 5. Continue to bleed right rear, left front, then right front brakes in that order. 6. Turn Off pressure bleeder, then slowly bleed off pressure from equipment. 7. Remove pressure bleeder from vehicle, ensure proper fluid level in master cylinder. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming 1. Place ignition switch in lock position. 2. Disconnect and tape battery ground cable connector. 3. Wait at least 1 minute after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy airbag for a short time even after battery has been disconnected. 4. After repairs are performed, connect battery ground cable. 5. From passenger side of vehicle, turn ignition switch to On position. 6. SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate if SRS system is functioning correctly. 7. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Circuit Location Amp Power Window Motors......................Fuse Block...........30 Power Door Locks, Seats & Mirror.........Fuse Block...........30 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1078 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1079 Circuit Breaker: Electrical Diagrams Circuit Location Amp Power Window Motors......................Fuse Block...........30 Power Door Locks, Seats & Mirror.........Fuse Block...........30 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Page 1080 Circuit Breaker: Testing and Inspection NOTE: Perform SWITCH VOLTAGE TEST, and verify that the battery is fully charged before starting this test. 1. Locate the circuit breaker (in the fuse box) and connect the positive lead of a voltmeter to the light green terminal. Connect the other lead of the voltmeter to a good ground and check that there is battery voltage. 2. If battery voltage is not present, connect the voltmeter to the other (battery) side of the circuit breaker and check for battery voltage. 3. If battery voltage is present, the circuit breaker is defective and needs to be replaced. If battery voltage is not present, check for an open wire in the harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuse Block: Locations Lower I/P Components RH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1086 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1087 Fuse Block: Connector Views Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1088 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1089 Fuse Panel Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1090 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1091 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1092 Fuse Block: Electrical Diagrams Fuse Panel Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1093 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1094 Fuse Panel Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1095 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1096 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1097 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Emissions Maintenance Light > Component Information > Locations Emissions Maintenance Light: Locations Upper I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Emissions Maintenance Light > Component Information > Locations > Page 1102 Emissions Maintenance Light: Service and Repair Refer to Powertrain Management/Emission Control Systems/Service and Repair for reset procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation On-Board Diagnosis Connector Location On-Board Diagnosis Connector Location On-Board Diagnosis Connector Location Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Page 1106 On-Board Diagnosis Connector Location On-Board Diagnosis Connector Location This reminder system uses ignition on time to calculate maintenance intervals. After necessary emission maintenance has been performed, connect Diagnosis Read-Out Box II (DRB II) to the on-board diagnostic connector. Follow instructions indicated by DRB II tool. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Page 1107 Maintenance Required Lamp/Indicator: Service and Repair On-Board Diagnosis Connector Location On certain models, this Emission Maintenance Reminder System is incorporated into the engine controller. The controller stores vehicle mileage into its memory every 8 miles, then at 60,000, 82,500 or 120,000 miles it will illuminate the EMR lamp. When the indicated mileage is reached or the EMR lamp is on at all times, the following parts must be replaced and the EMR lamp reset. 1. At 60,00 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. 2. At 82,500 miles, proceed as follows: a. Replace oxygen sensor. 3. At 120,000 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. 4. On 1990-95 models, after necessary emission maintenance has been performed, connect Diagnosis Read-Out Box II (DRB II) to the on-board diagnosis connector. See images above. 5. On all models, Follow instructions indicated by DRB II tool. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Malfunction Indicator Lamp Driver Module > Component Information > Locations Malfunction Indicator Lamp Driver Module: Locations Upper I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear Tires: Customer Interest Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Fig. 1-Shim Installation for Toe-Out Fig. 2-Shim Installation for Toe-in Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 1121 Fig. 3-Shim Installation for Positive Camber Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 1122 completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear Tires: All Technical Service Bulletins Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Fig. 1-Shim Installation for Toe-Out Fig. 2-Shim Installation for Toe-in Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 1128 Fig. 3-Shim Installation for Positive Camber Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 1129 completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Nut Torque Nut Torque Front Axle Nut Torque 180 ft.lb Rear Bearing Nut Torque 270 in.lb +/- 30 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1133 Wheel Bearing: Adjustments Fig. 3 Wheel bearing assembly 1. Raise and support rear of vehicle. 2. Tighten adjusting nut to 27 to 34nm (240 to 300 in. lbs.) while rotating wheel. 3. Stop wheel and loosen adjusting nut. 4. Tighten adjusting nut finger tight. End play should be 0.0001-0.0020 inch. 5. Install castle lock with slots aligned with cotter pin hole. 6. Install cotter pin and grease cap. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Permanent Bearings REMOVAL Fig. 15 Removing hub & bearing assembly 1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub and drive shaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6. Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor, then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV joint during this procedure. Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported. 9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as shown. 10. Remove hub and bearing assembly. INSTALLATION Fig. 16 Seal installation 1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve using a suitable lubricant. 4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install rotor, then position caliper over rotor and guide hold-down spring below machined guides on knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut, then with brakes applied, tighten nut to specifications. 10. Install spring washer, locknut and cotter pin. Replaceable Bearings REMOVAL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1136 Fig. 14 Hub removal Fig. 12 Removing bearing from knuckle 1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer. 4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle using tool No. C-4811-2 or equivalent. INSTALLATION Fig. 13 Installing bearing into knuckle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1137 Fig. 14 Installing hub into knuckle 1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer. Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No. C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No. C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1138 Wheel Bearing: Service and Repair Rear REMOVAL 1. Raise and support vehicle, then remove rear wheel and brake drum. 2. Remove cotter pin, nut lock, spring washer and hub nut. 3. Remove half shaft flange retaining bolts. 4. Half shaft is spring loaded, compress inner half shaft joint slightly pulling down to clear rear carrier output shaft. 5. Remove half shaft by pulling half shaft assembly inboard. 6. Remove wheel bearing mounting bolts, then wheel bearing and hub assembly. 7. Replace grease seal if needed. INSTALLATION 1. If grease seal was removed, install a new seal using installer tool No. 6536-A or equivalent. Lubricate circumference of seal before installation. 2. Install washer and hub nut. With brakes applied, torque to 180 ft. lbs. 3. Install spring washer, nut lock and cotter pin. 4. Install hub and bearing assembly. Torque bolts in a crossing pattern to 96 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Permanent Bearings Wheel Hub: Service and Repair Permanent Bearings REMOVAL Fig. 15 Removing hub & bearing assembly 1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub and drive shaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6. Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor, then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV joint during this procedure. Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported. 9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as shown. 10. Remove hub and bearing assembly. INSTALLATION Fig. 16 Seal installation 1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve using a suitable lubricant. 4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install rotor, then position caliper over rotor and guide hold-down spring below machined guides on knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut, then with brakes applied, tighten nut to specifications. 10. Install spring washer, locknut and cotter pin. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Permanent Bearings > Page 1143 Wheel Hub: Service and Repair Replaceable Bearings REMOVAL Fig. 14 Hub removal Fig. 12 Removing bearing from knuckle 1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer. 4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle using tool No. C-4811-2 or equivalent. INSTALLATION Fig. 13 Installing bearing into knuckle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Permanent Bearings > Page 1144 Fig. 14 Installing hub into knuckle 1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer. Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No. C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No. C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Lug Nuts 95 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications SERVICE SPECIFICATIONS Compression pressure ..................................................................................................................... 840 kPa (178 psi) +/- 100 kPa (14 psi) @ 250-400 rpm Maximum variation ....................................... .............................................................................................................................................................. .... 25% Manifold vacuum .................................................................................................................... ........................................................... 520 mmHg (20 in.Hg.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1153 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. NOTE: Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. NOTE: Correct engine compression pressures should be 178 psi +/- 14 psi, Maximum cylinder deviation 25% Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications CAMSHAFT Cam height: Intake .............................................................................................................................. .................................................................... 41.25 mm (1.6240 in.) Limit ..................................................................................................................................................... .......................................... 40.75 mm (1.6043 in.) Exhaust ................................................................................................................................................ ............................................... 41.25 mm (1.6240 in.) Limit ..................................................................................................................................................... .......................................... 40.75 mm (1.6043 in.) Journal O.D. ........................................................................................................................................ ........................................................ 34 mm (1.34 in.) Bearing oil clearance ....................................................................................................................................................... 0.05 - 0.09 mm (.0020 - .0035 in.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1158 Camshaft: Service and Repair Fig. 1 Cylinder Head-Camshaft-Valves Fig. 2 Rocker Cover REMOVE VALVE COVERS 1. Remove air cleaner assembly. 2. Disconnect battery and relocate spark plug wires. 3. Remove vacuum connections. 4. Remove rocker cover screws and remove cover. REMOVE CAMSHAFT SPROCKETS Refer to Engine/Timing Components/Timing Belt/Service and Repair, for disassembly and remove camshaft sprockets. See: Timing Components/Timing Belt/Service and Repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1159 Fig. 3 Auto Lash Adjuster Check CHECK AUTO LASH ADJUSTER FUNCTION Check auto adjusters for free play by inserting a small wire through the air bleed hole in the rocker arm and VERY LIGHTLY push the auto adjuster ball check down. While lightly holding the check ball down move the rocker up and down to check for free play. If there is no play replace the adjuster. NOTE: Do not disassemble the auto lash adjuster. Fig. 4 Auto Lash Adjuster Retainers REMOVE CAMSHAFTS 1. Install auto lash adjuster retainers. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1160 Fig. 11 Distributor Drive 2. Remove distributor extension. 3. When removing camshaft bearing caps do not remove the bolts from the bearing caps. Remove the rocker arm, rocker shafts and bearing cap as an assembly. Fig. 5 Check Camshafts INSPECT CAMSHAFTS 1. Inspect camshaft bearing journals for damage and binding. If journals are binding, also check the cylinder head for damage Fig. 1. Also check cylinder head oil holes for clogging. 2. Front cylinder head camshaft check the tooth surface of the distributor drive gear teeth of the camshaft and replace if abnormal wear is evident. 3. Check the cam surface for abnormal wear and damage and replace if defective. Also measure the cam height Fig. 5.and replace if out of limit, standard value is 41.25 mm 1.624 inch, wear limit is 40.75 mm 1.604 inch. Fig. 6 Inspect Rocker Arms INSPECT ROCKER ARMS Check rocker arms for wear or damage. Replace as necessary. INSPECT ROCKER ARM SHAFTS Fig. 7 Rocker Arm Shaft Identification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1161 NOTE: The rocker arm shaft is hollow and is used as a lubrication oil duct. The rocker arm shaft on the inlet side has a 3mm diameter oil passage hole from the cylinder head. The exhaust side does not have this oil passage. 1. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if heavily damaged or worn. 2. Check oil holes for clogging with small wire, clean as required. INSTALL CAMSHAFTS Lubricate camshaft journals and cams with engine oil and install camshaft on cylinder head. Fig. 8 Camshaft Bearing Caps Position REASSEMBLE ROCKER ARMS 1. Align the camshaft bearing caps with arrows depending on cylinder bank, directed as shown. and in numerical order. Fig. 9 Number One Camshaft Bearing Cap NOTE: Identify number one bearing cap number one and number four caps are similar. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1162 Fig. 10 Assemble Rocker Arm And Shafts 2. Install rocker shafts into bearing cap number one with end notches positioned as shown in Figs. 9 and 10 note that the machined portion of the rocker shaft is facing down. 3. Insert attaching bolts to retain assembly. INSTALL ROCKER ARM SHAFT ASSEMBLY 1. Apply Mopar Silicone Rubber Adhesive Sealant at bearing cap ends as shown in. 2. Install the rocker arm shaft assembly making sure that the arrow mark on the bearing cap and the arrow mark on the cylinder head are in the same direction. NOTE: The direction of arrow marks on the front and rear assemblies are opposite to each other. 3. Tighten bearing cap bolts in the following order to 10 Nm 85 in. lbs. First # 3, then # 2, # 1 and # 4. 4. Repeat step 3 increasing the torque to 20 Nm 180 in.lbs. Fig. 11 Distributor Drive 5. Install distributor drive adaptor assembly Fig. 11. INSTALL VALVE COVERS 1. Clean cylinder head and cover mating surfaces. Install new gasket. 2. See Fig. 2 and apply sealant such as Mopar Silicone Rubber Adhesive Sealant to cover ends. 3. Install cover and tighten cover bolt washer and gasket assembly to 10 Nm (88 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications ROCKER ARM Rocker arm I.D. ................................................................................................................................... .......................................................... 19 mm (.75 in.) Clearance (Rocker arm to shaft) .......................................................................................................................................... 0.01-0.04 mm (.0004-.0016 in.) Limit ..................................................................................................................................................... ............................................... 0.10 mm (0039 in.) Rocker arm shaft O.D. ......................................................................................................................... ..................................................... 18.9 mm (.744 in.) Rocker arm shaft spring free length: Intake ................................................................................................................................................... ............................................... 55.2 mm (2.173 in.) Exhaust ................................................................................................................................................ ............................................... 55.2 mm (2.173 in.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1166 Rocker Arm Assembly: Service and Repair Fig. 1 Cylinder Head-Camshaft-Valves Fig. 2 Rocker Cover REMOVE VALVE COVERS 1. Remove air cleaner assembly. 2. Disconnect battery and relocate spark plug wires. 3. Remove vacuum connections. 4. Remove rocker cover screws and remove cover. REMOVE CAMSHAFT SPROCKETS Refer to Engine/Timing Components/Timing Belt/Service and Repair, for disassembly and remove camshaft sprockets. See: Timing Components/Timing Belt/Service and Repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1167 Fig. 3 Auto Lash Adjuster Check CHECK AUTO LASH ADJUSTER FUNCTION Check auto adjusters for free play by inserting a small wire through the air bleed hole in the rocker arm and VERY LIGHTLY push the auto adjuster ball check down. While lightly holding the check ball down move the rocker up and down to check for free play. If there is no play replace the adjuster. NOTE: Do not disassemble the auto lash adjuster. Fig. 4 Auto Lash Adjuster Retainers REMOVE CAMSHAFTS 1. Install auto lash adjuster retainers. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1168 Fig. 11 Distributor Drive 2. Remove distributor extension. 3. When removing camshaft bearing caps do not remove the bolts from the bearing caps. Remove the rocker arm, rocker shafts and bearing cap as an assembly. Fig. 5 Check Camshafts INSPECT CAMSHAFTS 1. Inspect camshaft bearing journals for damage and binding. If journals are binding, also check the cylinder head for damage Fig. 1. Also check cylinder head oil holes for clogging. 2. Front cylinder head camshaft check the tooth surface of the distributor drive gear teeth of the camshaft and replace if abnormal wear is evident. 3. Check the cam surface for abnormal wear and damage and replace if defective. Also measure the cam height Fig. 5.and replace if out of limit, standard value is 41.25 mm 1.624 inch, wear limit is 40.75 mm 1.604 inch. Fig. 6 Inspect Rocker Arms INSPECT ROCKER ARMS Check rocker arms for wear or damage. Replace as necessary. INSPECT ROCKER ARM SHAFTS Fig. 7 Rocker Arm Shaft Identification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1169 NOTE: The rocker arm shaft is hollow and is used as a lubrication oil duct. The rocker arm shaft on the inlet side has a 3mm diameter oil passage hole from the cylinder head. The exhaust side does not have this oil passage. 1. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if heavily damaged or worn. 2. Check oil holes for clogging with small wire, clean as required. INSTALL CAMSHAFTS Lubricate camshaft journals and cams with engine oil and install camshaft on cylinder head. Fig. 8 Camshaft Bearing Caps Position REASSEMBLE ROCKER ARMS 1. Align the camshaft bearing caps with arrows depending on cylinder bank, directed as shown. and in numerical order. Fig. 9 Number One Camshaft Bearing Cap NOTE: Identify number one bearing cap number one and number four caps are similar. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1170 Fig. 10 Assemble Rocker Arm And Shafts 2. Install rocker shafts into bearing cap number one with end notches positioned as shown in Figs. 9 and 10 note that the machined portion of the rocker shaft is facing down. 3. Insert attaching bolts to retain assembly. INSTALL ROCKER ARM SHAFT ASSEMBLY 1. Apply Mopar Silicone Rubber Adhesive Sealant at bearing cap ends as shown in. 2. Install the rocker arm shaft assembly making sure that the arrow mark on the bearing cap and the arrow mark on the cylinder head are in the same direction. NOTE: The direction of arrow marks on the front and rear assemblies are opposite to each other. 3. Tighten bearing cap bolts in the following order to 10 Nm 85 in. lbs. First # 3, then # 2, # 1 and # 4. 4. Repeat step 3 increasing the torque to 20 Nm 180 in.lbs. Fig. 11 Distributor Drive 5. Install distributor drive adaptor assembly Fig. 11. INSTALL VALVE COVERS 1. Clean cylinder head and cover mating surfaces. Install new gasket. 2. See Fig. 2 and apply sealant such as Mopar Silicone Rubber Adhesive Sealant to cover ends. 3. Install cover and tighten cover bolt washer and gasket assembly to 10 Nm (88 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications CONNECTING ROD Length Center to Center ............................................................................................................................................... 140.9 141.0 mm (5.547 - 5.551 in.) Bend .................................................................................................................................................... ........................................ 0.05 mm (.0020 in.) or less Twist .................................................................................................................................................... ........................................... 0.1 mm (.004 in.) or less Connecting rod side clearance .................................................................................................................................................... 0.10-0.25( .0039-.0098 in.) Limit ..................................................................................................................................................... .................................................. 0.4 mm (.016 in.) Piston pin press-in load ................................................................................................................................................... 7,500-17,500 N (1,686-3,934 lbs.) CONNECTING ROD BEARING Oil clearance ........................................................................................................................................ ............................. 0.016-0.046 mm (.0006.0018 in.) Limit ..................................................................................................................................................... .................................................. 0.1 mm (.004 in.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts Connecting Rod: Specifications Connecting Rod Nuts 38 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 1179 Connecting Rod: Specifications Connecting Rod Specifications CONNECTING ROD Length Center to Center ............................................................................................................................................... 140.9 141.0 mm (5.547 - 5.551 in.) Bend .................................................................................................................................................... ........................................ 0.05 mm (.0020 in.) or less Twist .................................................................................................................................................... ........................................... 0.1 mm (.004 in.) or less Connecting rod side clearance .................................................................................................................................................... 0.10-0.25( .0039-.0098 in.) Limit ..................................................................................................................................................... .................................................. 0.4 mm (.016 in.) Piston pin press-in load ................................................................................................................................................... 7,500-17,500 N (1,686-3,934 lbs.) CONNECTING ROD BEARING Oil clearance ........................................................................................................................................ ............................. 0.016-0.046 mm (.0006.0018 in.) Limit ..................................................................................................................................................... .................................................. 0.1 mm (.004 in.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1180 Connecting Rod: Service and Repair Fig. 16 Piston & rod installation The piston and rod is assembled with front mark facing toward front of engine (toward timing belt), Fig. 16. Connecting rod front mark (72), must always face forward (toward timing belt), Fig. 16. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications CRANKSHAFT MAIN BEARINGS Oil clearance ........................................................................................................................................ .............................. 0.02-0.048 mm (.0008-.0019 in.) Limit ..................................................................................................................................................... .................................................. 0.1 mm (.004 in.) CRANKSHAFT Pin O.D. ............................................................................................................................................... ........................ 49.980 - 50.0 mm (1.968 - 1.969 in.) Journal O.D. ........................................................................................................................................ ......................... 59.980 - 60.0 mm (2.361 - 2.362 in.) Out-of-roundness of journal and pin ....................................................................................................................................... Less than 0.03 mm (.0012 in.) Taper of journal and pin ....................................................................................................................................................... Less than 0.005 mm (.0002 in.) End play ............................................................................................................................................... ................................ 0.05-0.25 mm (.0020-.0098 in.) Limit ..................................................................................................................................................... ................................................... 0.3 mm (012 in.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Technical Service Bulletins > Engine - Crankshaft Identification Crankshaft: Technical Service Bulletins Engine - Crankshaft Identification NO: 09-20-95 GROUP: Engine DATE: Dec. 8, 1995 SUBJECT: 2.5L/3.0L MMC Engine Crankshaft Identification MODELS: 1989 - 1995 (AA) Acclaim/Spirit/Lebaron Sedan 1988 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1992 - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC 1987 - 1995 (AS) Caravan/Voyager/Town & Country 1995 - 1996 (FJ) Avenger/Sebring 1995 - 1996 (JA) Breeze/Cirrus/Stratus 1996 (JX) Sebring Convertible 1996 (NS) Caravan/Voyager NOTE: This bulletin applies to vehicles equipped with a 2.5L or 3.0L MMC engine. DISCUSSION: Service replacement crankshaft main journal and connecting rod journal size identification marks have changed effective with crankshafts manufactured after August, 1995. The marks have changed from paint at each position to stamped marks located near the center counterweight as shown. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Rebuild Specifications Crankshaft: Specifications Rebuild Specifications CRANKSHAFT MAIN BEARINGS Oil clearance ........................................................................................................................................ .............................. 0.02-0.048 mm (.0008-.0019 in.) Limit ..................................................................................................................................................... .................................................. 0.1 mm (.004 in.) CRANKSHAFT Pin O.D. ............................................................................................................................................... ........................ 49.980 - 50.0 mm (1.968 - 1.969 in.) Journal O.D. ........................................................................................................................................ ......................... 59.980 - 60.0 mm (2.361 - 2.362 in.) Out-of-roundness of journal and pin ....................................................................................................................................... Less than 0.03 mm (.0012 in.) Taper of journal and pin ....................................................................................................................................................... Less than 0.005 mm (.0002 in.) End play ............................................................................................................................................... ................................ 0.05-0.25 mm (.0020-.0098 in.) Limit ..................................................................................................................................................... ................................................... 0.3 mm (012 in.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Rebuild Specifications > Page 1190 Crankshaft: Specifications Crankshaft Main Bearing Caps 60 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications PISTONS O.D. ..................................................................................................................................................... ................................................... 91.1 mm (3.587 in.) Clearance ............................................................................................................................................ ............................. 0.02 - 0.04 mm (.0008 - .0016 in.) Ring groove width No. 1 ...................................................................................................................... .............................................................. 1.51 - 1.53 mm (.0594.0602 in.) No.2 ..................................................................................................................................................... ................................. 1.51-1.53 mm (.0594-0602 in.) Oil ........................................................................................................................................................ ............................ 4.010-4.035 mm (.1579-.1589 in.) Service sizes ....................................................................................................................................... ............................................................ 0.25 mm (.010 in.) Oversize ................................................... ................................................................................................................................................ 0.50 mm (.020 in.) Oversize ........................................................................................................................ ............................................................................. 0.75 mm (.30 in.) Oversize .................................... .............................................................................................................................................................. . 1.00 mm (.039 in.) Oversize PISTON RINGS Side clearance No. 1 ........................................................................................................................... ......................................................... 0.03-0.09 mm (.0012-.0035 in.) Limit ..................................................................................................................................................... .................................................. 0.1 mm (.004 in.) No. 2 .................................................................................................................................................... ................................ 0.02-0.06 mm (.0008-.0024 in.) Limit ..................................................................................................................................................... .................................................. 0.1 mm (.004 in.) End gap No. 1 ...................................................................................................................................... .............................................. 0.30-0.45 mm (.0118-.0177 in.) Limit ..................................................................................................................................................... ................................................... 0.8 mm (031 in.) No. 2 .................................................................................................................................................... ................................ 0.25-0.40 mm (.0098-.0157 in.) Limit ..................................................................................................................................................... ................................................... 0.8 mm (031 in.) Oil ring side rail .................................................................................................................................... ........................... 0.20 - 0.70 mm (.0079 - .0276 in.) Limit ..................................................................................................................................................... .................................................. 1.0 mm (.039 in.) Service sizes ....................................................................................................................................... ............................................................ 0.25 mm (.010 in.) Oversize ................................................... ................................................................................................................................................ 0.50 mm (.020 in.) Oversize ........................................................................................................................ ........................................................................... 0.75 mm (.030 in.) Oversize .................................... .............................................................................................................................................................. . 1.00 mm (.039 in.) Oversize Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1194 Piston: Service and Repair Fig. 16 Piston & rod installation The piston and rod is assembled with front mark facing toward front of engine (toward timing belt), Fig. 16. Connecting rod front mark (72), must always face forward (toward timing belt), Fig. 16. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications PISTONS O.D. ..................................................................................................................................................... ................................................... 91.1 mm (3.587 in.) Clearance ............................................................................................................................................ ............................. 0.02 - 0.04 mm (.0008 - .0016 in.) Ring groove width No. 1 ...................................................................................................................... .............................................................. 1.51 - 1.53 mm (.0594.0602 in.) No.2 ..................................................................................................................................................... ................................. 1.51-1.53 mm (.0594-0602 in.) Oil ........................................................................................................................................................ ............................ 4.010-4.035 mm (.1579-.1589 in.) Service sizes ....................................................................................................................................... ............................................................ 0.25 mm (.010 in.) Oversize ................................................... ................................................................................................................................................ 0.50 mm (.020 in.) Oversize ........................................................................................................................ ............................................................................. 0.75 mm (.30 in.) Oversize .................................... .............................................................................................................................................................. . 1.00 mm (.039 in.) Oversize PISTON RINGS Side clearance No. 1 ........................................................................................................................... ......................................................... 0.03-0.09 mm (.0012-.0035 in.) Limit ..................................................................................................................................................... .................................................. 0.1 mm (.004 in.) No. 2 .................................................................................................................................................... ................................ 0.02-0.06 mm (.0008-.0024 in.) Limit ..................................................................................................................................................... .................................................. 0.1 mm (.004 in.) End gap No. 1 ...................................................................................................................................... .............................................. 0.30-0.45 mm (.0118-.0177 in.) Limit ..................................................................................................................................................... ................................................... 0.8 mm (031 in.) No. 2 .................................................................................................................................................... ................................ 0.25-0.40 mm (.0098-.0157 in.) Limit ..................................................................................................................................................... ................................................... 0.8 mm (031 in.) Oil ring side rail .................................................................................................................................... ........................... 0.20 - 0.70 mm (.0079 - .0276 in.) Limit ..................................................................................................................................................... .................................................. 1.0 mm (.039 in.) Service sizes ....................................................................................................................................... ............................................................ 0.25 mm (.010 in.) Oversize ................................................... ................................................................................................................................................ 0.50 mm (.020 in.) Oversize ........................................................................................................................ ........................................................................... 0.75 mm (.030 in.) Oversize .................................... .............................................................................................................................................................. . 1.00 mm (.039 in.) Oversize Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1198 Piston Ring: Service and Repair Fig. 17 Installing piston rings Fig. 18 Positioning ring end gaps Install piston rings as shown in Figs. 17 and 18. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1203 Valve Clearance: Adjustments This engine uses hydraulic lash adjusters. No provision for adjustment is provided. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair 1. Loosen gas cap and allow tank pressure to release. 2. Remove wiring harness connector from any injector, then ground one injector terminal. 3. Connect a suitable jumper wire to a second terminal, then touch the positive post of the battery for approximately 10 seconds and release system pressure. 4. Remove jumper wires and service fuel system as required. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications ROCKER ARM Rocker arm I.D. ................................................................................................................................... .......................................................... 19 mm (.75 in.) Clearance (Rocker arm to shaft) .......................................................................................................................................... 0.01-0.04 mm (.0004-.0016 in.) Limit ..................................................................................................................................................... ............................................... 0.10 mm (0039 in.) Rocker arm shaft O.D. ......................................................................................................................... ..................................................... 18.9 mm (.744 in.) Rocker arm shaft spring free length: Intake ................................................................................................................................................... ............................................... 55.2 mm (2.173 in.) Exhaust ................................................................................................................................................ ............................................... 55.2 mm (2.173 in.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1210 Rocker Arm Assembly: Service and Repair Fig. 1 Cylinder Head-Camshaft-Valves Fig. 2 Rocker Cover REMOVE VALVE COVERS 1. Remove air cleaner assembly. 2. Disconnect battery and relocate spark plug wires. 3. Remove vacuum connections. 4. Remove rocker cover screws and remove cover. REMOVE CAMSHAFT SPROCKETS Refer to Engine/Timing Components/Timing Belt/Service and Repair, for disassembly and remove camshaft sprockets. See: Timing Components/Timing Belt/Service and Repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1211 Fig. 3 Auto Lash Adjuster Check CHECK AUTO LASH ADJUSTER FUNCTION Check auto adjusters for free play by inserting a small wire through the air bleed hole in the rocker arm and VERY LIGHTLY push the auto adjuster ball check down. While lightly holding the check ball down move the rocker up and down to check for free play. If there is no play replace the adjuster. NOTE: Do not disassemble the auto lash adjuster. Fig. 4 Auto Lash Adjuster Retainers REMOVE CAMSHAFTS 1. Install auto lash adjuster retainers. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1212 Fig. 11 Distributor Drive 2. Remove distributor extension. 3. When removing camshaft bearing caps do not remove the bolts from the bearing caps. Remove the rocker arm, rocker shafts and bearing cap as an assembly. Fig. 5 Check Camshafts INSPECT CAMSHAFTS 1. Inspect camshaft bearing journals for damage and binding. If journals are binding, also check the cylinder head for damage Fig. 1. Also check cylinder head oil holes for clogging. 2. Front cylinder head camshaft check the tooth surface of the distributor drive gear teeth of the camshaft and replace if abnormal wear is evident. 3. Check the cam surface for abnormal wear and damage and replace if defective. Also measure the cam height Fig. 5.and replace if out of limit, standard value is 41.25 mm 1.624 inch, wear limit is 40.75 mm 1.604 inch. Fig. 6 Inspect Rocker Arms INSPECT ROCKER ARMS Check rocker arms for wear or damage. Replace as necessary. INSPECT ROCKER ARM SHAFTS Fig. 7 Rocker Arm Shaft Identification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1213 NOTE: The rocker arm shaft is hollow and is used as a lubrication oil duct. The rocker arm shaft on the inlet side has a 3mm diameter oil passage hole from the cylinder head. The exhaust side does not have this oil passage. 1. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if heavily damaged or worn. 2. Check oil holes for clogging with small wire, clean as required. INSTALL CAMSHAFTS Lubricate camshaft journals and cams with engine oil and install camshaft on cylinder head. Fig. 8 Camshaft Bearing Caps Position REASSEMBLE ROCKER ARMS 1. Align the camshaft bearing caps with arrows depending on cylinder bank, directed as shown. and in numerical order. Fig. 9 Number One Camshaft Bearing Cap NOTE: Identify number one bearing cap number one and number four caps are similar. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1214 Fig. 10 Assemble Rocker Arm And Shafts 2. Install rocker shafts into bearing cap number one with end notches positioned as shown in Figs. 9 and 10 note that the machined portion of the rocker shaft is facing down. 3. Insert attaching bolts to retain assembly. INSTALL ROCKER ARM SHAFT ASSEMBLY 1. Apply Mopar Silicone Rubber Adhesive Sealant at bearing cap ends as shown in. 2. Install the rocker arm shaft assembly making sure that the arrow mark on the bearing cap and the arrow mark on the cylinder head are in the same direction. NOTE: The direction of arrow marks on the front and rear assemblies are opposite to each other. 3. Tighten bearing cap bolts in the following order to 10 Nm 85 in. lbs. First # 3, then # 2, # 1 and # 4. 4. Repeat step 3 increasing the torque to 20 Nm 180 in.lbs. Fig. 11 Distributor Drive 5. Install distributor drive adaptor assembly Fig. 11. INSTALL VALVE COVERS 1. Clean cylinder head and cover mating surfaces. Install new gasket. 2. See Fig. 2 and apply sealant such as Mopar Silicone Rubber Adhesive Sealant to cover ends. 3. Install cover and tighten cover bolt washer and gasket assembly to 10 Nm (88 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Valve Cover Gasket > Component Information > Technical Service Bulletins > Customer Interest for Valve Cover Gasket: > 091689 > Oct > 89 > Engine - Oil Consumption Valve Cover Gasket: Customer Interest Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Valve Cover Gasket > Component Information > Technical Service Bulletins > Customer Interest for Valve Cover Gasket: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 1224 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Valve Cover Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover Gasket: > 091689 > Oct > 89 > Engine - Oil Consumption Valve Cover Gasket: All Technical Service Bulletins Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Valve Cover Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover Gasket: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 1230 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Technical Service Bulletins > Customer Interest for Valve Guide: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption Technical Service Bulletin # 091892A Date: 930113 Engine - Smoky Exhaust/Oil Consumption NO.: 09-18-92 Rev. A GROUP: Engine DATE: Jan. 13, 1993 SUBJECT: Excessive Oil Consumption 3.0L MMC Engine THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-18-92 WHICH SHOULD BE REMOVED FROM YOUR FILES. MODELS: 1989 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon/New Yorker Landau 1990 - 1993 (AG) Daytona 1990 - 1993 (AJ) LeBaron Coupe/Lebaron Convertible 1992 - 1993 (AP) Shadow/Shadow Convertible/Sundance 1987 - 1993 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1990 - 1991 (AQ) Chrysler TC 1988 (C) Dynasty/New Yorker DISCUSSION: Engines built since 11/15/91 (build code BDL7.067) have snap rings installed on the exhaust valve guides. Engines built since 10/2/92 (build code BDL7.416) have improved intake and exhaust valve stem seals in addition to the snap rings on the exhaust valve guides. The build code label is located on the intake plenum. SYMPTOM/CONDITION: Observed oil smoke in the exhaust at idle or during deceleration (conditions causing high intake manifold vacuum. Excessive oil consumption is more than one quart per 1,000 miles on vehicles with less than 50,000 miles or more than one quart per 750 miles on vehicles with more than 50,000 miles. DIAGNOSIS: Verify the PCV system is functioning properly and engine compression is within specifications. Refer to the appropriate technical service manual for test procedures and specifications. If the PCV system and engine compression are within specification, perform the repair procedure. PARTS REQUIRED: SPECIAL TOOLS REQUIRED: REPAIR PROCEDURE: This bulletin involves installing snap rings on the exhaust valve guides and replacing all of the valve stem seals or cylinder head replacement as determined by inspection. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Technical Service Bulletins > Customer Interest for Valve Guide: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1239 1. Remove the intake plenum and manifold. 2. Remove the rocker cover, rocker shaft and cam bearing cap assembly on the forward bank using the procedure in the appropriate technical service manual. 3. Remove one of the cam journal caps from the assembly and reinstall on the head. This will prevent the cam from possibly coming out of the journals when the engine is rotated later. 4. Check front bank cylinders in # 4, # 2, then # 6 sequence. NOTE: IF A VALVE GUIDE CAN BE MOVED WITH FINGER PRESSURE, REPLACE THE CYLINDER HEAD. 5. Remove the spark plug and apply compressed air to the cylinder to prevent valve dropping. Use special tool MD998772A to remove the intake and exhaust valve locks, the valve spring retainer, valve spring and valve spring seat. 6. Remove the valve stem seals. 7. Using the height gauge that is integrated into the Groove Cutter (Special tool MD998790), measure the distance between the top of the exhaust valve guide and the top of the valve guide boss on the cylinder head (refer to illustrations of Fig. 1). If the distance is .335" (8.5 mm) or less the cylinder head will have to be removed for repair, perform PROCEDURE B. If the distance is .335" (8.5 mm) or more, perform PROCEDURE A. 8. Repeat steps 2 through 7 for the rear bank. Do the cylinders in # 3, # 1, and # 5 sequence. Procedure A PROCEDURE A: Snap Ring Installation and Valve Stem Seal Replacement (On the Vehicle) 1. Using the groove cutter (Special tool MD998790), make a groove in the exhaust valve guide (refer to Fig. 2 and 3). a. Install the special tool on the exhaust valve guide. b. Turn the tool clockwise until the force required to turn the tool suddenly decreases. c. Remove the tool. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Technical Service Bulletins > Customer Interest for Valve Guide: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1240 2. Using a magnet and shop towel, remove the cuttings from the cylinder head. 3. Install a snap ring in the groove cut in the exhaust valve guide (refer to Fig. 4). 4. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790 and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will not fit between special tool and top of valve guide) install the valve spring seat. Install all of the intake valve spring seats. 5. Install new valve stem seals on the intake and exhaust valve guides using special tool MD998729. 6. Reinstall the valve spring assemblies including the valve spring seats if not already installed step 4 of PROCEDURE A. 7. Return to step 4 of the PROCEDURE A and proceed to the next cylinder in sequence unless, all exhaust valve guide snap rings have been installed and all valve stem seals replaced on this head. 8. Reinstall the rocker shaft assembly, camshaft bearing caps, rocker cover and spark plugs. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads. 9. Using the procedures in the appropriate service manual, reassemble the engine. Procedure B PROCEDURE B: Valve Guide Height Correction, Snap Ring Installation 1. Remove the cylinder head using the procedure in the appropriate service manual. 2. Remove all of the valve spring assemblies and valves. Mark the valves so they can be returned to their original position at reassembly. 3. Remove all of the valve stem seals. 4. Check the height on any exhaust valve guides not already checked to determine if height correction will be required on more than one guide. 5. Remove any carbon from the bottom of the exhaust valve guides that need to have their height corrected, especially the face that special tool MD998115 will contact. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Technical Service Bulletins > Customer Interest for Valve Guide: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1241 6. Using special tool MD998115 and hammer, carefully drive the exhaust valve guides from the combustion chamber side to provide a valve guide height from the top of the guide to the top of the boss for the valve guide on the cylinder head of .453" (11.5 mm). Check the distance using the height gauge that is integrated into the groove cutter (Special tool MD998790). Refer to Figure 1 and Figure 5. If the valve guide is driven up too far and the valve guide height exceeds .453" (11.5 mm) use special tool MD998115 to drive the valve guide from the rocker shaft side of the head until the .453" (11.5 mm) height is achieved. 7. Inspect the valve seats using the prussian blue procedure in the appropriate service manual. 8. Using the groove cutter (Special tool MD998790), make a groove on all of the exhaust valve guides (refer to Fig. 2 and 3). a. Install the special tool on the exhaust valve guide. b. Turn the tool clockwise until the force required to turn the tool suddenly decreases. c. Remove the tool. 9. Use a magnet and shop towel or wash the cylinder head to remove the cuttings. 10. Install a snap ring on each exhaust valve guide (refer to fig. 4). 11. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790 and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will not fit between special tool and top of valve guide) install the valve spring seat. Install all of the intake valve spring seats. 12. Install new valve stem seals on the intake and exhaust valve guides using special tool MD998729. 13. Reassemble the cylinder head and install using the procedure in the appropriate service manual. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads. 14. Using the procedures in the appropriate service manual, reassemble the engine. POLICY: Reimbursable within the provisions of the warranty. Labor Operation TIME ALLOWANCE: Labor Operation No. 09-35-01-92 Repair Valve Guides and Replace 4.1 Hrs. Seals, Both Heads on Vehicle 09-35-01-93 Repair Rear Head On Vehicle 6.0 Hrs. Remove Front Head and repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Technical Service Bulletins > Customer Interest for Valve Guide: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1242 or Replace Head as Required 09-35-01-94 Repair Front Head On Vehicle 6.2 Hrs. Remove Rear Head and Repair or Replace Head as Required 09-35-01-95 Remove Both Heads and Repair 6.4 Hrs. or Replace Head as Required FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption Technical Service Bulletin # 091892A Date: 930113 Engine - Smoky Exhaust/Oil Consumption NO.: 09-18-92 Rev. A GROUP: Engine DATE: Jan. 13, 1993 SUBJECT: Excessive Oil Consumption 3.0L MMC Engine THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-18-92 WHICH SHOULD BE REMOVED FROM YOUR FILES. MODELS: 1989 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon/New Yorker Landau 1990 - 1993 (AG) Daytona 1990 - 1993 (AJ) LeBaron Coupe/Lebaron Convertible 1992 - 1993 (AP) Shadow/Shadow Convertible/Sundance 1987 - 1993 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1990 - 1991 (AQ) Chrysler TC 1988 (C) Dynasty/New Yorker DISCUSSION: Engines built since 11/15/91 (build code BDL7.067) have snap rings installed on the exhaust valve guides. Engines built since 10/2/92 (build code BDL7.416) have improved intake and exhaust valve stem seals in addition to the snap rings on the exhaust valve guides. The build code label is located on the intake plenum. SYMPTOM/CONDITION: Observed oil smoke in the exhaust at idle or during deceleration (conditions causing high intake manifold vacuum. Excessive oil consumption is more than one quart per 1,000 miles on vehicles with less than 50,000 miles or more than one quart per 750 miles on vehicles with more than 50,000 miles. DIAGNOSIS: Verify the PCV system is functioning properly and engine compression is within specifications. Refer to the appropriate technical service manual for test procedures and specifications. If the PCV system and engine compression are within specification, perform the repair procedure. PARTS REQUIRED: SPECIAL TOOLS REQUIRED: REPAIR PROCEDURE: This bulletin involves installing snap rings on the exhaust valve guides and replacing all of the valve stem seals or cylinder head replacement as determined by inspection. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1248 1. Remove the intake plenum and manifold. 2. Remove the rocker cover, rocker shaft and cam bearing cap assembly on the forward bank using the procedure in the appropriate technical service manual. 3. Remove one of the cam journal caps from the assembly and reinstall on the head. This will prevent the cam from possibly coming out of the journals when the engine is rotated later. 4. Check front bank cylinders in # 4, # 2, then # 6 sequence. NOTE: IF A VALVE GUIDE CAN BE MOVED WITH FINGER PRESSURE, REPLACE THE CYLINDER HEAD. 5. Remove the spark plug and apply compressed air to the cylinder to prevent valve dropping. Use special tool MD998772A to remove the intake and exhaust valve locks, the valve spring retainer, valve spring and valve spring seat. 6. Remove the valve stem seals. 7. Using the height gauge that is integrated into the Groove Cutter (Special tool MD998790), measure the distance between the top of the exhaust valve guide and the top of the valve guide boss on the cylinder head (refer to illustrations of Fig. 1). If the distance is .335" (8.5 mm) or less the cylinder head will have to be removed for repair, perform PROCEDURE B. If the distance is .335" (8.5 mm) or more, perform PROCEDURE A. 8. Repeat steps 2 through 7 for the rear bank. Do the cylinders in # 3, # 1, and # 5 sequence. Procedure A PROCEDURE A: Snap Ring Installation and Valve Stem Seal Replacement (On the Vehicle) 1. Using the groove cutter (Special tool MD998790), make a groove in the exhaust valve guide (refer to Fig. 2 and 3). a. Install the special tool on the exhaust valve guide. b. Turn the tool clockwise until the force required to turn the tool suddenly decreases. c. Remove the tool. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1249 2. Using a magnet and shop towel, remove the cuttings from the cylinder head. 3. Install a snap ring in the groove cut in the exhaust valve guide (refer to Fig. 4). 4. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790 and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will not fit between special tool and top of valve guide) install the valve spring seat. Install all of the intake valve spring seats. 5. Install new valve stem seals on the intake and exhaust valve guides using special tool MD998729. 6. Reinstall the valve spring assemblies including the valve spring seats if not already installed step 4 of PROCEDURE A. 7. Return to step 4 of the PROCEDURE A and proceed to the next cylinder in sequence unless, all exhaust valve guide snap rings have been installed and all valve stem seals replaced on this head. 8. Reinstall the rocker shaft assembly, camshaft bearing caps, rocker cover and spark plugs. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads. 9. Using the procedures in the appropriate service manual, reassemble the engine. Procedure B PROCEDURE B: Valve Guide Height Correction, Snap Ring Installation 1. Remove the cylinder head using the procedure in the appropriate service manual. 2. Remove all of the valve spring assemblies and valves. Mark the valves so they can be returned to their original position at reassembly. 3. Remove all of the valve stem seals. 4. Check the height on any exhaust valve guides not already checked to determine if height correction will be required on more than one guide. 5. Remove any carbon from the bottom of the exhaust valve guides that need to have their height corrected, especially the face that special tool MD998115 will contact. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1250 6. Using special tool MD998115 and hammer, carefully drive the exhaust valve guides from the combustion chamber side to provide a valve guide height from the top of the guide to the top of the boss for the valve guide on the cylinder head of .453" (11.5 mm). Check the distance using the height gauge that is integrated into the groove cutter (Special tool MD998790). Refer to Figure 1 and Figure 5. If the valve guide is driven up too far and the valve guide height exceeds .453" (11.5 mm) use special tool MD998115 to drive the valve guide from the rocker shaft side of the head until the .453" (11.5 mm) height is achieved. 7. Inspect the valve seats using the prussian blue procedure in the appropriate service manual. 8. Using the groove cutter (Special tool MD998790), make a groove on all of the exhaust valve guides (refer to Fig. 2 and 3). a. Install the special tool on the exhaust valve guide. b. Turn the tool clockwise until the force required to turn the tool suddenly decreases. c. Remove the tool. 9. Use a magnet and shop towel or wash the cylinder head to remove the cuttings. 10. Install a snap ring on each exhaust valve guide (refer to fig. 4). 11. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790 and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will not fit between special tool and top of valve guide) install the valve spring seat. Install all of the intake valve spring seats. 12. Install new valve stem seals on the intake and exhaust valve guides using special tool MD998729. 13. Reassemble the cylinder head and install using the procedure in the appropriate service manual. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads. 14. Using the procedures in the appropriate service manual, reassemble the engine. POLICY: Reimbursable within the provisions of the warranty. Labor Operation TIME ALLOWANCE: Labor Operation No. 09-35-01-92 Repair Valve Guides and Replace 4.1 Hrs. Seals, Both Heads on Vehicle 09-35-01-93 Repair Rear Head On Vehicle 6.0 Hrs. Remove Front Head and repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1251 or Replace Head as Required 09-35-01-94 Repair Front Head On Vehicle 6.2 Hrs. Remove Rear Head and Repair or Replace Head as Required 09-35-01-95 Remove Both Heads and Repair 6.4 Hrs. or Replace Head as Required FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Free length .......................................................................................................................................... ......................................................... 1.995 - 1.998 in. Maximum straightness deviation .................... .............................................................................................................................................................. ..... 4 ° Installed height .................................................................................................................................... ..................................................................... 1.590 in. Pressure Closed ............................................. ........................................................................................................................................... 73 lbs. @ 1.590 in. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 18-05-97 > Feb > 97 > Engine Driveway Die Out/Rough Idle/Low Power Valve: Customer Interest Engine - Driveway Die Out/Rough Idle/Low Power NO: 18-05-97 GROUP: Vehicle Performance DATE: Feb. 14, 1997 SUBJECT: Intake Valve Deposits THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-16-93, DATED NOV. 12, 1993 AND 18-20-94, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1993 AND 1994 TECHNICAL SERVICE BULLETIN MANUALS (PUBLICATION NO's. 81-699-94000 AND 81-699-95054). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE MODEL AND APPLICATION CHANGES. MODELS: **1989 - 1995** (AA) Spirit/Acclaim/LeBaron Sedan **1988 - 1993** (AC) Dynasty/New Yorker Salon **1990 - 1994** (AG) Daytona **1990 - 1995** (AJ) LeBaron Coupe/LeBaron Convertible **1992 - 1994** (AP) Shadow/Shadow Convertible/Sundance **1987 - 1995** (AS) Town & Country/Caravan/Voyager **1996 - 1997** (NS) Town & Country/Caravan/Voyager **NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.0L ENGINE.** SYMPTOM/CONDITION: Driveway die out, rough idle, lack of power, sags, and hesitation. DISCUSSION: The above conditions may be the result of a build up of deposits on the back of the intake valves causing blockage of fuel delivery into the upper combustion chamber. This blockage results in fuel starvation. The deposits can be the result of fuel blending methods that have insufficient or ineffective fuel detergent additives. Fuel quality is a direct result of the crude oil used, the refinement process, the storage, delivery and distribution methods, and the blending of additive compounds. Using fuel with a higher posted octane number does not guarantee high quality, or that it is blended with adequate or effective detergent, corrosion inhibitors, or additives. Gasoline/Oxygenate blends which use unleaded gasoline and compounds that contain oxygen, such as alcohol, ethanol, MTBE, and ETBE may not indicate that adequate or effective detergent additives are available either. Gasoline Companies acknowledge that fuel quality is important. A number of them advertise, as well as warrant their fuel is blended to contain the necessary additives for efficient and clean operation of modern vehicles. Fuels available from these companies should be considered to assure full performance and clean operation. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, make sure the PCM is at the latest software version. If all systems are functioning as designed, ask the customer about the fuel that is being used in the vehicle. If there is a question about the quality of the fuel, suggest that only fuels be used that are warranted by the gasoline company against the build up of deposits. REPAIR PROCEDURE: Depending on the amount of deposit on the valves, there are several methods that can be used to remove them. 1. The use of Mopar Fuel Injector Cleaner has shown reasonable results on light deposits. Add one bottle of Mopar Fuel Injector Cleaner, p/n 4318007, to a full tank of gas. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 18-05-97 > Feb > 97 > Engine Driveway Die Out/Rough Idle/Low Power > Page 1263 CAUTION: UNDER NO CIRCUMSTANCES SHOULD THIS FUEL INJECTOR CLEANER BE ADDED TO A PARTIALLY FILLED FUEL TANK. Mopar Fuel Injector Cleaner will remove light deposits that have built up over a period of time. However, it is not intended for continuous use. Owners should be advised of the cause of their driveability concern and a recommendation should be made to try other brands of fuel. 2. For moderate to heavy deposits, the intake valves should be cleaned. The suggested method for cleaning involves removal of the cylinder head from the engine. The head must be disassembled, and the carbon removed from the valves and surrounding components with a wire brush. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 091892A > Jan > 93 > Engine Smoky Exhaust/Oil Consumption Technical Service Bulletin # 091892A Date: 930113 Engine - Smoky Exhaust/Oil Consumption NO.: 09-18-92 Rev. A GROUP: Engine DATE: Jan. 13, 1993 SUBJECT: Excessive Oil Consumption 3.0L MMC Engine THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-18-92 WHICH SHOULD BE REMOVED FROM YOUR FILES. MODELS: 1989 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon/New Yorker Landau 1990 - 1993 (AG) Daytona 1990 - 1993 (AJ) LeBaron Coupe/Lebaron Convertible 1992 - 1993 (AP) Shadow/Shadow Convertible/Sundance 1987 - 1993 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1990 - 1991 (AQ) Chrysler TC 1988 (C) Dynasty/New Yorker DISCUSSION: Engines built since 11/15/91 (build code BDL7.067) have snap rings installed on the exhaust valve guides. Engines built since 10/2/92 (build code BDL7.416) have improved intake and exhaust valve stem seals in addition to the snap rings on the exhaust valve guides. The build code label is located on the intake plenum. SYMPTOM/CONDITION: Observed oil smoke in the exhaust at idle or during deceleration (conditions causing high intake manifold vacuum. Excessive oil consumption is more than one quart per 1,000 miles on vehicles with less than 50,000 miles or more than one quart per 750 miles on vehicles with more than 50,000 miles. DIAGNOSIS: Verify the PCV system is functioning properly and engine compression is within specifications. Refer to the appropriate technical service manual for test procedures and specifications. If the PCV system and engine compression are within specification, perform the repair procedure. PARTS REQUIRED: SPECIAL TOOLS REQUIRED: REPAIR PROCEDURE: This bulletin involves installing snap rings on the exhaust valve guides and replacing all of the valve stem seals or cylinder head replacement as determined by inspection. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 091892A > Jan > 93 > Engine Smoky Exhaust/Oil Consumption > Page 1268 1. Remove the intake plenum and manifold. 2. Remove the rocker cover, rocker shaft and cam bearing cap assembly on the forward bank using the procedure in the appropriate technical service manual. 3. Remove one of the cam journal caps from the assembly and reinstall on the head. This will prevent the cam from possibly coming out of the journals when the engine is rotated later. 4. Check front bank cylinders in # 4, # 2, then # 6 sequence. NOTE: IF A VALVE GUIDE CAN BE MOVED WITH FINGER PRESSURE, REPLACE THE CYLINDER HEAD. 5. Remove the spark plug and apply compressed air to the cylinder to prevent valve dropping. Use special tool MD998772A to remove the intake and exhaust valve locks, the valve spring retainer, valve spring and valve spring seat. 6. Remove the valve stem seals. 7. Using the height gauge that is integrated into the Groove Cutter (Special tool MD998790), measure the distance between the top of the exhaust valve guide and the top of the valve guide boss on the cylinder head (refer to illustrations of Fig. 1). If the distance is .335" (8.5 mm) or less the cylinder head will have to be removed for repair, perform PROCEDURE B. If the distance is .335" (8.5 mm) or more, perform PROCEDURE A. 8. Repeat steps 2 through 7 for the rear bank. Do the cylinders in # 3, # 1, and # 5 sequence. Procedure A PROCEDURE A: Snap Ring Installation and Valve Stem Seal Replacement (On the Vehicle) 1. Using the groove cutter (Special tool MD998790), make a groove in the exhaust valve guide (refer to Fig. 2 and 3). a. Install the special tool on the exhaust valve guide. b. Turn the tool clockwise until the force required to turn the tool suddenly decreases. c. Remove the tool. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 091892A > Jan > 93 > Engine Smoky Exhaust/Oil Consumption > Page 1269 2. Using a magnet and shop towel, remove the cuttings from the cylinder head. 3. Install a snap ring in the groove cut in the exhaust valve guide (refer to Fig. 4). 4. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790 and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will not fit between special tool and top of valve guide) install the valve spring seat. Install all of the intake valve spring seats. 5. Install new valve stem seals on the intake and exhaust valve guides using special tool MD998729. 6. Reinstall the valve spring assemblies including the valve spring seats if not already installed step 4 of PROCEDURE A. 7. Return to step 4 of the PROCEDURE A and proceed to the next cylinder in sequence unless, all exhaust valve guide snap rings have been installed and all valve stem seals replaced on this head. 8. Reinstall the rocker shaft assembly, camshaft bearing caps, rocker cover and spark plugs. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads. 9. Using the procedures in the appropriate service manual, reassemble the engine. Procedure B PROCEDURE B: Valve Guide Height Correction, Snap Ring Installation 1. Remove the cylinder head using the procedure in the appropriate service manual. 2. Remove all of the valve spring assemblies and valves. Mark the valves so they can be returned to their original position at reassembly. 3. Remove all of the valve stem seals. 4. Check the height on any exhaust valve guides not already checked to determine if height correction will be required on more than one guide. 5. Remove any carbon from the bottom of the exhaust valve guides that need to have their height corrected, especially the face that special tool MD998115 will contact. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 091892A > Jan > 93 > Engine Smoky Exhaust/Oil Consumption > Page 1270 6. Using special tool MD998115 and hammer, carefully drive the exhaust valve guides from the combustion chamber side to provide a valve guide height from the top of the guide to the top of the boss for the valve guide on the cylinder head of .453" (11.5 mm). Check the distance using the height gauge that is integrated into the groove cutter (Special tool MD998790). Refer to Figure 1 and Figure 5. If the valve guide is driven up too far and the valve guide height exceeds .453" (11.5 mm) use special tool MD998115 to drive the valve guide from the rocker shaft side of the head until the .453" (11.5 mm) height is achieved. 7. Inspect the valve seats using the prussian blue procedure in the appropriate service manual. 8. Using the groove cutter (Special tool MD998790), make a groove on all of the exhaust valve guides (refer to Fig. 2 and 3). a. Install the special tool on the exhaust valve guide. b. Turn the tool clockwise until the force required to turn the tool suddenly decreases. c. Remove the tool. 9. Use a magnet and shop towel or wash the cylinder head to remove the cuttings. 10. Install a snap ring on each exhaust valve guide (refer to fig. 4). 11. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790 and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will not fit between special tool and top of valve guide) install the valve spring seat. Install all of the intake valve spring seats. 12. Install new valve stem seals on the intake and exhaust valve guides using special tool MD998729. 13. Reassemble the cylinder head and install using the procedure in the appropriate service manual. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads. 14. Using the procedures in the appropriate service manual, reassemble the engine. POLICY: Reimbursable within the provisions of the warranty. Labor Operation TIME ALLOWANCE: Labor Operation No. 09-35-01-92 Repair Valve Guides and Replace 4.1 Hrs. Seals, Both Heads on Vehicle 09-35-01-93 Repair Rear Head On Vehicle 6.0 Hrs. Remove Front Head and repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 091892A > Jan > 93 > Engine Smoky Exhaust/Oil Consumption > Page 1271 or Replace Head as Required 09-35-01-94 Repair Front Head On Vehicle 6.2 Hrs. Remove Rear Head and Repair or Replace Head as Required 09-35-01-95 Remove Both Heads and Repair 6.4 Hrs. or Replace Head as Required FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 18-05-97 > Feb > 97 > Engine - Driveway Die Out/Rough Idle/Low Power Valve: All Technical Service Bulletins Engine - Driveway Die Out/Rough Idle/Low Power NO: 18-05-97 GROUP: Vehicle Performance DATE: Feb. 14, 1997 SUBJECT: Intake Valve Deposits THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-16-93, DATED NOV. 12, 1993 AND 18-20-94, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1993 AND 1994 TECHNICAL SERVICE BULLETIN MANUALS (PUBLICATION NO's. 81-699-94000 AND 81-699-95054). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE MODEL AND APPLICATION CHANGES. MODELS: **1989 - 1995** (AA) Spirit/Acclaim/LeBaron Sedan **1988 - 1993** (AC) Dynasty/New Yorker Salon **1990 - 1994** (AG) Daytona **1990 - 1995** (AJ) LeBaron Coupe/LeBaron Convertible **1992 - 1994** (AP) Shadow/Shadow Convertible/Sundance **1987 - 1995** (AS) Town & Country/Caravan/Voyager **1996 - 1997** (NS) Town & Country/Caravan/Voyager **NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.0L ENGINE.** SYMPTOM/CONDITION: Driveway die out, rough idle, lack of power, sags, and hesitation. DISCUSSION: The above conditions may be the result of a build up of deposits on the back of the intake valves causing blockage of fuel delivery into the upper combustion chamber. This blockage results in fuel starvation. The deposits can be the result of fuel blending methods that have insufficient or ineffective fuel detergent additives. Fuel quality is a direct result of the crude oil used, the refinement process, the storage, delivery and distribution methods, and the blending of additive compounds. Using fuel with a higher posted octane number does not guarantee high quality, or that it is blended with adequate or effective detergent, corrosion inhibitors, or additives. Gasoline/Oxygenate blends which use unleaded gasoline and compounds that contain oxygen, such as alcohol, ethanol, MTBE, and ETBE may not indicate that adequate or effective detergent additives are available either. Gasoline Companies acknowledge that fuel quality is important. A number of them advertise, as well as warrant their fuel is blended to contain the necessary additives for efficient and clean operation of modern vehicles. Fuels available from these companies should be considered to assure full performance and clean operation. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, make sure the PCM is at the latest software version. If all systems are functioning as designed, ask the customer about the fuel that is being used in the vehicle. If there is a question about the quality of the fuel, suggest that only fuels be used that are warranted by the gasoline company against the build up of deposits. REPAIR PROCEDURE: Depending on the amount of deposit on the valves, there are several methods that can be used to remove them. 1. The use of Mopar Fuel Injector Cleaner has shown reasonable results on light deposits. Add one bottle of Mopar Fuel Injector Cleaner, p/n 4318007, to a full tank of gas. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 18-05-97 > Feb > 97 > Engine - Driveway Die Out/Rough Idle/Low Power > Page 1277 CAUTION: UNDER NO CIRCUMSTANCES SHOULD THIS FUEL INJECTOR CLEANER BE ADDED TO A PARTIALLY FILLED FUEL TANK. Mopar Fuel Injector Cleaner will remove light deposits that have built up over a period of time. However, it is not intended for continuous use. Owners should be advised of the cause of their driveability concern and a recommendation should be made to try other brands of fuel. 2. For moderate to heavy deposits, the intake valves should be cleaned. The suggested method for cleaning involves removal of the cylinder head from the engine. The head must be disassembled, and the carbon removed from the valves and surrounding components with a wire brush. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption Technical Service Bulletin # 091892A Date: 930113 Engine - Smoky Exhaust/Oil Consumption NO.: 09-18-92 Rev. A GROUP: Engine DATE: Jan. 13, 1993 SUBJECT: Excessive Oil Consumption 3.0L MMC Engine THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-18-92 WHICH SHOULD BE REMOVED FROM YOUR FILES. MODELS: 1989 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon/New Yorker Landau 1990 - 1993 (AG) Daytona 1990 - 1993 (AJ) LeBaron Coupe/Lebaron Convertible 1992 - 1993 (AP) Shadow/Shadow Convertible/Sundance 1987 - 1993 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1990 - 1991 (AQ) Chrysler TC 1988 (C) Dynasty/New Yorker DISCUSSION: Engines built since 11/15/91 (build code BDL7.067) have snap rings installed on the exhaust valve guides. Engines built since 10/2/92 (build code BDL7.416) have improved intake and exhaust valve stem seals in addition to the snap rings on the exhaust valve guides. The build code label is located on the intake plenum. SYMPTOM/CONDITION: Observed oil smoke in the exhaust at idle or during deceleration (conditions causing high intake manifold vacuum. Excessive oil consumption is more than one quart per 1,000 miles on vehicles with less than 50,000 miles or more than one quart per 750 miles on vehicles with more than 50,000 miles. DIAGNOSIS: Verify the PCV system is functioning properly and engine compression is within specifications. Refer to the appropriate technical service manual for test procedures and specifications. If the PCV system and engine compression are within specification, perform the repair procedure. PARTS REQUIRED: SPECIAL TOOLS REQUIRED: REPAIR PROCEDURE: This bulletin involves installing snap rings on the exhaust valve guides and replacing all of the valve stem seals or cylinder head replacement as determined by inspection. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1282 1. Remove the intake plenum and manifold. 2. Remove the rocker cover, rocker shaft and cam bearing cap assembly on the forward bank using the procedure in the appropriate technical service manual. 3. Remove one of the cam journal caps from the assembly and reinstall on the head. This will prevent the cam from possibly coming out of the journals when the engine is rotated later. 4. Check front bank cylinders in # 4, # 2, then # 6 sequence. NOTE: IF A VALVE GUIDE CAN BE MOVED WITH FINGER PRESSURE, REPLACE THE CYLINDER HEAD. 5. Remove the spark plug and apply compressed air to the cylinder to prevent valve dropping. Use special tool MD998772A to remove the intake and exhaust valve locks, the valve spring retainer, valve spring and valve spring seat. 6. Remove the valve stem seals. 7. Using the height gauge that is integrated into the Groove Cutter (Special tool MD998790), measure the distance between the top of the exhaust valve guide and the top of the valve guide boss on the cylinder head (refer to illustrations of Fig. 1). If the distance is .335" (8.5 mm) or less the cylinder head will have to be removed for repair, perform PROCEDURE B. If the distance is .335" (8.5 mm) or more, perform PROCEDURE A. 8. Repeat steps 2 through 7 for the rear bank. Do the cylinders in # 3, # 1, and # 5 sequence. Procedure A PROCEDURE A: Snap Ring Installation and Valve Stem Seal Replacement (On the Vehicle) 1. Using the groove cutter (Special tool MD998790), make a groove in the exhaust valve guide (refer to Fig. 2 and 3). a. Install the special tool on the exhaust valve guide. b. Turn the tool clockwise until the force required to turn the tool suddenly decreases. c. Remove the tool. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1283 2. Using a magnet and shop towel, remove the cuttings from the cylinder head. 3. Install a snap ring in the groove cut in the exhaust valve guide (refer to Fig. 4). 4. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790 and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will not fit between special tool and top of valve guide) install the valve spring seat. Install all of the intake valve spring seats. 5. Install new valve stem seals on the intake and exhaust valve guides using special tool MD998729. 6. Reinstall the valve spring assemblies including the valve spring seats if not already installed step 4 of PROCEDURE A. 7. Return to step 4 of the PROCEDURE A and proceed to the next cylinder in sequence unless, all exhaust valve guide snap rings have been installed and all valve stem seals replaced on this head. 8. Reinstall the rocker shaft assembly, camshaft bearing caps, rocker cover and spark plugs. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads. 9. Using the procedures in the appropriate service manual, reassemble the engine. Procedure B PROCEDURE B: Valve Guide Height Correction, Snap Ring Installation 1. Remove the cylinder head using the procedure in the appropriate service manual. 2. Remove all of the valve spring assemblies and valves. Mark the valves so they can be returned to their original position at reassembly. 3. Remove all of the valve stem seals. 4. Check the height on any exhaust valve guides not already checked to determine if height correction will be required on more than one guide. 5. Remove any carbon from the bottom of the exhaust valve guides that need to have their height corrected, especially the face that special tool MD998115 will contact. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1284 6. Using special tool MD998115 and hammer, carefully drive the exhaust valve guides from the combustion chamber side to provide a valve guide height from the top of the guide to the top of the boss for the valve guide on the cylinder head of .453" (11.5 mm). Check the distance using the height gauge that is integrated into the groove cutter (Special tool MD998790). Refer to Figure 1 and Figure 5. If the valve guide is driven up too far and the valve guide height exceeds .453" (11.5 mm) use special tool MD998115 to drive the valve guide from the rocker shaft side of the head until the .453" (11.5 mm) height is achieved. 7. Inspect the valve seats using the prussian blue procedure in the appropriate service manual. 8. Using the groove cutter (Special tool MD998790), make a groove on all of the exhaust valve guides (refer to Fig. 2 and 3). a. Install the special tool on the exhaust valve guide. b. Turn the tool clockwise until the force required to turn the tool suddenly decreases. c. Remove the tool. 9. Use a magnet and shop towel or wash the cylinder head to remove the cuttings. 10. Install a snap ring on each exhaust valve guide (refer to fig. 4). 11. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790 and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will not fit between special tool and top of valve guide) install the valve spring seat. Install all of the intake valve spring seats. 12. Install new valve stem seals on the intake and exhaust valve guides using special tool MD998729. 13. Reassemble the cylinder head and install using the procedure in the appropriate service manual. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads. 14. Using the procedures in the appropriate service manual, reassemble the engine. POLICY: Reimbursable within the provisions of the warranty. Labor Operation TIME ALLOWANCE: Labor Operation No. 09-35-01-92 Repair Valve Guides and Replace 4.1 Hrs. Seals, Both Heads on Vehicle 09-35-01-93 Repair Rear Head On Vehicle 6.0 Hrs. Remove Front Head and repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1285 or Replace Head as Required 09-35-01-94 Repair Front Head On Vehicle 6.2 Hrs. Remove Rear Head and Repair or Replace Head as Required 09-35-01-95 Remove Both Heads and Repair 6.4 Hrs. or Replace Head as Required FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Page 1286 Valve: Specifications VALVES Valve length Intake .............................................................................................................................. ...................................................................... 103.0 mm (4.055 in.) Exhaust ................................................................................................................................................ ................................................. 102.7 mm (4.043 in.) Stem O.D. Intake ................................................................................................................................. .............................................. 7.960-7.975 mm (.3134-.3140 in.) Exhaust ................................................................................................................................................ ............................ 7.930-7.950 mm (.3122-.3130 in.) Face angle ........................................................................................................................................... .................................................................. 45° - 45.5° Thickness of valve head (Margin) Intake ................................................................................................................................................... ....................................................... 1.2 mm (.047 in.) Limit ..................................................................................................................................................... .................................................. 0.7 mm (.028 in.) Exhaust ................................................................................................................................................ ....................................................... 2.0 mm (.079 in.) Limit ..................................................................................................................................................... .................................................. 1.5 mm (.059 in.) Valve stem to valve guide clearance Intake ................................................................................................................................................... ................................ 0.03-0.06 mm (.0012-.0024 in.) Limit ..................................................................................................................................................... .............................................. 0.10 mm (.0039 in.) Exhaust ................................................................................................................................................ ................................ 0.05-0.09 mm (.0020-.0035 in.) Limit ..................................................................................................................................................... .............................................. 0.15 mm (.0059 in.) Valve guide length: Intake ................................................................................................................... ........................................................................................ 44 mm (1.73 in.) Exhaust ................................................................................................................................................ ........................................................ 48 mm (1.89 in.) Service sizes: ...................................................................................................................................... ............................................................. 0.05 mm (.002 in.) Oversize .................................................. ................................................................................................................................................. 0.25 mm (.010 in.) Oversize ........................................................................................................................ ........................................................................... 0.50 mm (.020 in.) Oversize Valve seat Width of seat contact ........................................................................................................................... .................................... 0.9 - 1.3 mm (.035 - .051 in.) Seat angle ........................................................................................................................................... ................................................................... 44° - 44.5° Valve spring Free length .......................................................................................................................................... .................................................... 50.5 mm (1.988 in.) Limit ..................................................................................................................................................... .............................................. 49.5 mm (1.949 in.) Load ..................................................................................................................................................... ............................. 329 N (74 lbs.) at installed height installed height ..................................................................................................................................... .................................................. 40.4 mm (1.591 in.) Limit ..................................................................................................................................................... .............................................. 41.4 mm (1.630 in.) Out of squareness ............................................................................................................................... ................................................................. Less than 2° Limit ..................................................................................................................................................... .......................................................................... 4° Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications Drive Belt: Specifications Fig. 23 Belt deflection check points AIR CONDITIONING BELT Belt deflection under a ten pound push or pull should be between 1/4 to 5/16 at locations shown in Fig. 23. Measure deflection while applying tension to accessory, then tighten mounting mounts to specification. Deflection on a new belt should be between 1/4 to 1/2; a belt is considered used after 15 minutes of engine operation, tension on a used belt should be 1/4 and 5/16 under a tension pound load. ACCESSORY BELT Correct belt tension is 5/16 deflection between pulleys. Fig. 24 Serpentine drive belt SERPENTINE DRIVE BELT ROUTINGS Refer to Fig. 24, for serpentine belt routing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1291 Fig. 24 Serpentine drive belt Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1292 Drive Belt: Adjustments Fig. 23 Belt deflection check points AIR CONDITIONING BELT Belt deflection under a ten pound push or pull should be between 1/4 to 5/16 at locations shown in Fig. 23. Measure deflection while applying tension to accessory, then tighten mounting mounts to specification. Deflection on a new belt should be between 1/4 to 1/2; a belt is considered used after 15 minutes of engine operation, tension on a used belt should be 1/4 and 5/16 under a tension pound load. ACCESSORY BELT Correct belt tension is 5/16 deflection between pulleys. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Belt Drive Belt: Service and Repair A/C Belt Fig. 27 A/C Pulley Removal 1. Loosen adjusting locknut, then turn jack-screw, Fig. 27, counterclockwise to reduce belt tension and remove belt. 2. When reinstalling belt, adjust belt tension to 5/16 inch deflection between pulleys. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Belt > Page 1295 Drive Belt: Service and Repair Accessory Drive Belt WARNING: Belts must be checked with engine not running. ACCESSORY DRIVE BELTS Fig. 2 Air Conditioning Belt A/C Belt 1. Loosen Adjusting Lock Nut Fig. 2. 2. Turn adjusting "jack" screw counterclockwise to reduce belt tension. Remove belt. 3. Reinstall. 4. Adjust belt tension. A small spring scale can be used to establish the ten-pound belt load. Belt deflection under a ten-pound push or pull should be between 6 mm (1/4 in.) to 8mm (5/16 in.). Tighten pulley nut to 57 Nm (40 ft. lbs.) after adjustment. Fig. 3 Alternator/Power Steering Belt Alternator/Power Steering Belt 1. Install breaker bar into 1/2 square opening in tensioner. 2. Rotate tensioner counterclockwise to remove (and install) belt Fig. 3. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Belt > Page 1296 Drive Belt: Service and Repair Alternator & Power Steering Belt Fig. 29 Alternator & Power Steering Belt Removal. 1989-90 Models Fig. 30 Alternator & Power Steering Belt Removal. 1990-92 Models 1. Install breaker bar into square opening in tensioner, Figs. 29 and 30. 2. ^ On 1990 and earlier models, rotate tensioner counterclockwise to remove or install belt. ^ On 1991 and later models, rotate tensioner counterclockwise to remove or install belt. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Service and Repair Engine Accessory Bracket: Service and Repair Fig. 28 Accessory Mounting Brackets Expanded View Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Service and Repair > Page 1300 Accessory Mounting Brackets 1. Remove air conditioning compressor to mounting bracket screws and position compressor aside. 2. Remove A/C mounting bracket and adjustable drive belt tensioner retaining bolts. 3. Remove steering pump belt tensioner mounting bolt and automatic belt tensioner. 4. Remove two steering pump to engine mounting bracket screws and rear support locknut, then position power steering pump aside. 5. Reverse procedure to install. Torque bolts to specifications. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Left Motor Mount Bolt 40 ft.lb Front Motor Mount Bolt 40 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 1304 Engine Mount: Service and Repair Fig. 1 Engine mount replacement RIGHT MOUNT 1. Remove right engine mount insulator vertical fasteners from frame rail. Fig. 1. 2. Remove load on engine motor mounts by carefully supporting engine and transaxle assembly with suitable floor jack. 3. Remove through bolt from insulator assembly. Remove insulator. 4. Reverse procedure to install. LEFT MOUNT 1. Raise and support vehicle. Remove left front wheel. 2. Remove inner splash shield. 3. Support transaxle with suitable jack, then remove insulator through bolt from mount. Fig. 1. 4. Remove transaxle mount fasteners and remove mount. 5. Reverse procedure to install. FRONT MOUNT 1. Support engine and transaxle assembly with suitable floor jack, so it will not rotate. 2. Remove through bolt from insulator and front crossmember mounting bracket. Fig. 1. 3. Remove front engine mount bracket to front crossmember bolts and nuts. Remove insulator assembly. 4. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - New `SG' Level Oil Engine Oil: Technical Service Bulletins Engine Oil - New `SG' Level Oil Models All 1989 And Earlier Domestic & Import Vehicles Subject New "SG" Quality Engine Oil Index LUBRICATION Date April 24, 1989 No. 10-01-89 (C10-01-9) BODY CODE LEGEND ALL 1989 AND EARLIER CHRYSLER/PLYMOUTH & DODGE DOMESTIC & IMPORT VEHICLES "SG" QUALITY ENGINE OIL The quality of engine oil recommended for use in all Chrysler Motors' vehicles has been upgraded to an "SG" level. The new "SG" quality engine oils can provide significant improvements concerning sludge, varnish and wear control. These new quality oils may also be used in older vehicles where lower quality oils (SE, SF, SF/CC) were recommended. Specific recommendations for all 1989 vehicles may be found in the vehicle "Owners Manual". The new "SG" engine oils are currently being introduced into the MOPAR product line in addition to being commercially available through many automotive supply outlets. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Page 1310 Engine Oil: Specifications Oil Capacity Oil Capacity Crankcase Only With Filter Change 4.0 Quarts 4.5 Quarts Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Gauge: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1315 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1316 Oil Pressure & Temperature System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Page 1317 Oil Pressure Gauge: Description and Operation The oil pressure indicating system consists of an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuates the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, increasing current flow to the gauge, resulting in an increased gauge reading. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Page 1318 Oil Pressure Gauge: Testing and Inspection Oil Pressure Gauge Pins Combination Oil Pressure Sending Unit 1. Remove oil pressure gauge assembly from the cluster. 2. Check for continuity in wire between oil pressure sending unit and gauge (sensor input pin). 3. With ignition switch in On position, check for battery voltage across B+ pin and ground pin. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Lower LH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1324 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1325 Oil Pressure & Temperature System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair Oil Pump: Service and Repair REMOVAL Fig. 19 Oil pump clearance check locations NOTE: Oil pan must be removed prior to removing oil pump. 1. Remove timing belt. Refer to TIMING BELT & COVER. 2. Remove timing belt tensioner and crankshaft sprocket. 3. Remove oil pump assembly attaching bolts, then the oil pump. 4. Remove oil seal from oil pump housing. INSPECTION 1. Check oil pump case for cracks and damage. 2. Using a suitable feeler gauge, measure the following clearances as follows: a. Body ............................................................................................................................................................. 0.004-0.007 inch (0.10-0.18 mm). b. Side .......................................................................................................................................................... 0.0015-0.0035 inch (0.04-0.09 mm). c. Inner Rotor to Case ..................................................................................................................................... 0.001-0.002 inch (0.03-0.07 mm). INSTALLATION 1. Install oil pump assembly and tighten attaching bolts to specifications. 2. Using oil seal installer tool No. MB998306, install new front oil seal into oil pump housing. 3. Reverse steps 1 and 2 in removal procedure, to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake Manifold Nuts 174 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1332 Intake Manifold: Service and Repair 1. Relieve fuel system pressure as described under Engine/Service Precautions/Technician Safety Information/Fuel System Pressure Release. 2. Disconnect battery ground cable and drain cooling system. Fig. 4 Throttle Cable Removal 3. Remove air cleaner to throttle body hose, then disconnect throttle cable and transaxle kickdown linkage, Fig. 4. 4. Disconnect Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) electrical connectors from throttle body. 5. Disconnect vacuum hoses from throttle body. 6. Remove EGR tube flange from intake plenum. 7. Disconnect coolant temperature sensor and charge temperature sensor electrical connectors. 8. Disconnect air intake plenum vacuum connector, then disconnect fuel hoses from fuel rail. Fig. 8 Air Intake Plenum To Intake Manifold Attaching Bolts Fig. 9 Removing Air Intake Plenum Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1333 9. Remove air intake plenum to intake manifold attaching bolts, then air intake plenum. 10. Disconnect vacuum hoses from fuel rail and fuel pressure regulator, then disconnect fuel injector electrical connector from engine wiring harness. 11. Remove fuel pressure regulator attaching bolts, then loosen hose clamps and remove regulator from rail. 12. Remove fuel rail attaching bolts, then lift fuel rail assembly from intake manifold. 13. Disconnect radiator hose from thermostat housing and heater hose from heater pipe. 14. Remove intake manifold attaching bolts, then intake manifold. 15. Reverse procedure to install, noting following: a. Discard gaskets and clean gasket surfaces on both manifolds and cylinder head. b. Use a straightedge to ensure gasket surfaces on manifolds are flat and within .004-.008 inch per foot of manifold length. Fig. 5 Intake Manifold Tightening Sequence c. Torque intake manifold bolts to 20 Nm (174 in. lbs.), in sequence shown in Fig. 5. d. Tighten fuel rail attaching bolts to specifications. Fig. 6 Intake Plenum Tightening Sequence e. Torque air intake plenum attaching bolts to 10-11 ft. lbs., in sequence shown in Fig. 6. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Gauge: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1339 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1340 Oil Pressure & Temperature System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Page 1341 Oil Pressure Gauge: Description and Operation The oil pressure indicating system consists of an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuates the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, increasing current flow to the gauge, resulting in an increased gauge reading. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Page 1342 Oil Pressure Gauge: Testing and Inspection Oil Pressure Gauge Pins Combination Oil Pressure Sending Unit 1. Remove oil pressure gauge assembly from the cluster. 2. Check for continuity in wire between oil pressure sending unit and gauge (sensor input pin). 3. With ignition switch in On position, check for battery voltage across B+ pin and ground pin. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair Camshaft Oil Seal: Service and Repair Fig. 10 Checking auto lash adjuster Oil leak or seepage at rear cam plugs may be caused by defective or missing cam plug. This condition may be found on engines built prior to date codes of 7-593. Inspect at rear right-hand side of engine on each cylinder head for evidence of oil leaks or seepage. If found, replace plugs, using a light coat of RTV sealer or equivalent. Before removing rocker arms and camshafts, check auto adjusters for freeplay. Insert a piece of wire through bleed hole in rocker arm and carefully push adjuster check ball down, while pushing down on check ball, move rocker arm up and down to check for freeplay. If there is no play replace adjuster. Fig. 3 Intake manifold tightening sequence 1. Remove intake manifold. 2. Remove valve covers. Fig. 11 Installing auto lash adjuster retainers 3. Install auto lash adjuster retainers M0998443 or equivalent, as shown. 4. Remove distributor housing attaching bolts, then distributor housing and O-ring. 5. When removing camshaft bearing caps do not remove bolts from bearing caps. Remove rocker arm, rocker shafts and bearing cap as an assembly. 6. Remove camshafts, oil seals and end seals. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > Page 1347 7. Lubricate camshaft journals and cams with engine oil, then install camshafts on cylinder head. Fig. 12 Camshaft bearing caps installation 8. Align camshaft bearing caps with arrows (depending on cylinder bank) as shown. Fig. 13 Identifying bearing caps 9. Identify number 1 bearing cap as shown, then install rocker shafts into bearing cap 1 with end notches positioned as shown, and machined portion of rocker shaft is facing down. 10. Install rocker arms, bearing caps and springs onto rocker arm shafts. 11. Temporarily install number 4 bearing cap bolts to retain assembly. 12. Apply a suitable sealant at bearing cap ends as shown. 13. Install rocker arm shaft assembly. Ensure arrow on bearing cap and arrow mark on cylinder head are pointing in same direction. 14. Torque bearing caps as follows: a. Numbers 3, 2, 1, then 4 to 85 inch lbs. b. In same sequence mentioned above, torque bearing cap bolts to 180 inch lbs. 15. Install distributor housing and tighten bolts to specifications. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > Page 1348 Camshaft Oil Seal 16. Lubricate camshaft oil seals lip with engine oil, then using camshaft oil seal installer tool No. MD998713 or equivalent, install camshaft oil seals. Camshaft End Seal 17. Using oil seal installer tool No. MB998306 or equivalent, install end seals. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest for Cylinder Head Gasket: > 090191 > Feb > 91 > Cylinder Head Gasket - Coolant Leakage Cylinder Head Gasket: Customer Interest Cylinder Head Gasket - Coolant Leakage SUBJECT: Head Gasket Coolant Leakage, 3.0L Engine NO.: 09-01-91 GROUP: ENGINE DATE: Feb. 25, 1991 MODELS: 1987 - 1989 (S/AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY 1988 - 1989 (C/AC) DYNASTY/NEW YORKER 1989 (AA) SPIRIT/ACCLAIM SYMPTOM/CONDITION: Some 1987-1989 vehicles equipped with the 3.0L engine may experience loss of engine coolant from an external cylinder head(s) gasket leak. A new head gasket, PN MD143540, entered engine production December 1988, beginning with engine serial number MM6619. NOTE: THE ENGINE SERIAL NUMBER IS LOCATED ON THE MACHINED SURFACE ON THE RIGHT REAR SIDE OF THE ENGINE BLOCK. DIAGNOSIS: Attach a radiator pressure tester and apply 15 psi pressure. Carefully inspect the engine for coolant leakage. If leakage is present at the cylinder head(s) to block mating surfaces perform the repair procedure. If no leakage is evident at the head(s) to block mating surfaces but pressure test indicates leakage, continue the leakage diagnosis as outlined in the Cooling System section of the appropriate Service Manual and repair as required. PARTS REQUIRED: 1 - Cylinder Head Gasket Kit PN MD172539 Gasket Kit Contains 2 - Head Gaskets PN MD143540 2 - Intake Manifold Gaskets PN MD157195 2 - Surge Tank Gaskets PN MD094128 REPAIR PROCEDURE: This repair involves removing BOTH cylinder heads and replacing the cylinder head gaskets even though the leakage is evident from one bank only. 1. Drain the cooling system. 2. Turn the ignition key to the off position and disconnect the battery negative battery cable. 3. Remove both cylinder heads as outlined in the appropriate Service Manual. 4. Clean the cylinder heads and block mating surfaces. 5. Check cylinder head(s) flatness as outlined in the appropriate Service Manual. 6. Install both cylinder heads as outlined in the appropriate Service Manual. 7. Fill cooling system as outlined in the appropriate Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest for Cylinder Head Gasket: > 090191 > Feb > 91 > Cylinder Head Gasket - Coolant Leakage > Page 1357 8. Connect the negative battery cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 09-35-30-90 . . . . . . . . . 5.3 Hrs. FAILURE CODE: 65 - Leaks Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 090191 > Feb > 91 > Cylinder Head Gasket - Coolant Leakage Cylinder Head Gasket: All Technical Service Bulletins Cylinder Head Gasket - Coolant Leakage SUBJECT: Head Gasket Coolant Leakage, 3.0L Engine NO.: 09-01-91 GROUP: ENGINE DATE: Feb. 25, 1991 MODELS: 1987 - 1989 (S/AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY 1988 - 1989 (C/AC) DYNASTY/NEW YORKER 1989 (AA) SPIRIT/ACCLAIM SYMPTOM/CONDITION: Some 1987-1989 vehicles equipped with the 3.0L engine may experience loss of engine coolant from an external cylinder head(s) gasket leak. A new head gasket, PN MD143540, entered engine production December 1988, beginning with engine serial number MM6619. NOTE: THE ENGINE SERIAL NUMBER IS LOCATED ON THE MACHINED SURFACE ON THE RIGHT REAR SIDE OF THE ENGINE BLOCK. DIAGNOSIS: Attach a radiator pressure tester and apply 15 psi pressure. Carefully inspect the engine for coolant leakage. If leakage is present at the cylinder head(s) to block mating surfaces perform the repair procedure. If no leakage is evident at the head(s) to block mating surfaces but pressure test indicates leakage, continue the leakage diagnosis as outlined in the Cooling System section of the appropriate Service Manual and repair as required. PARTS REQUIRED: 1 - Cylinder Head Gasket Kit PN MD172539 Gasket Kit Contains 2 - Head Gaskets PN MD143540 2 - Intake Manifold Gaskets PN MD157195 2 - Surge Tank Gaskets PN MD094128 REPAIR PROCEDURE: This repair involves removing BOTH cylinder heads and replacing the cylinder head gaskets even though the leakage is evident from one bank only. 1. Drain the cooling system. 2. Turn the ignition key to the off position and disconnect the battery negative battery cable. 3. Remove both cylinder heads as outlined in the appropriate Service Manual. 4. Clean the cylinder heads and block mating surfaces. 5. Check cylinder head(s) flatness as outlined in the appropriate Service Manual. 6. Install both cylinder heads as outlined in the appropriate Service Manual. 7. Fill cooling system as outlined in the appropriate Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 090191 > Feb > 91 > Cylinder Head Gasket - Coolant Leakage > Page 1363 8. Connect the negative battery cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 09-35-30-90 . . . . . . . . . 5.3 Hrs. FAILURE CODE: 65 - Leaks Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal Cylinder Head Gasket: Service and Repair Cylinder Head Removal Fig. 1 Cylinder Head-Camshaft-Valves Fig. 2 Rocker Cover REMOVE VALVE COVERS 1. Remove air cleaner assembly. 2. Disconnect battery and relocate spark plug wires. 3. Remove vacuum connections. 4. Remove rocker cover screws and remove cover Fig. 2. REMOVE CAMSHAFT SPROCKETS Refer to Engine/Timing Components/Timing Belt/Service and Repair, for disassembly and remove camshaft sprockets. See: Timing Components/Timing Belt/Service and Repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal > Page 1366 Fig. 3 Auto Lash Adjuster Check CHECK AUTO LASH ADJUSTER FUNCTION Check auto adjusters for free play by inserting a small wire through the air bleed hole in the rocker arm and VERY LIGHTLY push the auto adjuster ball check down Fig. 3. While lightly holding the check ball down move the rocker up and down to check for free play. If there is no play replace the adjuster. NOTE: Do not disassemble the auto lash adjuster. Fig. 4 Auto Lash Adjuster Retainers REMOVE CAMSHAFTS 1. Install auto lash adjuster retainers. Fig. 4. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal > Page 1367 Fig. 11 Distributor Drive 2. Remove distributor extension Fig. 11. 3. When removing camshaft bearing caps do not remove the bolts from the bearing caps. Remove the rocker arm, rocker shafts and bearing cap as an assembly. Fig. 5 Check Camshafts INSPECT CAMSHAFTS 1. Inspect camshaft bearing journals for damage and binding Fig. 5. If journals are binding, also check the cylinder head for damage Fig. 1. Also check cylinder head oil holes for clogging. 2. Front cylinder head camshaft check the tooth surface of the distributor drive gear teeth of the camshaft and replace if abnormal wear is evident Fig. 5. 3. Check the cam surface for abnormal wear and damage and replace if defective. Also measure the cam height Fig. 5.and replace if out of limit, standard value is 41.25 mm 1.624 inch, wear limit is 40.75 mm 1.604 inch. Fig. 6 Inspect Rocker Arms INSPECT ROCKER ARMS Check rocker arms for wear or damage Fig. 6. Replace as necessary. INSPECT ROCKER ARM SHAFTS Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal > Page 1368 Fig. 7 Rocker Arm Shaft Identification NOTE: The rocker arm shaft is hollow and is used as a lubrication oil duct. The rocker arm shaft on the inlet side has a 3mm diameter oil passage hole from the cylinder head. The exhaust side does not have this oil passage Fig. 7. 1. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if heavily damaged or worn. 2. Check oil holes for clogging with small wire, clean as required Fig. 7. REMOVE INTAKE MANIFOLD ASSEMBLY Refer to Engine/Intake Manifold/Service and Repair. See: Intake Manifold/Service and Repair REMOVE EXHAUST MANIFOLDS Remove exhaust manifolds and cross over, Refer to Exhaust System/Exhaust Manifold/Service and Repair. See: Exhaust System/Exhaust Manifold/Service and Repair REMOVE CYLINDER HEADS Fig. 14 Cylinder Head Bolt Removal Sequence Remove cylinder head bolts in sequence shown in Fig. 14 and remove cylinder head. INSPECTION 1. Before cleaning, check for leaks, damage and cracks. 2. Clean cylinder head and oil passages. Fig. 15 Check Cylinder Head 3. Check cylinder head for flatness Fig. 15. 4. Cylinder head must be flat within: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal > Page 1369 ^ Standard dimension = less than 0.05mm .002 inch ^ Service Limit = 0.2mm .008 inch ^ Grinding Limit = Maximum of 0.2 mm .008 inch is permitted. CAUTION: This is a combined total dimension of stock removal from cylinder head if any and block top surface. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal > Page 1370 Cylinder Head Gasket: Service and Repair Cylinder Head Installation INSTALL HEADS 1. Clean surfaces of head and block, install head gasket over locating dowels. 2. Install head on locating dowels. 3. Install 10mm Allen Hex head bolts with washers. Fig. 16 Cylinder Head Bolt Tightening Sequence 4. Tighten bolts in the order shown in Fig. 16. When tightening the cylinder head bolts, tighten gradually, working in two or three steps and finally tighten to specified torque of 108 Nm 80 ft. lbs.. INSTALL CAMSHAFTS Lubricate camshaft journals and cams with engine oil and install camshaft on cylinder head. Fig. 8 Camshaft Bearing Caps Position REASSEMBLE ROCKER ARMS 1. Align the camshaft bearing caps with arrows depending on cylinder bank, directed as shown in Fig. 8 and in numerical order. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal > Page 1371 Fig. 9 Number One Camshaft Bearing Cap NOTE: Identify number one bearing cap number one and number four caps are similar Fig. 9. Fig. 10 Assemble Rocker Arm And Shafts 2. Install rocker shafts into bearing cap number one with end notches positioned as shown in Figs. 9 and 10 note that the machined portion of the rocker shaft is facing down. 3. Insert attaching bolts to retain assembly. INSTALL ROCKER ARM SHAFT ASSEMBLY 1. Apply Mopar Silicone Rubber Adhesive Sealant at bearing cap ends as shown in Fig. 8. 2. Install the rocker arm shaft assembly making sure that the arrow mark on the bearing cap and the arrow mark on the cylinder head are in the same direction Fig. 8. NOTE: The direction of arrow marks on the front and rear assemblies are opposite to each other. 3. Tighten bearing cap bolts in the following order to 10 Nm 85 in. lbs. First # 3, then # 2, # 1 and # 4. 4. Repeat step 3 increasing the torque to 20 Nm 180 in.lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal > Page 1372 Fig. 11 Distributor Drive 5. Install distributor drive adaptor assembly Fig. 11. Fig. 1 Cylinder Head-Camshaft-Valves Fig. 2 Rocker Cover Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal > Page 1373 INSTALL VALVE COVERS 1. Clean cylinder head and cover mating surfaces. Install new gasket. 2. See Fig. 2 and apply sealant such as Mopar Silicone Rubber Adhesive Sealant to cover ends. 3. Install cover and tighten cover bolt washer and gasket assembly to 10 Nm (88 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Cover Gasket > Component Information > Technical Service Bulletins > Customer Interest for Valve Cover Gasket: > 091689 > Oct > 89 > Engine - Oil Consumption Valve Cover Gasket: Customer Interest Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Cover Gasket > Component Information > Technical Service Bulletins > Customer Interest for Valve Cover Gasket: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 1382 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Cover Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover Gasket: > 091689 > Oct > 89 > Engine - Oil Consumption Valve Cover Gasket: All Technical Service Bulletins Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Cover Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover Gasket: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 1388 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Customer Interest for Valve Guide Seal: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption Technical Service Bulletin # 091892A Date: 930113 Engine - Smoky Exhaust/Oil Consumption NO.: 09-18-92 Rev. A GROUP: Engine DATE: Jan. 13, 1993 SUBJECT: Excessive Oil Consumption 3.0L MMC Engine THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-18-92 WHICH SHOULD BE REMOVED FROM YOUR FILES. MODELS: 1989 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon/New Yorker Landau 1990 - 1993 (AG) Daytona 1990 - 1993 (AJ) LeBaron Coupe/Lebaron Convertible 1992 - 1993 (AP) Shadow/Shadow Convertible/Sundance 1987 - 1993 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1990 - 1991 (AQ) Chrysler TC 1988 (C) Dynasty/New Yorker DISCUSSION: Engines built since 11/15/91 (build code BDL7.067) have snap rings installed on the exhaust valve guides. Engines built since 10/2/92 (build code BDL7.416) have improved intake and exhaust valve stem seals in addition to the snap rings on the exhaust valve guides. The build code label is located on the intake plenum. SYMPTOM/CONDITION: Observed oil smoke in the exhaust at idle or during deceleration (conditions causing high intake manifold vacuum. Excessive oil consumption is more than one quart per 1,000 miles on vehicles with less than 50,000 miles or more than one quart per 750 miles on vehicles with more than 50,000 miles. DIAGNOSIS: Verify the PCV system is functioning properly and engine compression is within specifications. Refer to the appropriate technical service manual for test procedures and specifications. If the PCV system and engine compression are within specification, perform the repair procedure. PARTS REQUIRED: SPECIAL TOOLS REQUIRED: REPAIR PROCEDURE: This bulletin involves installing snap rings on the exhaust valve guides and replacing all of the valve stem seals or cylinder head replacement as determined by inspection. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Customer Interest for Valve Guide Seal: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1397 1. Remove the intake plenum and manifold. 2. Remove the rocker cover, rocker shaft and cam bearing cap assembly on the forward bank using the procedure in the appropriate technical service manual. 3. Remove one of the cam journal caps from the assembly and reinstall on the head. This will prevent the cam from possibly coming out of the journals when the engine is rotated later. 4. Check front bank cylinders in # 4, # 2, then # 6 sequence. NOTE: IF A VALVE GUIDE CAN BE MOVED WITH FINGER PRESSURE, REPLACE THE CYLINDER HEAD. 5. Remove the spark plug and apply compressed air to the cylinder to prevent valve dropping. Use special tool MD998772A to remove the intake and exhaust valve locks, the valve spring retainer, valve spring and valve spring seat. 6. Remove the valve stem seals. 7. Using the height gauge that is integrated into the Groove Cutter (Special tool MD998790), measure the distance between the top of the exhaust valve guide and the top of the valve guide boss on the cylinder head (refer to illustrations of Fig. 1). If the distance is .335" (8.5 mm) or less the cylinder head will have to be removed for repair, perform PROCEDURE B. If the distance is .335" (8.5 mm) or more, perform PROCEDURE A. 8. Repeat steps 2 through 7 for the rear bank. Do the cylinders in # 3, # 1, and # 5 sequence. Procedure A PROCEDURE A: Snap Ring Installation and Valve Stem Seal Replacement (On the Vehicle) 1. Using the groove cutter (Special tool MD998790), make a groove in the exhaust valve guide (refer to Fig. 2 and 3). a. Install the special tool on the exhaust valve guide. b. Turn the tool clockwise until the force required to turn the tool suddenly decreases. c. Remove the tool. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Customer Interest for Valve Guide Seal: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1398 2. Using a magnet and shop towel, remove the cuttings from the cylinder head. 3. Install a snap ring in the groove cut in the exhaust valve guide (refer to Fig. 4). 4. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790 and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will not fit between special tool and top of valve guide) install the valve spring seat. Install all of the intake valve spring seats. 5. Install new valve stem seals on the intake and exhaust valve guides using special tool MD998729. 6. Reinstall the valve spring assemblies including the valve spring seats if not already installed step 4 of PROCEDURE A. 7. Return to step 4 of the PROCEDURE A and proceed to the next cylinder in sequence unless, all exhaust valve guide snap rings have been installed and all valve stem seals replaced on this head. 8. Reinstall the rocker shaft assembly, camshaft bearing caps, rocker cover and spark plugs. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads. 9. Using the procedures in the appropriate service manual, reassemble the engine. Procedure B PROCEDURE B: Valve Guide Height Correction, Snap Ring Installation 1. Remove the cylinder head using the procedure in the appropriate service manual. 2. Remove all of the valve spring assemblies and valves. Mark the valves so they can be returned to their original position at reassembly. 3. Remove all of the valve stem seals. 4. Check the height on any exhaust valve guides not already checked to determine if height correction will be required on more than one guide. 5. Remove any carbon from the bottom of the exhaust valve guides that need to have their height corrected, especially the face that special tool MD998115 will contact. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Customer Interest for Valve Guide Seal: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1399 6. Using special tool MD998115 and hammer, carefully drive the exhaust valve guides from the combustion chamber side to provide a valve guide height from the top of the guide to the top of the boss for the valve guide on the cylinder head of .453" (11.5 mm). Check the distance using the height gauge that is integrated into the groove cutter (Special tool MD998790). Refer to Figure 1 and Figure 5. If the valve guide is driven up too far and the valve guide height exceeds .453" (11.5 mm) use special tool MD998115 to drive the valve guide from the rocker shaft side of the head until the .453" (11.5 mm) height is achieved. 7. Inspect the valve seats using the prussian blue procedure in the appropriate service manual. 8. Using the groove cutter (Special tool MD998790), make a groove on all of the exhaust valve guides (refer to Fig. 2 and 3). a. Install the special tool on the exhaust valve guide. b. Turn the tool clockwise until the force required to turn the tool suddenly decreases. c. Remove the tool. 9. Use a magnet and shop towel or wash the cylinder head to remove the cuttings. 10. Install a snap ring on each exhaust valve guide (refer to fig. 4). 11. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790 and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will not fit between special tool and top of valve guide) install the valve spring seat. Install all of the intake valve spring seats. 12. Install new valve stem seals on the intake and exhaust valve guides using special tool MD998729. 13. Reassemble the cylinder head and install using the procedure in the appropriate service manual. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads. 14. Using the procedures in the appropriate service manual, reassemble the engine. POLICY: Reimbursable within the provisions of the warranty. Labor Operation TIME ALLOWANCE: Labor Operation No. 09-35-01-92 Repair Valve Guides and Replace 4.1 Hrs. Seals, Both Heads on Vehicle 09-35-01-93 Repair Rear Head On Vehicle 6.0 Hrs. Remove Front Head and repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Customer Interest for Valve Guide Seal: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1400 or Replace Head as Required 09-35-01-94 Repair Front Head On Vehicle 6.2 Hrs. Remove Rear Head and Repair or Replace Head as Required 09-35-01-95 Remove Both Heads and Repair 6.4 Hrs. or Replace Head as Required FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide Seal: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption Technical Service Bulletin # 091892A Date: 930113 Engine - Smoky Exhaust/Oil Consumption NO.: 09-18-92 Rev. A GROUP: Engine DATE: Jan. 13, 1993 SUBJECT: Excessive Oil Consumption 3.0L MMC Engine THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-18-92 WHICH SHOULD BE REMOVED FROM YOUR FILES. MODELS: 1989 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon/New Yorker Landau 1990 - 1993 (AG) Daytona 1990 - 1993 (AJ) LeBaron Coupe/Lebaron Convertible 1992 - 1993 (AP) Shadow/Shadow Convertible/Sundance 1987 - 1993 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1990 - 1991 (AQ) Chrysler TC 1988 (C) Dynasty/New Yorker DISCUSSION: Engines built since 11/15/91 (build code BDL7.067) have snap rings installed on the exhaust valve guides. Engines built since 10/2/92 (build code BDL7.416) have improved intake and exhaust valve stem seals in addition to the snap rings on the exhaust valve guides. The build code label is located on the intake plenum. SYMPTOM/CONDITION: Observed oil smoke in the exhaust at idle or during deceleration (conditions causing high intake manifold vacuum. Excessive oil consumption is more than one quart per 1,000 miles on vehicles with less than 50,000 miles or more than one quart per 750 miles on vehicles with more than 50,000 miles. DIAGNOSIS: Verify the PCV system is functioning properly and engine compression is within specifications. Refer to the appropriate technical service manual for test procedures and specifications. If the PCV system and engine compression are within specification, perform the repair procedure. PARTS REQUIRED: SPECIAL TOOLS REQUIRED: REPAIR PROCEDURE: This bulletin involves installing snap rings on the exhaust valve guides and replacing all of the valve stem seals or cylinder head replacement as determined by inspection. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide Seal: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1406 1. Remove the intake plenum and manifold. 2. Remove the rocker cover, rocker shaft and cam bearing cap assembly on the forward bank using the procedure in the appropriate technical service manual. 3. Remove one of the cam journal caps from the assembly and reinstall on the head. This will prevent the cam from possibly coming out of the journals when the engine is rotated later. 4. Check front bank cylinders in # 4, # 2, then # 6 sequence. NOTE: IF A VALVE GUIDE CAN BE MOVED WITH FINGER PRESSURE, REPLACE THE CYLINDER HEAD. 5. Remove the spark plug and apply compressed air to the cylinder to prevent valve dropping. Use special tool MD998772A to remove the intake and exhaust valve locks, the valve spring retainer, valve spring and valve spring seat. 6. Remove the valve stem seals. 7. Using the height gauge that is integrated into the Groove Cutter (Special tool MD998790), measure the distance between the top of the exhaust valve guide and the top of the valve guide boss on the cylinder head (refer to illustrations of Fig. 1). If the distance is .335" (8.5 mm) or less the cylinder head will have to be removed for repair, perform PROCEDURE B. If the distance is .335" (8.5 mm) or more, perform PROCEDURE A. 8. Repeat steps 2 through 7 for the rear bank. Do the cylinders in # 3, # 1, and # 5 sequence. Procedure A PROCEDURE A: Snap Ring Installation and Valve Stem Seal Replacement (On the Vehicle) 1. Using the groove cutter (Special tool MD998790), make a groove in the exhaust valve guide (refer to Fig. 2 and 3). a. Install the special tool on the exhaust valve guide. b. Turn the tool clockwise until the force required to turn the tool suddenly decreases. c. Remove the tool. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide Seal: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1407 2. Using a magnet and shop towel, remove the cuttings from the cylinder head. 3. Install a snap ring in the groove cut in the exhaust valve guide (refer to Fig. 4). 4. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790 and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will not fit between special tool and top of valve guide) install the valve spring seat. Install all of the intake valve spring seats. 5. Install new valve stem seals on the intake and exhaust valve guides using special tool MD998729. 6. Reinstall the valve spring assemblies including the valve spring seats if not already installed step 4 of PROCEDURE A. 7. Return to step 4 of the PROCEDURE A and proceed to the next cylinder in sequence unless, all exhaust valve guide snap rings have been installed and all valve stem seals replaced on this head. 8. Reinstall the rocker shaft assembly, camshaft bearing caps, rocker cover and spark plugs. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads. 9. Using the procedures in the appropriate service manual, reassemble the engine. Procedure B PROCEDURE B: Valve Guide Height Correction, Snap Ring Installation 1. Remove the cylinder head using the procedure in the appropriate service manual. 2. Remove all of the valve spring assemblies and valves. Mark the valves so they can be returned to their original position at reassembly. 3. Remove all of the valve stem seals. 4. Check the height on any exhaust valve guides not already checked to determine if height correction will be required on more than one guide. 5. Remove any carbon from the bottom of the exhaust valve guides that need to have their height corrected, especially the face that special tool MD998115 will contact. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide Seal: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1408 6. Using special tool MD998115 and hammer, carefully drive the exhaust valve guides from the combustion chamber side to provide a valve guide height from the top of the guide to the top of the boss for the valve guide on the cylinder head of .453" (11.5 mm). Check the distance using the height gauge that is integrated into the groove cutter (Special tool MD998790). Refer to Figure 1 and Figure 5. If the valve guide is driven up too far and the valve guide height exceeds .453" (11.5 mm) use special tool MD998115 to drive the valve guide from the rocker shaft side of the head until the .453" (11.5 mm) height is achieved. 7. Inspect the valve seats using the prussian blue procedure in the appropriate service manual. 8. Using the groove cutter (Special tool MD998790), make a groove on all of the exhaust valve guides (refer to Fig. 2 and 3). a. Install the special tool on the exhaust valve guide. b. Turn the tool clockwise until the force required to turn the tool suddenly decreases. c. Remove the tool. 9. Use a magnet and shop towel or wash the cylinder head to remove the cuttings. 10. Install a snap ring on each exhaust valve guide (refer to fig. 4). 11. Check the exhaust valve guide height with the .453" (11.5 mm) side of special tool MD998790 and a .040" (1 mm) feeler gauge. If the measurement is .413 (10.5 mm) or more (feeler gauge will not fit between special tool and top of valve guide) install the valve spring seat. Install all of the intake valve spring seats. 12. Install new valve stem seals on the intake and exhaust valve guides using special tool MD998729. 13. Reassemble the cylinder head and install using the procedure in the appropriate service manual. Return to step 8 of the REPAIR PROCEDURE unless this step completed the repair to both heads. 14. Using the procedures in the appropriate service manual, reassemble the engine. POLICY: Reimbursable within the provisions of the warranty. Labor Operation TIME ALLOWANCE: Labor Operation No. 09-35-01-92 Repair Valve Guides and Replace 4.1 Hrs. Seals, Both Heads on Vehicle 09-35-01-93 Repair Rear Head On Vehicle 6.0 Hrs. Remove Front Head and repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide Seal: > 091892A > Jan > 93 > Engine - Smoky Exhaust/Oil Consumption > Page 1409 or Replace Head as Required 09-35-01-94 Repair Front Head On Vehicle 6.2 Hrs. Remove Rear Head and Repair or Replace Head as Required 09-35-01-95 Remove Both Heads and Repair 6.4 Hrs. or Replace Head as Required FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Lower LH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1416 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1417 Oil Pressure & Temperature System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Testing and Inspection Timing Belt: Testing and Inspection ABNORMAL NOISES FROM TIMING BELT Incorrect Belt Tension Timing belts which are too loose or too tight are prone to making a humming sound, especially on heavy deceleration. Inspect the timing belt and re-adjust the tension. Pulley or Belt Rubbing on Cover A rubbing or whining sound can occur when the pulleys (or belt) are rubbing against the timing covers. Remove the covers and inspect for wear. If the timing belt shows any signs of wear or fraying along the outer edge it should be replaced. - Inspect the pulleys for proper alignment. An incorrectly placed washer or spacer may move one pulley out of alignment with the rest. - Verify all pulleys have no lateral movement (wobble) . Replace any pulley which wobbles. - Verify the timing cover is not warped. The cover should be replaced if warped. - Verify the timing cover rubber gasket is properly installed. Incorrect Type of Timing Belt Timing belt teeth are available in several different types. Compare the new belt to the old one and verify the teeth are the same shape. Timing belt types are not interchangeable. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Initial Checks Timing Belt: Service and Repair Initial Checks INITIAL CHECKS (PRIOR TO REMOVAL) PURPOSE Checking and recording the ignition timing and manifold vacuum level before and after the timing belt replacement allows for two assurances: Initial conditions are correct. - Verifies the quality of the job after the belt has been installed. WHY Ignition Timing Ignition timing is the position of the piston on its compression stroke when the ignition coil fires the associated sparkplug. Ignition timing is affected by two sources. Physical rotation of the distributor. - Alignment of the camshaft and crankshaft via the timing belt. Prior to replacing the timing belt it is very important to verify that this relationship is correct. If the timing belt is installed correctly the after-repairs timing check should be within 2 degrees of the pre-repairs timing check. NOTE: Minor differences, +/- 2 degrees may result from original belt stretching as it aged. If the timing belt is initially installed incorrectly, the prerepairs ignition timing may not be correct, and the after-repairs timing will differ greatly from the initial. Checking the timing before and after the job will help prevent confusion and verify the job was done correctly. Notes on Timing: An ignition timing of 0 degrees BTDC (Before Top Dead Center) implies that the ignition coil fires the spark exactly as the piston reaches its highest position (top dead center). - An ignition timing of 10 degrees BTDC implies that the spark is triggered 10 degrees of crankshaft rotation Before to the piston reaching top dead center. - An ignition timing of 10 degrees IT'D implies that the spark is triggered 10 degrees of crank shaft rotation After the piston reaches top dead center. Manifold Vacuum If the camshaft is out of alignment with the crankshaft, the intake and exhaust valves will not open and close at the optimum times. This will reduce the volumetric efficiency of the engine and thus reduce the manifold vacuum level. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 1424 NOTE: The ignition timing will also affect the manifold vacuum levels, verify the timing is correct prior to measuring the vacuum. If the after-repair vacuum level is lower than the pre-repairs level this would be an indication that the timing belt may not be installed correctly. NOTE: The vacuum checks should be made at similar engine speeds and temperatures. - Check "manifold vacuum" at a source downstream of the throttle plates. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 1425 Timing Belt: Service and Repair Pre-Installation Inspection PRE-INSTALLATION INSPECTION - Prior to installing the timing belt inspect the teeth of the crank and cam pulleys for burrs or damage. Light burrs may be removed, but any damage which permanently mars the teeth/belt mating surface will require the pulley to be replaced. - Inspect the inside of the timing belt covers for rubbing or wear. The plastic covers may warp, causing the pulleys or belts to rub against the inside of the cover. - Inspect the tensioner and water pump pulleys for wobble or looseness. The pulleys should spin freely with no rough spots or lateral (side-to-side) movement. - Inspect the tensioner and water pump pulley surfaces. They should be clean and free of nicks and burrs. If any damage is noted the pulleys should be replaced. - Inspect the camshaft and crankshaft oil seals for leakage. Any seal which shows signs of leakage should be replaced. WARNING: Oil leakage will damage the new timing belt. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 1426 Timing Belt: Service and Repair Timing Belt Removal and Installation Removal NOTE: Always carefully inspect the Water Pump when replacing the Timing Belt, as the pump is timing belt driven. Fig. 5 Accessories & mounting brackets removal & installation 1. Disconnect battery ground cable. Air Conditioning Belt Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 1427 Alternator/Power Steering Belt 2. Remove accessory drive belts. a Loosen adjusting lock nut on A/C belt adjuster, Turn adjusting jack screw counterclockwise to reduce belt tension. b Install breaker bar into 1/2 square opening in tensioner on Alternator/Power Steering belt. Rotate tensioner counterclockwise to remove belt. 3. Remove A/C compressor, alternator, power steering pump, tensioners and mounting brackets as shown in Fig. 5, and set aside. Right Inner Splash Shield - Typical 4. Raise and support vehicle, then remove right inner splash shield. Fig. 6 Crankshaft pulley removal Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 1428 5. Remove crankshaft drive pulleys and torsional damper, Fig. 6, then lower vehicle and position a suitable jack under engine. Fig. 7 Engine mount removal - Typical 6. Remove engine mount insulator from engine mount bracket, raise engine slightly, then remove engine mount bracket as shown in Fig. 7. Fig. 8 Timing belt cover removal 7. Remove timing belt covers as shown in Fig. 8. 8. If belt is to be reused, mark belt running direction for reassembly reference. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 1429 Fig. 9 Timing Belt Routing 9. Loosen timing belt tensioner, Fig. 9, then remove timing belt. 10. Remove crankshaft sprocket flange, if necessary. 11. Remove camshaft sprocket attaching bolts, then the sprockets, if necessary. Camshaft Sprockets 12. Install camshaft sprockets, then using camshaft sprocket holder tool MB990775, torque bolts to 73 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 1430 Fig. 10 Positioning timing belt tensioner 13. Install timing belt tensioner and spring. Rotate tensioner counterclockwise, Fig. 10, then temporarily tighten bolt. 14. Install timing belt on crankshaft sprocket first, while keeping belt tight on tension side, then position belt over front camshaft sprocket, Fig. 9. 15. Then, install belt on water pump pulley and rear camshaft sprocket and finally on the timing belt tensioner, Fig. 9. 16. Rotate front camshaft sprocket in opposite direction and check that all timing marks align, Fig. 9. 17. Install crankshaft sprocket flange, then loosen tensioner bolt to allow spring to tension belt. Rotate crankshaft two complete revolutions, in direction of normal rotation and check timing marks. 18. Tighten tensioner bolt to 23 ft. lbs. 19. Install timing belt covers as shown in Fig. 8. 20. Install engine brackets, pulleys, and accessories as shown in Fig. 5, then the drive belts. Installation NOTE: Always carefully inspect the Water Pump when replacing the Timing Belt, as the pump is timing belt driven. Camshaft Sprockets 1. Install camshaft sprockets, then using camshaft sprocket holder tool MB990775, torque bolts to 73 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 1431 Fig. 10 Positioning timing belt tensioner 2. Install timing belt tensioner and spring. Rotate tensioner counterclockwise, Fig. 10, then temporarily tighten bolt. Fig. 9 Timing Belt Routing 3. Install timing belt on crankshaft sprocket first, while keeping belt tight on tension side, then position belt over front camshaft sprocket, Fig. 9. 4. Then, install belt on water pump pulley and rear camshaft sprocket and finally on the timing belt tensioner, Fig. 9. 5. Rotate front camshaft sprocket in opposite direction and check that all timing marks align, Fig. 9. 6. Install crankshaft sprocket flange, then loosen tensioner bolt to allow spring to tension belt. Rotate crankshaft two complete revolutions, in direction of normal rotation and check timing marks. 7. Tighten tensioner bolt to 23 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 1432 Fig. 8 Timing belt cover removal 8. Install timing belt covers as shown in Fig. 8. Fig. 5 Accessories & mounting brackets removal & installation Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Initial Checks > Page 1433 Air Conditioning Belt Alternator/Power Steering Belt Fig. 7 Engine mount removal - Typical 9. Install engine brackets, pulleys, and accessories as shown in Fig. 5, then the drive belts. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Page 1434 Timing Belt: Tools and Equipment RECOMMENDED TOOLS - Floor jack (for supporting the engine while removing the front engine mount). - Timing light (for measuring timing before and after). - Vacuum gauge (for measuring engine vacuum levels before and after). Crankshaft Pulley Removal - Crankshaft Holding Tool MD998784 (used in conjunction with an old drive belt), or an air powered impact gun (for removing the crankshaft bolt). Timing Belt Tensioner Release - Large flat blade screw driver (for moving timing belt tensioner). - Torque Wrenches: Low Range (0-50 ft-lb) for covers and brackets. - High Range (0-150 ft-lb) for crankshaft pulley bolt. - Full set of Metric sockets and wrenches. - Fender covers. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Fundamentals and Basics > General Information Timing Belt: Fundamentals and Basics General Information TIMING BELT, GENERAL INFORMATION PURPOSE The timing belt synchronizes (times) the opening and closing of the intake and exhaust valves with the movement/stroke of the pistons. The timing belt also matches the rotation of the distributor with the movement of the pistons. OPERATION The crankshaft represents the movement of the pistons while the camshaft controls the opening and closing of the valves. The timing belt connects the crankshaft to the camshaft and uses the rotation of the crankshaft to drive the camshaft in a 2 to 1 relationship. For every two revolutions of the crankshaft the camshaft is rotated only once. Why 2:1 In 4 stoke engine each piston must complete 4 separate strokes (intake, compression, power, and exhaust) to complete a cycle. For a single piston to complete all four strokes the crankshaft must rotate two full revolutions. The camshaft controls the opening and closing of the valves. During the four piston strokes of an engine cycle the intake and exhaust valves (for each cylinder) will open and close only once. This requires only one revolution of the camshaft. NOTE: The intake valves will open and close only during the intake stroke and the exhaust valves will open and close only during the exhaust stroke. During the compression and power strokes the valves remain closed. How This 2 to 1 reduction is accomplished by making the circumference of the camshaft pulley twice as large as the crankshaft pulley. This allows the smaller crankshaft to complete two revolutions while the larger camshaft completes only one revolution. NOTE: The distributor also requires only one rotation for every two rotations of the crankshaft. FIRST INDICATIONS OF A BROKEN BELT 1. The engine will immediately die or fail to start. 2. When attempting to restart the engine, the cranking speed (rpm) will be unusually fast. 3. The sound of the engine while attempting to restart will be different than normal. Instead of the usual rhythmic "Rir. . .Rir. . .Rir..." cranking sound it will sound more like "RirRirRirRir" with no detectable rhythm. Why When the timing belt brakes the camshaft and distributor quit rotating. - Without distributor rotation the ignition system stops producing spark and the engine immediately dies or fails to start. - Without the rotation of the camshaft the intake and exhaust valves stop opening and closing. This prevents the pistons from developing compression which also causes the engine to die. This lack of compression also produces the unusually fast and non- rhythmic cranking speed when attempting to restart the engine. NOTE: The normal rhythmic cranking sound is a result of the starter having to work harder as each piston begins its compression stroke. VERIFYING TIMING BELT IS BROKEN Check for camshaft rotation while cranking the engine (with the starter or by hand, using the crankshaft bolt). WARNING: When rotating the crankshaft by hand always disconnect the battery. Camshaft rotation can be verified by: Remove oil filler cap and check if camshaft is visible. - Remove valve cover and directly observe camshaft. - Remove distributor cap and check for rotor rotation (the rotor is driven by the camshaft) - Remove upper timing belt cover and check camshaft pulley rotation and belt integrity. Other Indications the Timing Belt may be broken. No ignition spark. - Very low compression (<15 psi) on all cylinders. Due to the low compression the following additional symptoms may be present. While attempting to start the car, the battery strength remains high for an unusually long length of time. - The sound of the engine while attempting to restart will be different than normal. Instead of the usual rhythmic "Rir.. .Rir. . .Rir..." cranking sound it will sound more like "RirRirRirRir" with no detectable rhythm. NOTE: For an experienced technician this unique sound will often be the initial symptom that leads to a more in-depth check of the timing belt. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 1437 OTHER RELATED PROBLEMS The Timing Belt has Jumped Teeth If the belt is excessively worn, loose, or missing teeth it is possible for the belt to jump teeth on the crankshaft. - A belt which is off by just one tooth will cause an engine to run very poorly or not run at all. A belt which is off by more than one tooth will generally prevent the engine from starting. To verify the problem, remove the timing belt covers and check the crankshaft and camshaft alignment marks. The Camshaft is Seized - A seized camshaft will produce the same symptoms as a broken timing belt. WARNING: Rotating the camshaft with the timing belt removed on an interference engine can result in additional valve damage. INTERFERENCE/FREE RUNNING Interference - Upon reaching Top Dead Center a piston will impact a valve which is fully open. This situation occurs when the timing belt breaks and a valve is left fully open while the pistons continue to operate. NOTE: This engine is an Interference design. Free Running - The engine has been designed such that should the timing belt break there will still be clearance between a fully open valve and a piston at TDC. Valve Damage - Interference engines will generally bend intake or exhaust valves when a timing belt is broken. When a timing belt breaks the rotational momentum of the camshaft will cause several valves to open and close out of sequence with the movement of the pistons. Any valve which is left open when the associated piston reaches TDC will be struck and bent. Bent valves will generally stick in a partially open position, resulting in a loss of vacuum and compression on that cylinder. If a timing belt breaks during normal city or highway driving the probability that an interference engine will bend at least one valve is very high. NOTE: If a timing belt breaks, an interference type engine will not always bend or damage valves. If the timing belt breaks during start-up with camshaft remaining in a position where no valve is fully open there will be no valve damage. Free running engines will generally not bend or damage valves when a timing belt is broken. However the design clearance between a fully open valve and a piston at TDC may be quite small (<0.020 inches) . A build up of carbon on top of the piston in conjunction with improperly adjusted valve clearances can result in a free running engine bending valves when the timing belt breaks. VERIFYING VALVE DAMAGE Install a new timing belt with the camshaft and crankshaft aligned properly and attempt to start the engine. If the engine starts and runs smoothly with steady high vacuum levels, the valves are not damaged. WARNING: Rotating the camshaft with the timing belt removed on an interference engine can result in additional valve damage. If the engine fails to start or runs roughly with the manifold vacuum reading rapidly oscillating over a 4-6 inch range there may be valve damage. NOTE: Verify that the crankshaft and camshaft are aligned properly. A timing belt which is off Dust one tooth may produce similar performance symptoms. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 1438 Remove the valve cover and inspect the valve clearances. A valve which is bent will be stuck in the open position or will have an excessively larger clearance. Perform a compression check or a cylinder leak down check. Cylinders with bent valves will have very low compression (<50.0 psi) and will not hold pressure. If valve damage is detected the cylinder head will have to be removed and the damaged valves replaced. Also inspect top of the pistons for damage. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 1439 Timing Belt: Fundamentals and Basics Initial Preparations INITIAL PREPARATIONS Disconnect Battery When working near or around the crankshaft/camshaft pulleys, accidentally engaging the starter can result in serious personal injury and major engine damage. The negative battery terminal should be disconnected prior to commencing work and should not be reconnected until the timing belt is re-installed and the engine is ready to start. Remove Front Tire Access to lower timing belt components can be gained by removing the associated front tire and working through the wheel well. Fender Covers Fender covers will prevent damage to the vehicles finish while performing the job. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 1440 Timing Belt: Fundamentals and Basics Positioning Crankshaft to Number 1 TDC POSITIONING CRANKSHAFT TO #1 TDC, Compression NOTE: If the timing belt is broken, pre-position only the crankshaft and ignore references in this article to compression stroke, camshaft, and distributor position. Rotating the camshaft with a broken timing belt may damage the valves. WHY Timing belt installation alignment marks correspond to the crankshaft positioned at #1 Top Dead Center (TDC), during the compression stroke. Moving the crankshaft to this point prior to removing the belt allows you to verify the original alignment of the crankshaft and camshaft. This also reduces crank/cam pulley movement once the belt is removed which helps to minimize any possible confusion. The alignment marks may be dirty and difficult to locate. Pre-positioning the crankshaft will make it easier to locate the marks. HOW - Remove the distributor cap and observe the position of the rotor. - Using the crankshaft bolt, rotate the crankshaft until the distributor rotor is nearly pointing towards the #1 cylinder position. - Then slowly rotate the crankshaft until the timing indicator is pointing at the "0"/TDC degree mark. NOTE: Remember that the crankshaft rotates twice for every rotation of the camshaft. The rotor must be pointing towards #1 cylinder terminal when the timing mark reaches 0 degrees. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 1441 Timing Belt: Fundamentals and Basics Removal and Installation Tips and Hints (Maintenance) TIMING BELT REMOVAL - Prior to removing the timing belt, inspect all drive belts. Since the drive belts will need to be removed to replace the timing belt it would be convenient to have any necessary replacement belts on hand should any the drive belts show excessive wear. - After the timing belt covers are removed, verify the camshaft and crankshaft are properly aligned. - Verify that all timing belt cover gaskets and inspection hole covers are intact. Any missing gaskets or covers could allow moisture and debris to enter the covers and damage the belt. NOTE: In cold climates, any moisture which enters the covers may eventually freeze on the timing belt or between the belt and the pulley, resulting in the belt skipping teeth. - When removing the engine mount, Slightly raise the engine with a floor jack. This will take the weight of the engine off of engine mount bolts and will ease in removal. CAUTION: Never apply the lifting surface of the floor jack directly to the oil pan. Use a block of wood or other soft material to prevent puncturing the oil pan. TIMING BELT INSTALLATION - When positioning or removing the camshaft and crankshaft pulleys, do not grasp the teeth of the pulleys with pliers or any other metal object. CAUTION: Any nick or burr left on the pulleys may result in premature belt failure. - When installing the timing belt: Do not use any device to pry the belt over a pulley - Do not lubricate the pulleys with any type of fluid or penetrating oil to ease in slipping the belt on. - Always install the belt such that the initial slack is on the tensioner side of the pulleys. If any slack is left on the opposite side, when the tensioner is released the pulleys will turn and the belt alignment will be incorrect. - After installing and tensioning the belt, recheck the alignment of the camshafts and crankshaft. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 1442 Timing Belt: Fundamentals and Basics General Information TIMING BELT, GENERAL INFORMATION PURPOSE The timing belt synchronizes (times) the opening and closing of the intake and exhaust valves with the movement/stroke of the pistons. The timing belt also matches the rotation of the distributor with the movement of the pistons. OPERATION The crankshaft represents the movement of the pistons while the camshaft controls the opening and closing of the valves. The timing belt connects the crankshaft to the camshaft and uses the rotation of the crankshaft to drive the camshaft in a 2 to 1 relationship. For every two revolutions of the crankshaft the camshaft is rotated only once. Why 2:1 In 4 stoke engine each piston must complete 4 separate strokes (intake, compression, power, and exhaust) to complete a cycle. For a single piston to complete all four strokes the crankshaft must rotate two full revolutions. The camshaft controls the opening and closing of the valves. During the four piston strokes of an engine cycle the intake and exhaust valves (for each cylinder) will open and close only once. This requires only one revolution of the camshaft. NOTE: The intake valves will open and close only during the intake stroke and the exhaust valves will open and close only during the exhaust stroke. During the compression and power strokes the valves remain closed. How This 2 to 1 reduction is accomplished by making the circumference of the camshaft pulley twice as large as the crankshaft pulley. This allows the smaller crankshaft to complete two revolutions while the larger camshaft completes only one revolution. NOTE: The distributor also requires only one rotation for every two rotations of the crankshaft. FIRST INDICATIONS OF A BROKEN BELT 1. The engine will immediately die or fail to start. 2. When attempting to restart the engine, the cranking speed (rpm) will be unusually fast. 3. The sound of the engine while attempting to restart will be different than normal. Instead of the usual rhythmic "Rir. . .Rir. . .Rir..." cranking sound it will sound more like "RirRirRirRir" with no detectable rhythm. Why When the timing belt brakes the camshaft and distributor quit rotating. - Without distributor rotation the ignition system stops producing spark and the engine immediately dies or fails to start. - Without the rotation of the camshaft the intake and exhaust valves stop opening and closing. This prevents the pistons from developing compression which also causes the engine to die. This lack of compression also produces the unusually fast and non- rhythmic cranking speed when attempting to restart the engine. NOTE: The normal rhythmic cranking sound is a result of the starter having to work harder as each piston begins its compression stroke. VERIFYING TIMING BELT IS BROKEN Check for camshaft rotation while cranking the engine (with the starter or by hand, using the crankshaft bolt). WARNING: When rotating the crankshaft by hand always disconnect the battery. Camshaft rotation can be verified by: Remove oil filler cap and check if camshaft is visible. - Remove valve cover and directly observe camshaft. - Remove distributor cap and check for rotor rotation (the rotor is driven by the camshaft) - Remove upper timing belt cover and check camshaft pulley rotation and belt integrity. Other Indications the Timing Belt may be broken. No ignition spark. - Very low compression (<15 psi) on all cylinders. Due to the low compression the following additional symptoms may be present. While attempting to start the car, the battery strength remains high for an unusually long length of time. - The sound of the engine while attempting to restart will be different than normal. Instead of the usual rhythmic "Rir.. .Rir. . .Rir..." cranking sound it will sound more like "RirRirRirRir" with no detectable rhythm. NOTE: For an experienced technician this unique sound will often be the initial symptom that leads to a more in-depth check of the Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 1443 timing belt. OTHER RELATED PROBLEMS The Timing Belt has Jumped Teeth If the belt is excessively worn, loose, or missing teeth it is possible for the belt to jump teeth on the crankshaft. - A belt which is off by just one tooth will cause an engine to run very poorly or not run at all. - A belt which is off by more than one tooth will generally prevent the engine from starting. - To verify the problem, remove the timing belt covers and check the crankshaft and camshaft alignment marks. The Camshaft is Seized - A seized camshaft will produce the same symptoms as a broken timing belt. WARNING: Rotating the camshaft with the timing belt removed on an interference engine can result in additional valve damage. INTERFERENCE/FREE RUNNING Interference - Upon reaching Top Dead Center a piston will impact a valve which is fully open. This situation occurs when the timing belt breaks and a valve is left fully open while the pistons continue to operate. NOTE: This engine is an Interference design. Free Running - The engine has been designed such that should the timing belt break there will still be clearance between a fully open valve and a piston at TDC. Valve Damage - Interference engines will generally bend intake or exhaust valves when a timing belt is broken. When a timing belt breaks the rotational momentum of the camshaft will cause several valves to open and close out of sequence with the movement of the pistons. Any valve which is left open when the associated piston reaches TDC will be struck and bent. Bent valves will generally stick in a partially open position, resulting in a loss of vacuum and compression on that cylinder. If a timing belt breaks during normal city or highway driving the probability that an interference engine will bend at least one valve is very high. NOTE: If a timing belt breaks, an interference type engine will not always bend or damage valves. If the timing belt breaks during start-up with camshaft remaining in a position where no valve is fully open there will be no valve damage. Free running engines will generally not bend or damage valves when a timing belt is broken. However the design clearance between a fully open valve and a piston at TDC may be quite small (<0.020 inches) . A build up of carbon on top of the piston in conjunction with improperly adjusted valve clearances can result in a free running engine bending valves when the timing belt breaks. VERIFYING VALVE DAMAGE Install a new timing belt with the camshaft and crankshaft aligned properly and attempt to start the engine. If the engine starts and runs smoothly with steady high vacuum levels, the valves are not damaged. WARNING: Rotating the camshaft with the timing belt removed on an interference engine can result in additional valve damage. If the engine fails to start or runs roughly with the manifold vacuum reading rapidly oscillating over a 4-6 inch range there may be valve damage. NOTE: Verify that the crankshaft and camshaft are aligned properly. A timing belt which is off Dust one tooth may produce similar Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 1444 performance symptoms. Remove the valve cover and inspect the valve clearances. A valve which is bent will be stuck in the open position or will have an excessively larger clearance. Perform a compression check or a cylinder leak down check. Cylinders with bent valves will have very low compression (<50.0 psi) and will not hold pressure. If valve damage is detected the cylinder head will have to be removed and the damaged valves replaced. Also inspect top of the pistons for damage. Initial Preparations INITIAL PREPARATIONS Disconnect Battery When working near or around the crankshaft/camshaft pulleys, accidentally engaging the starter can result in serious personal injury and major engine damage. The negative battery terminal should be disconnected prior to commencing work and should not be reconnected until the timing belt is re-installed and the engine is ready to start. Remove Front Tire Access to lower timing belt components can be gained by removing the associated front tire and working through the wheel well. Fender Covers Fender covers will prevent damage to the vehicles finish while performing the job. Positioning Crankshaft to Number 1 TDC POSITIONING CRANKSHAFT TO #1 TDC, Compression NOTE: If the timing belt is broken, pre-position only the crankshaft and ignore references in this article to compression stroke, camshaft, and distributor position. Rotating the camshaft with a broken timing belt may damage the valves. WHY Timing belt installation alignment marks correspond to the crankshaft positioned at #1 Top Dead Center (TDC), during the compression stroke. Moving the crankshaft to this point prior to removing the belt allows you to verify the original alignment of the crankshaft and camshaft. This also reduces crank/cam pulley movement once the belt is removed which helps to minimize any possible confusion. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 1445 The alignment marks may be dirty and difficult to locate. Pre-positioning the crankshaft will make it easier to locate the marks. HOW - Remove the distributor cap and observe the position of the rotor. - Using the crankshaft bolt, rotate the crankshaft until the distributor rotor is nearly pointing towards the #1 cylinder position. - Then slowly rotate the crankshaft until the timing indicator is pointing at the "0"/TDC degree mark. NOTE: Remember that the crankshaft rotates twice for every rotation of the camshaft. The rotor must be pointing towards #1 cylinder terminal when the timing mark reaches 0 degrees. Removal and Installation Tips and Hints (Maintenance) TIMING BELT REMOVAL - Prior to removing the timing belt, inspect all drive belts. Since the drive belts will need to be removed to replace the timing belt it would be convenient to have any necessary replacement belts on hand should any the drive belts show excessive wear. - After the timing belt covers are removed, verify the camshaft and crankshaft are properly aligned. - Verify that all timing belt cover gaskets and inspection hole covers are intact. Any missing gaskets or covers could allow moisture and debris to enter the covers and damage the belt. NOTE: In cold climates, any moisture which enters the covers may eventually freeze on the timing belt or between the belt and the pulley, resulting in the belt skipping teeth. - When removing the engine mount, Slightly raise the engine with a floor jack. This will take the weight of the engine off of engine mount bolts and will ease in removal. CAUTION: Never apply the lifting surface of the floor jack directly to the oil pan. Use a block of wood or other soft material to prevent puncturing the oil pan. TIMING BELT INSTALLATION - When positioning or removing the camshaft and crankshaft pulleys, do not grasp the teeth of the pulleys with pliers or any other metal object. CAUTION: Any nick or burr left on the pulleys may result in premature belt failure. - When installing the timing belt: Do not use any device to pry the belt over a pulley - Do not lubricate the pulleys with any type of fluid or penetrating oil to ease in slipping the belt on. - Always install the belt such that the initial slack is on the tensioner side of the pulleys. If any slack is left on the opposite side, when the tensioner is released the pulleys will turn and the belt alignment will be incorrect. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 1446 - After installing and tensioning the belt, recheck the alignment of the camshafts and crankshaft. Removal and Installation Tips and Hints (Broken Belt) TIMING BELT REMOVAL - Prior to removing the timing belt, inspect all drive belts. Since the drive belts will need to be removed to replace the timing belt it would be convenient to have any necessary replacement belts on hand should any the drive belts show excessive wear. - After the timing belt covers are removed, align the camshaft and crankshaft. 1. Position the crankshaft to a safe position (approaching #1 Top Dead Center (TDC) with no cylinder at or near top dead center) 2. Align the camshaft with its timing marks. 3. Rotate the crankshaft to #1 TDC WARNING: Valve damage will occur if any cylinder reaches Top Dead Center, while an associated valve is at or near its fully open position. NOTES When positioning the camshaft or crankshaft always rotate the shafts slowly and in small increments, while frequently stopping to observe the relationship of the valves and pistons. - With the spark plugs removed the crankshaft should rotate easily. If any resistance is felt, immediately stop and verify that a piston is not striking a valve. - Verify that all timing belt cover gaskets and inspection hole covers are intact. Any missing gaskets or covers could allow moisture and debris to enter the covers and damage the belt. NOTE: In cold climates, any moisture which enters the covers may eventually freeze on the timing belt or between the belt and the pulley, resulting in the belt skipping teeth. - When removing the engine mount, slightly raise the engine with a floor jack. This will take the weight of the engine off of engine mount bolts and will ease in removal. CAUTION: Never apply the lifting surface of the floor jack directly to the oil pan. Use a block of wood or other soft material to prevent puncturing the oil pan. INSPECTION - Prior to installing the timing belt inspect the teeth of the crank and cam pulleys for burrs or damage. Light burrs may be removed, but any damage which permanently mars the teeth/belt mating surface will require the pulley to be replaced. - Inspect the inside of the timing belt covers for rubbing or wear. The plastic covers may warp, causing the pulleys or belts to rub against the inside of the cover. - Inspect the tensioner/idler/water-pump pulleys for wobble or looseness. The pulleys should spin freely with no rough spots or lateral (side-to-side) movement. - Inspect the tensioner/idler/water pump pulley surfaces. They should be clean and free of nicks and burrs. If any damage is noted the pulleys should be replaced. - Inspect the water pump for signs of leakage, replace if necessary. - Inspect the camshaft and crankshaft oil seals for leakage. Any seal which shows signs of leakage should be replaced. CAUTION: Oil leakage will damage the new timing belt. TIMING BELT INSTALLATION - When positioning or moving the camshaft and crankshaft pulleys, do not grasp the teeth of the pulleys with pliers or any other metal object. CAUTION: Any nick or burr left on the pulleys may result in premature belt failure. - When installing the timing belt: Do not use any device to pry the belt over a pulley - Do not lubricate the pulleys with any type of fluid or penetrating oil to ease in slipping the belt on. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 1447 - Always install the belt such that the initial slack is on the tensioner side of the pulleys. If any slack is left on the opposite side, when the tensioner is released the pulleys will turn and the belt alignment will be incorrect. - After installing and tensioning the belt, recheck the alignment of the camshafts and crankshafts. Checking Engine Vacuum CHECKING ENGINE VACUUM Manifold vacuum readings (taken at a vacuum port downstream of the throttle plate) should be steady and smooth. If valve damage has occurred the needle will rapidly fluctuate back and forth. NOTE: Prior to checking vacuum, the ignition timing should be checked and adjusted. Ignition timing will affect the vacuum levels. To verify valve, perform a compression check or leak down check on all cylinders. Cylinders with damaged valves will not develop compression and will not hold pressure. If valve damage is detected the cylinder head will need to be removed. Recommended Parts RECOMMENDED PARTS - New Timing Belt - Compare length, width, and shape of teeth to the old belt. They should match exactly. OPTIONAL, PENDING INSPECTION Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Fundamentals and Basics > General Information > Page 1448 - Water Pump - Replacing the water pump requires removing the timing belt. A thorough examination of the water pump while the timing belt is removed is highly recommended. - Gasket Sealant - When removing the timing belt covers the gaskets may come unglued from the covers. - Camshaft and Crankshaft Seals - These seals are located behind the timing belt gears. Leakage from these seals can rapidly deteriorate a new timing belt. - Drive Belts - Drive belt removal is required to access the timing belt. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations System not equipped with fuel pressure test port. (To test fuel pressure tee into system with adapter.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle mixture using this screw! Idle mixture is electronically controlled by the Powertrain Control Module (PCM), and is not adjustable. If an idle mixture problem is suspected, check oxygen sensor and feedback system. SEE Computers and Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications IDLE SPEED Idle speed adjustment is electronically controlled by the Automatic Idle Speed (AIS) Motor and is not adjustable. For diagnosis of incorrect idle speed, refer to COMPUTERIZED ENGINE CONTROLS. IDLE SPEED Automatic ............................................................................................................................................. .................................................................. 800 RPM Manual .............................................................. ...................................................................................................................................................... 800 RPM Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1460 Idle Speed: Testing and Inspection 1. Remove air cleaner assembly, then plug heated air door vacuum hose. 2. With vehicle in PARK for A/T, or NEUTRAL for M/T, START engine and warm until cooling fan cycles ON and OFF at least once. STOP engine. 3. Connect suitable timing light, then disconnect coolant temperature sensor. START engine, and ensure basic timing is set to 12° BTDC. 4. STOP engine and reconnect coolant temperature sensor wire. 5. Disconnect PCV valve hose from intake manifold nipple. 6. Attach tool No. C-5004 or equivalent (.125 inch orifice in attached hose) to intake manifold PCV nipple. 7. Connect DRB II or equivalent scanner, then START engine and allow to idle for at least 1 minute. 8. Using scanner, place read/hold switch in read position and depress ATM button until code 70 appears. 9. Place read/hold switch to hold position, then the following should occur: a. AIS motor will fully close. b. Idle spark advance will become fixed. c. Idle fuel will become enriched. d. Engine rpm will be displayed on diagnostic read-out tool in units of rpm x 10. For example, display 95 equals 95 x 10 which indicates 950 rpm. 10. Check idle rpm. If idle rpm is within 850-1250 rpm then throttle body minimum air flow is satisfactory. If idle rpm is not as specified, clean or replace throttle body, refer to MAINTENANCE PROCEDURES. Retest minimum air flow after throttle body cleaning. 11. STOP engine, then remove tool No. C-5004 (orifice) from intake manifold PCV nipple. Install PCV valve hose. 12 Erase fault codes. Remove scanner, then install air cleaner assembly and heated air door vacuum hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1461 Idle Speed: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle speed using this screw, unless directed to do so in a service procedure. Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air Control (IAC) motor, and is not adjustable. If idle is outside of specified RPM, or is rough, or unstable, inspect and clean throttle body if deposits are visible. Perform Minimum Idle Air Flow Test if applicable. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair 1. Loosen gas cap and allow tank pressure to release. 2. Remove wiring harness connector from any injector, then ground one injector terminal. 3. Connect a suitable jumper wire to a second terminal, then touch the positive post of the battery for approximately 10 seconds and release system pressure. 4. Remove jumper wires and service fuel system as required. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Cylinder Location 1988-1996 3.0L (182) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Cylinder Location > Page 1470 Distributor Cap From The Top - Includes Connections Inside The Cap. (Round Terminals Are Plug Wire Connections On The Top Of The Cap.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations 1988-1996 3.0L (182) 3.0L Except Stealth Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Marks and Indicators: Diagrams TIMING MARK 3.0L Timing Scale Above Crank Pulley--Viewed From Front Of Car Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications Distributor: Specifications Distributer Adapter ............................................................................................................................... .......................................... 14 Nm (120 in lbs) Distributer Housing Bolt ............................................. .................................................................................................................... 15 Nm (130 in lbs) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications > Page 1484 Distributor: Locations Distributor Hold-Down The Optical Distributor is located at the back of the engine, behind the right-hand cylinder head. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications > Page 1485 Distributor: Service and Repair REMOVAL 1. Disconnect distributor lead wire at wiring harness connector. 2. Remove distributor cap retaining screws and remove distributor cap. 3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum. Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when reinstalling the distributor. 4. Remove the distributor hold down nut and remove the distributor from the engine. DISASSEMBLY 1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and remove lead wire. 2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or damaged slots. 3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing. 4. Remove 2 bearing retainer screws. 5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the distributor drive gear roll pin. 6. Remove distributor drive gear, remove distributor shaft and bearing assembly. REASSEMBLY 1. Install shaft and bearing assembly in distributor housing. 2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference marks made during disassembly, and install roll pin. 3. Install distributor shaft bearing retaining screws. 4. Install the photo optic sensing unit and bushing and tighten with 3 screws. 5. Install disk spacers and disk. Install disk assembly screw. 6. Install lead wire, and lead wire clamp screw. 7. Install protective cover on distributor housing. INSTALLATION 1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If engine has been cranked with distributor removed proceed to step 3 for installation. 2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the distributor is installed, the rotor will be in line with the previously scribed line on the air intake plenum. Proceed to step 4. 3. If the engine has been cranked with the distributor removed perform the following procedure: a. Rotate the crankshaft until the number one piston is at the top of its compression stroke. Distributor Cap Terminal Routing b. Rotate the distributor shaft until the rotor points to number one terminal. c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam shaft. With the distributor fully seated the rotor should be under the number one terminal. 4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers. Install hold down nut finger tight. 5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to ADJUSTMENT PROCEDURES for timing adjustment. . Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. .................... 0.9 to 1.1 mm (0.039 to 0.044 in) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 1490 Spark Plug: Specifications Tightening Specifications Spark Plug Torque ............................................................................................................................... ...................................................... 28 Nm (20 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications SERVICE SPECIFICATIONS Compression pressure ..................................................................................................................... 840 kPa (178 psi) +/- 100 kPa (14 psi) @ 250-400 rpm Maximum variation ....................................... .............................................................................................................................................................. .... 25% Manifold vacuum .................................................................................................................... ........................................................... 520 mmHg (20 in.Hg.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1494 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. NOTE: Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. NOTE: Correct engine compression pressures should be 178 psi +/- 14 psi, Maximum cylinder deviation 25% Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1498 Valve Clearance: Adjustments This engine uses hydraulic lash adjusters. No provision for adjustment is provided. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem Water Pump: Testing and Inspection Verifying Water Pump Problem VERIFYING WATER PUMP PROBLEM Check for Loose Water Pump Pulley As the pump shaft seals and bearings wear with age the pulley/shaft may develop a wobble or lateral runout. With the engine off and the key removed from the ignition, attempt to move the pulley from side to side and back and forth. There should be no detectable movement. The pulley should turn smoothly, with no rough spots. The water pump should be replaced if any pulley wobble is detected. If the water pump is not replaced the pump shaft may eventually seize or break. NOTE: Incorrect belt tension (too tight) may cause premature wear of the bearings and seals. WARNING: Never remove a radiator cap while the engine is hot. Severe personal injury may result. Inspect for Leakage 1. With the engine "OFF" and cold: - Check coolant level and refill if necessary. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 1503 - Inspect the water pump for leakage. Closely check the following areas: - Inspection (weep) hole. - Pump shaft. - Gasket. 2. Pressurize the cooling system with a pressure tester and again check for leaks. Do not exceed the rated pressure of the radiator cap. NOTE: If any leaks are found, verify that they are not originating from a component near or above the water pump (i.e. thermostat, loose radiator hoses, intake gasket, engine coolant temperature sensor) CAUTION: When finished, immediately re-install the radiator cap. 3. If no leaks are found, start and warm the engine until the thermostat opens. Stop the engine and check for fresh leakage around the water pump shaft. NOTE: Occasionally water pumps will only leak around the shaft seals while the shaft is rotating. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 1504 Water Pump: Testing and Inspection After Repairs Operational Check COOLING SYSTEM OPERATIONAL CHECK IMPORTANT: Always verify the operation of the thermostat and cooling fan prior to driving the vehicle after a cooling system repair. HOW - With the cooling system filled with coolant and the radiator cap installed, start the engine and allow the coolant to warm up. - The upper radiator hose should remain cool to the touch until the coolant within the engine block and head has reached the thermostat opening temperature. The thermostat opening should be indicated by a rapid warm up of the upper radiator hose. - If upper hose gradually warms up, the thermostat may be stuck open (assuming the engine is started cold) - If the coolant temperature reaches the normal operating temperature (as indicated by the temperature gauge) before the upper hose becomes warm, the engine should be turned off, and the cooling system allowed to cool down. The thermostat may be stuck closed and should be removed and tested. WARNING: Never remove the radiator cap, or disconnect a coolant hose on a warm engine. A warm cooling system may contain a large amount of stored energy in the form of steam and high pressure, which could seriously injure you. - If the thermostat opened properly, continue to allow the cooling system to warm up. As the coolant temperature reaches its maximum operating temperature the electrical cooling fan should energize. Verify the fan energizes and de-energizes. WHY Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 1505 Thermostat Closed, Cold Engine - With the thermostat closed, coolant flow through the radiator is blocked forcing the coolant to re-circulate through the block and head. This allows for a rapid warm up. During this time there should be little or no coolant flow through the upper radiator hose. Thermostat Open, Warm Engine - Once the coolant has reached normal operating temperature, the thermostat begins to open, allowing coolant flow through the upper hose and into the radiator. The thermostat will continue to regulate the amount of coolant flow to the radiator to maintain a "Minimum" operating temperature. Electric Cooling Fan Operation The cooling fan ground circuit is controlled by the cooling fan relay. The relay opens and closes to supply or remove ground (-) from the fan. With the ignition key "ON" positive (+) voltage is constantly supplied to the motor. The relay is controlled by the cooling fan temperature switch. The switch supplies the ground path for the operating coil within the cooling fan relay. When the coolant temperature reaches the maximum set point, the coolant switch closes and grounds the operating coil within the fan relay. The coil then closes the relay contacts, supplying ground to the fan motor. When the coolant temperature fails to the lower set point, the coolant switch opens, removing ground from the fan relay. The fan relay then opens and de-energizes the cooling fan. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 1506 Water Pump: Testing and Inspection After Repairs Leak Check AFTER REPAIRS LEAK CHECK PURPOSE Initially fill the cooling system and check for leaks prior to starting the engine and bleeding the system. Although the system will not be completely full, any leaks which are detected may be fixed before the engine and cooling system are hot. NOTE: It is much easier to repair a leak on a cold engine than on a hot engine. HOW - Fill the cooling system until the radiator is full. - Apply pressure to the system with a pressure tester. - Carefully check for leaks around: All hoses and clamps. - Water pump sealing surfaces. - Any cooling system component which was removed or replaced. - If no leaks are detected continue with the fill and bleed procedure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Page 1507 Water Pump: Service and Repair Water Pump And Coolant Tube Fig. 32 Water Pump Removal & Installation NOTE: The water pump bolts directly to the engine block, using a gasket for pump-to-block sealing, Fig. 32. The water pump is driven by the timing belt and is serviced as a unit. 1. Disconnect battery ground cable. Fig. 13 Crankshaft Pulley Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Page 1508 2. Remove crankshaft drive pulleys and torsional damper, Fig. 13. Fig. 14 Right Engine Mount & Bracket 3. Place a jack under engine to support and slightly raise engine, then remove engine mount bracket, Fig. 14. Fig. 15 Timing Belt Cover 4. Remove timing belt cover, Fig. 15, then mark belt running direction for reinstallation. 5. Loosen timing belt tensioner, then remove belt and crankshaft sprocket flange shield. 6. Drain cooling system. 7. Remove water pump mounting bolts. 8. Separate water pump from water inlet pipe Fig. 32, then remove water pump. 9. Reverse procedure to install, noting the following: a. Use a new O-ring on water inlet pipe. b. Torque water pump mounting bolts to 27 Nm (20 ft. lbs.). c. Refer to Engine/Timing Components/Timing Belt/Service and Repair for timing belt installation and tensioning procedure. See: Timing Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Page 1509 Water Pump: Tools and Equipment RECOMMENDED TOOLS - Drip pan - For draining coolant. - Gasket scraper. - Torque Wrenches: Low Range (0-50 ft-lb) for covers and brackets. - High Range (0-150 ft-lb) for crankshaft pulley bolt. - Full set of Metric sockets and wrenches. Timing Belt Removal Is Required Timing light (for measuring timing before and after). - Vacuum gauge (for measuring engine vacuum levels before and after). Crankshaft Pulley Removal Crankshaft Holding Tool MD998784 (used in conjunction with an old drive belt), or an air powered impact gun (for removing the crankshaft bolt). Timing Belt Tensioner Release - Large flat blade screw driver (for moving timing belt tensioner). - Fender covers. OPTIONAL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Page 1510 - Radiator hose removal tool. - Cooling system pressure tester. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations Water Pump: Fundamentals and Basics Initial Preparations INITIAL PREPARATIONS Disconnect Battery When working near or around the cooling fan or drive belts, accidentally engaging the starter or cooling fan can result in serious personal injury. The negative battery terminal should be disconnected prior to commencing work and should not be reconnected until after the water pump is installed and the engine is ready to restart. Fender Covers Fender covers will prevent damage to the vehicles finish while performing the job. Coolant Drip Pan Pre-position a drip pan under the vehicle to prevent any incidental spills Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 1513 Water Pump: Fundamentals and Basics Removal Tips and Hints WATER PUMP REMOVAL TIPS AND HINTS FROZEN AND BROKEN BOLTS Frozen and broken bolts are often a major problem when removing water pumps. Coolant can seep into the bolt holes resulting in corrosion and frozen bolts. Prior to starting the job, spray all water pump retaining bolts with a penetrating oil. Upon removal, any bolt or nut which shows signs of corrosion should be replaced. The threads of the associated bolt hole should be re-tapped or chased. Inspect the coolant hoses, drive belts, and associated pulleys. Since these components will need to be removed to replace the timing belt it would be convenient/time saving to have any necessary replacement parts on hand prior to removing the pump. COOLANT HOSES Inspect the hoses for the following: Cracks, especially near the hose clamps. - Swelling, look for areas of the hose that appear unnaturally bulged outwards. NOTE: This is often caused by improper removal techniques, see Hose Removal in this article. - Oil contamination, soft spots, oil contamination breaks down the structure of the rubber and significantly weakens the hose. NOTE: The oil leak should be fixed prior to replacing the hose. - Hard or brittle hoses, as the hoses age the rubber looses its resiliency and becomes brittle. The hoses need to be able to flex to compensate for the movement of the engine. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 1514 DRIVE BELTS Small cracks that run across that run across the ribbed surface of the belt from rib to rib , are considered normal, These are not reasons to replace the belt. If chunks of belt material are missing between the cracks, the belt should be replaced. Cracks running along the rib (not across) are not normal. Any belts with cracks running along the rib should be replaced. Replace the belt if it has excessive wear, frayed cords or severe glazing. Drive Pulleys - Verify the pulleys have no side to side wobble, and rotate freely. Replace if necessary. - Verify the pulleys are properly aligned. Adjust or replace as necessary. Belt Removal Do not attempt to bump the drive belts off with the starter. This practice can damage the belt, pulley, and technician. Removing the belt by relaxing the tension will allow you to correctly adjust the tension when installing the belt. DRIP PAN Prior to removing any hose or the water pump, place a large drip pan under the engine. Although the coolant may be drained from the radiator, there is still a large amount of residual coolant trapped in the hoses and water pump. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 1515 HOSE REMOVAL Prior to pulling the hose from the fitting, rotate/twist the hose on the fitting to break the grip of any corrosion present. If the hose is to be replaced, it may be quicker to cut hose from the fitting. CAUTION: When cutting the hose be careful not to damage the fitting. A radiator hose removal tool may help free up stubborn hoses. CAUTION: Do not use any device to pry the hose off of the fitting. - If at any time a tearing or ripping sound is heard (though the hose appears fine) the hose should be replaced. The sound is coming from the internal reinforcing fibers embedded in the hose. Once the fibers have been broken the hose will be subject to swelling and rupture when pressure is applied. WATER PUMP REMOVAL After removing the retaining bolts the water pump may still be stuck to the engine. The original gasket sealant may cause the pump to firmly stick to engine. A few soft blows from a rubber mallet or block of wood will generally loosen the pump. CAUTION: Verify that ALL of the retaining bolts are removed. - Do not pry between the pump and the gasket. This may damage the pump sealing surface. - Upon breaking the seal, a large amount of coolant trapped in the block will generally pour out from the water pump opening. Be sure to have a drip pan prepositioned. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 1516 Water Pump: Fundamentals and Basics Gasket Removal and Inspection GASKET REMOVAL - Remove all traces of the old gasket material. It only takes a very small amount of left over material to cause the new gasket to leak. - Never reuse gaskets. After a gasket has been initially installed and removed it will no longer be able to compensate for the varying expansion rates of the water pump and block. An old gasket may seal initially but as the engine heats up cools down, the old gasket will be prone to leakage. - When removing the gasket with a gasket scraper, be very careful not to gouge the sealing surface. Very small scratches in the sealing surface are likely to leak. HINT: Always sharpen your gasket scraper prior to starting a job. A dull scraper is more likely to slip and gouge the sealing surface. - If you are using a buffing wheel to clean the gasket surface, be very careful not to burn the surface. CAUTION: Buffing wheels can rapidly remove metal from the sealing surface, be very careful and check your work frequently. INSPECTION - Verify the gasket sealing surfaces are free of all gasket material, dirt, gouges, and contaminants (such as coolant or oil) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 1517 Water Pump: Fundamentals and Basics Installation Tips and Hints WATER PUMP INSTALLATION TIPS AND HINTS - Compare the old pump to the new pump and verify: Shaft lengths match exactly. - Retaining bolt holes match exactly. - Prior to applying the sealant to the gasket and pump, practice installing the pump to the engine. If any problems are encountered they will be easier to solve without the silicone applied. - Verify the retaining bolts and bolt holes have clean threads. Re-tap or chase the threads as necessary. - To simply the gasket installation process and minimize errors, install the gasket as follows: 1. Verify the gasket is correct. 2. Apply the sealant to the pump sealing surface and the gasket inner surface. Apply only a light film of sealant to the sealing surfaces. CAUTION: Excess sealant will squeeze out on the inside of the pump and may block the radiator or heater core coolant passages. 3. Install two retaining bolts through the pump. NOTE: This will help maintain the correct alignment of gasket in the next step. 4. While holding the bolts, place the gasket over the bolts and onto the pump sealing surface. 5. Install the pump and gasket onto the engine. - Do not over tighten the retaining bolts, use a torque wrench to properly tighten the bolts to the correct specification. CAUTION: Water pump retaining bolts may be easily broken or stripped, do not tighten the retaining bolts with an air wrench or impact gun. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 1518 - When tightening hose clamps: Position the hose squarely on the fitting. - Verify the hose clamp is clear of the retaining rim on the fitting. Do not over tighten the clamps. - While working on the cooling system it is a good habit to clean the radiator and A/C condenser fins of bugs and dirt. This build up of debris can seriously reduce the cooling ability of the system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 1519 Water Pump: Fundamentals and Basics Recommended Parts RECOMMENDED PARTS - New water pump, gasket and O-ring. - RTV sealant (for sealing water pump gasket, do not apply to O-ring). NOTE: Use only non-volatile oxygen sensor safe RTV sealant. This should be clearly indicated on the package. - Engine Coolant: Manual transmission - 8.9 qts. Automatic transmission- 8.8 qts NOTE: For optimum performance, use 50/50 mixture of high quality ethylene glycol coolant and water. - Intake gasket set (if intake manifold removal is necessary) NOTE: A coolant pipe runs from the back of the water pump, under the intake manifold and to the rear of the engine. This pipe has may leak and should be inspected. Replacing the pipe requires removing the intake manifold. OPTIONAL, PENDING INSPECTION - Timing belt - Radiator hoses. - Bypass hose. - Drive belts. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1525 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1526 Coolant: Technical Service Bulletins Engine Coolant - Recycling Recommendations SUBJECT: Engine Coolant Recycling NO.: 07-03-90 GROUP: COOLING DATE: Dec. 21, 1990 MODELS: All Domestic & Import Vehicles DISCUSSION: A number of systems are being marketed to "recycle" or "reconstitute" used ethylene glycol antifreeze/coolant in the dealership. Some of the systems have been advertised as producing a recycled antifreeze "as good as" original and suggest the recycled product is suitable for use in Chrysler Corporation vehicles. Tests, so far, indicate most of these systems merely remove suspended solids from the used antifreeze/coolant through the use of various size filters. These systems do not remove glycol degradation products, or dissolved solids, which can cause water pump seal wear. These systems use a universal "reinhibitor package". The "reinhibitor package" can not restore every type antifreeze/coolant inhibitor system to a like new condition. Tests results indicate these "recycled" products do not consistently provide the protection required in Chrysler Corporation engines and cooling systems. The use of these "reconstituted" antifreeze/coolants is not authorized in the performance of any repair covered under the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Page 1527 Coolant: Specifications COOLING SYSTEM CAPACITY 1988-89 Caravan / Voyager / Grand Caravan / Grand Voyager 2.5L Engine ......................................................................................................................................... ........................................................ 8.1 L (8.5 qts) 3.0L Engine without rear heater ............................................................................................................................... ............................................... 9.5 L (10.0 qts) with rear heater .......................................................... ....................................................................................................................... 10.5 L (11.0 qts) NOTES: - Includes 0.47 L (1.0 pt) for the heater and coolant reserve bottle. - Includes 0.95 L (1.0 qt) for rear heater systems, if equipped. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Page 1528 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Locations Water Pump And Coolant Tube Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1537 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1538 Radiator Cooling Fan Motor: Electrical Diagrams A/C & Heater Wiring Circuit (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1539 A/C & Heater Wiring Circuit (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1540 Radiator Cooling Fan Motor: Description and Operation Electric Fan Motor (Typical). RADIATOR FAN CONTROL Fan control is accomplished two ways. The fan always runs when the air conditioning compressor clutch is engaged. In addition to this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant temperature sensor which sends the message to the on-board computer. The computer turns on the fan through the fan relay. Switching through the on-board computer provides fan control for the following conditions. 1. The fan will not run during cranking until the engine starts no matter what the coolant temperature is. 2. Fan will always run when the air conditioning clutch is engaged. 3. On non-air conditioned vehicles or with air conditioning off the fan will run at vehicle speeds above about 40 mph only if coolant temperature reaches 110°C (230°F) and will turn off when the temperature drops to 1O4°C (220°F). At speeds below 40 mph the fan switches on at 99°C (210 °F) and off at 93°C (2OO°F). 4. There also is included a method to help prevent "steaming" (water vapor evaporated by hot water circulating through the radiator evaporating moisture on the outside of the radiator - and when there is no ram air to blow it under the vehicle) the fan will run only below 16°C (60°F) ambient, from 38°C (100°F) to 97°C (195°F) coolant temperature. only at idle, and zero vehicle speed and then only for three minutes. TEMPERATURE GAGE INDICATION At idle with Air Conditioning off the temperature gage will rise slowly to about 5/8 gauge travel, the fan will come on and the gauge will quickly drop to about 1/2 gauge travel - this is normal. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Testing Procedures Radiator Cooling Fan Motor: Testing and Inspection Testing Procedures Electric Fan Motor (Typical). ELECTRIC FAN MOTOR TEST PROCEDURE To check out the electric fan motor, disconnect the fan motor wire connector and connect it with #14 gage wires to a good 12-volt battery observing correct polarity per figure. If the fan runs normally, the motor is functioning properly. If not, replace motor. If the motor is noticeably overheated (i.e.; wire insulation melted, motor charred) the system voltage may be too high. Check charging system. SMEC (Engine Controller) 60-Way Connector From Terminal End RADIATOR FAN MOTOR CONTROL TEST PROCEDURE (Fan Relay and SMEC Operated) Equipment Required ^ Diagnostic Tool C-4850 or equivalent ^ Volt/Ohm Meter ^ Wiring Diagrams. 1. Bring the engine to normal running temperature. 2. Check wiring connector in C25, C9. and C26 for proper engagement, see Wiring Diagrams. 3. Using a diagnostic tool, plugged into the diagnostic connector rearward of the battery, check the On-Board Diagnostics (OBD) in the Single Module Engine Control (SMEC) for fault codes. 4. If fault code 88-12-35-55 is detected. proceed to Step 5. 5. With the ignition switch in the run position, test for battery voltage at single pin connector at the fan relay. ^ Voltage reading OK. proceed to Step 6a. ^ Voltage at 0-1 volt, proceed to Step 6b. 6a With the ignition OFF, disconnect the 60-way connector from the SMEC (outboard of battery) and return the ignition to the RUN position. Test for battery voltage at cavity 31 of the 60-way connector. ^ Voltage reading OK and female terminal is not damaged, replace the SMEC. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Testing Procedures > Page 1543 ^ Voltage reading 0. repair open or short in C27 circuit. 6b With the ignition off, disconnect the 60-way connector from the SMEC (outboard of battery) and return the ignition to the RUN position. Test for battery voltage at the single pin connector at the fan relay. ^ Voltage reading OK. replace the SMEC. ^ Voltage reading 0-1 volt. proceed to Step 7. 7. With ignition in the run position. test for battery voltage at the blue wire (C27) in the 3-way connector of the fan relay. ^ Voltage reading OK. replace the fan relay. ^ Voltage reading 0. repair open or short, in C27 circuit 8. Turn ignition off, connect the 60-way connector at the SMEC, and test the system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Testing Procedures > Page 1544 Radiator Cooling Fan Motor: Testing and Inspection Motor Circuit Testing Refer to SCHEMATIC DIAGRAMS/ELECTRICAL AND ELECTRONIC DIAGRAMS for wiring diagrams when performing the following procedure. 1. Check engine and bring to normal operating temperature. 2. Check fan motor electrical connector for proper engagement. 3. Connect diagnostic tool to connector, if fault code 88-12-35-55 is displayed, proceed to step 4. 4. With ignition switch in run position, test battery voltage at single pin connector at fan relay. Fig. 25 SBEC 60-way connector 5. If voltage reading is normal: a. With ignition off, disconnect 60 way connector from single board engine control (SBEC), and return ignition to run position. Test battery voltage at cavity 31 of 60-way connector. b. If voltage reading okay and female terminal is not damaged, replace the SBEC. If voltage reading is 0, repair open or short in circuit C27. 6. If voltage reading is 0-1 volt: a. With ignition off, disconnect 60-way connector from SBEC, and return ignition to run position. Test battery voltage at single pin connector at fan relay. b. If voltage reading is okay, replace SBEC. c. If voltage is 0-1, test voltage at blue wire in 3-way connector of fan relay. d. If voltage reading okay, replace fan relay. If voltage reading 0, repair open or short in circuit C27. 7. Turn ignition off, connect 60-way connector at SBEC and test system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Testing Procedures > Page 1545 Radiator Cooling Fan Motor: Testing and Inspection Radiator Fan Control Electric Fan Motor (Typical). RADIATOR FAN CONTROL Fan control is accomplished two ways. The fan always runs when the air conditioning compressor clutch is engaged. In addition to this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant temperature sensor which sends the message to the on-board computer. The computer turns on the fan through the fan relay. Switching through the on-board computer provides fan control for the following conditions. 1. The fan will not run during cranking until the engine starts no matter what the coolant temperature is. 2. Fan will always run when the air conditioning clutch is engaged. 3. On non-air conditioned vehicles or with air conditioning off the fan will run at vehicle speeds above about 40 mph only if coolant temperature reaches 110°C (230°F) and will turn off when the temperature drops to 1O4°C (220°F). At speeds below 40 mph the fan switches on at 99°C (210 °F) and off at 93°C (2OO°F). 4. There also is included a method to help prevent "steaming" (water vapor evaporated by hot water circulating through the radiator evaporating moisture on the outside of the radiator - and when there is no ram air to blow it under the vehicle) the fan will run only below 16°C (60°F) ambient, from 38°C (100°F) to 97°C (195°F) coolant temperature. only at idle, and zero vehicle speed and then only for three minutes. TEMPERATURE GAGE INDICATION At idle with Air Conditioning off the temperature gage will rise slowly to about 5/8 gauge travel, the fan will come on and the gauge will quickly drop to about 1/2 gauge travel - this is normal. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Page 1546 Radiator Cooling Fan Motor: Service and Repair There are no repairs to be made to the fan. If the fan is cracked, warped or otherwise damaged, it must be replaced as an assembly. 1. Disconnect battery ground cable and electrical connector from fan motor. 2. Remove shroud clips if equipped and support bolts, nuts and washers. 3. Remove fan, motor and shroud or support as an assembly from radiator support. 4. Remove fan from motor shaft by supporting assembly on bench, remove retaining clip and sliding fan away. 5. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair Place fan on flat surface with leading edge facing down. If there is a clearance between fan blade touching surface and opposite blade of more than 0.090 inch (2 mm), replace fan. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Top RH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 1559 Engine Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1560 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 5 Coolant & charge temperature sensors The coolant temperature sensor, Fig. 5, is mounted in the thermostat housing and allows the SMEC to monitor engine operating temperature in order to provide proper air/fuel mixtures. The sensor provides a variable resistance which is proportional to coolant temperature. When the engine is cold and sensor resistance is low, the SMEC provides richer air/fuel mixtures and increases engine idle speed to provide acceptable cold engine performance and allow quick warm up. When coolant temperature and sensor resistance increase, the SMEC provides leaner air/fuel mixtures and lowers engine idle speed to provide proper exhaust emission control and increased fuel economy. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Top RH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions Temperature Sensor (Gauge): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 1566 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 1567 Oil Pressure & Temperature System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 1568 Temperature Sensor (Gauge): Testing and Inspection When a malfunction occurs with a cluster gauge, before disassembling the cluster to check the gauge, check for a defective sending unit or wiring as follows: 1. Ground sending unit connector leads, at the sending unit, in the vehicle. 2. With ignition in On position, a grounded input will cause the fuel or temperature gauge to read maximum or above. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Blower Motor, Evaporator & Heater Core Heater Core: Service and Repair Blower Motor, Evaporator & Heater Core REMOVAL 1. Drain cooling system and discharge A/C system, if equipped. See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery 2. Disconnect vacuum line at brake booster. If equipped, disconnect vacuum line at water valve. 3. Disconnect heater hoses at heater core. Plug heater core tubes to prevent spilling coolant. Expansion Valve 4. On models with A/C, disconnect A/C plumbing at expansion valve and remove the expansion valve from the evaporator. Resistor Block And Drain Tube 5. Remove the condensate drain tube. 6. On all models, remove 4 nuts from unit mounting studs. 7. Remove steering column cover from left lower instrument panel. 8. Remove lower reinforcement from below steering column. 9. Remove right side cowl and sill trim. 10. Remove bolt attaching right side instrument panel to right cowl. 11. Loosen two brackets supporting lower edge of instrument panel to A/C and heater or heater housing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Blower Motor, Evaporator & Heater Core > Page 1573 Instrument Panel Assembly 12. Remove the instrument panel trim moulding from the right side dash panel. 13. Remove the nine screws that attach the lower instrument panel to the upper instrument panel. 14. Carefully pull the right side of lower instrument panel rearward until it reaches passenger seat. 15. Disconnect the blower motor and resistor electrical connectors and temperature control cable. 16. Disconnect hanger strap from evaporator heater assembly and bend rearward. 17. Pull heater-a/c assembly rearward from dash panel and remove from vehicle. 18. Place heater-a/c assembly on workbench, then remove vacuum harness attaching screw. Feed harness through hole in cover. 19. Remove thirteen cover attaching screws, then the cover. Temperature control door will come out with cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Blower Motor, Evaporator & Heater Core > Page 1574 Fig. 15 Evaporator heater assembly 20. Remove heater core tube retaining bracket attaching screw, then lift the heater core straight up. 21. Lift evaporator up and out of unit. 22. Remove sound shield attaching screws, then blower motor assembly. INSTALLATION Fig. 15 Evaporator heater assembly 1. Install the blower motor and sound shield. 2. Install the evaporator to the heater-a/c housing. 3. Install the heater core and secure with one screw through the attaching bracket. 4. Install the top cover, making sure the blend-air door is properly located in the bottom of the heater-a/c housing. Secure top cover with 13 screws. 5. Feed the vacuum harness through the hole and secure with one screw. 6. Slide the heater-a/c unit under the lower right instrument panel. Feed the vacuum hoses through the hole in the firewall. 7. Raise and install the heater-a/c unit to the firewall, making sure the mounting studs go completely through and the vacuum hoses are not pinched. 8. Secure the heater-a/c unit with one screws through the hangar strap and four nuts on the mounting studs. 9. Attach the temperature control cable, blower motor wiring, and resistor wiring. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Blower Motor, Evaporator & Heater Core > Page 1575 Instrument Panel Assembly 10. Position the right lower instrument panel and attach with 9 screws through the upper instrument panel and one bolt in the right side cowl. 11. Reinstall instrument panel trim moulding. 12. Reattach all previously removed dash wiring. 13. Install steering column reinforcement, lower steering column cover and right cowl and sill trim panels. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Blower Motor, Evaporator & Heater Core > Page 1576 Resistor Block And Drain Tube 14. Install the condensate drain tube. 15. Connect the vacuum hoses to the engine and water valve. 16. Connect the heater hoses and refill the engine coolent system. Expansion Valve 17. Connect the expansion valve to the evaporator with a new gasket. Torque the torx head screws to 100 +/- 30 in.lbs. (11 +/- 3 N-m.). 18. Connect the a/c plumbing to the expansion valve. Torque the bolt to 200 +/- 30 in.lbs. (23 +/- 3 N-m.). 19. Evacuate and recharge the a/c system. 20. Test system for overall performance. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Blower Motor, Evaporator & Heater Core > Page 1577 Heater Core: Service and Repair Heater Core Removal and Installation 1. Remove rear heat-a/c unit.See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 2. Remove rear unit top cover. 3. Remove the heater core by carefully lifting it straight up and out of the rear unit. 4. Reverse procedure to reinstall. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation This system consists of a sending unit, electrical temperature gauge and an instrument voltage regulator. As engine temperature increases or decreases, resistance of the sending unit changes, in turn controlling current flow to the gauge. When engine temperature is low, the resistance of the sending unit is high, restricting current flow to the gauge, in turn indicating low engine temperature. As engine temperature increases, resistance of the sending unit decreases, permitting an increased current flow to the gauge, resulting in an increased temperature reading. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis Temperature Gauge: Testing and Inspection Temperature Gauge Diagnosis Fig. 1 Cooling System Diagnosis (Part 1 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1584 Fig. 1 Cooling System Diagnosis (Part 2 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1585 Fig. 1 Cooling System Diagnosis (Part 3 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1586 Fig. 1 Cooling System Diagnosis (Part 4 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1587 Fig. 1 Cooling System Diagnosis (Part 5 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1588 Temperature Gauge: Testing and Inspection Temperature Gauge Test Temperature Gauge Pins 1. Remove temperature gauge assembly from the cluster. 2. Check for continuity in wire between temperature sending unit and gauge (sensor input pin). 3. With ignition switch in On position, check for battery voltage across B+ pin and ground pin. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Top RH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 1600 Engine Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1601 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 5 Coolant & charge temperature sensors The coolant temperature sensor, Fig. 5, is mounted in the thermostat housing and allows the SMEC to monitor engine operating temperature in order to provide proper air/fuel mixtures. The sensor provides a variable resistance which is proportional to coolant temperature. When the engine is cold and sensor resistance is low, the SMEC provides richer air/fuel mixtures and increases engine idle speed to provide acceptable cold engine performance and allow quick warm up. When coolant temperature and sensor resistance increase, the SMEC provides leaner air/fuel mixtures and lowers engine idle speed to provide proper exhaust emission control and increased fuel economy. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Top RH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions Temperature Sensor (Gauge): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 1607 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 1608 Oil Pressure & Temperature System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 1609 Temperature Sensor (Gauge): Testing and Inspection When a malfunction occurs with a cluster gauge, before disassembling the cluster to check the gauge, check for a defective sending unit or wiring as follows: 1. Ground sending unit connector leads, at the sending unit, in the vehicle. 2. With ignition in On position, a grounded input will cause the fuel or temperature gauge to read maximum or above. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation This system consists of a sending unit, electrical temperature gauge and an instrument voltage regulator. As engine temperature increases or decreases, resistance of the sending unit changes, in turn controlling current flow to the gauge. When engine temperature is low, the resistance of the sending unit is high, restricting current flow to the gauge, in turn indicating low engine temperature. As engine temperature increases, resistance of the sending unit decreases, permitting an increased current flow to the gauge, resulting in an increased temperature reading. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis Temperature Gauge: Testing and Inspection Temperature Gauge Diagnosis Fig. 1 Cooling System Diagnosis (Part 1 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1615 Fig. 1 Cooling System Diagnosis (Part 2 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1616 Fig. 1 Cooling System Diagnosis (Part 3 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1617 Fig. 1 Cooling System Diagnosis (Part 4 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1618 Fig. 1 Cooling System Diagnosis (Part 5 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 1619 Temperature Gauge: Testing and Inspection Temperature Gauge Test Temperature Gauge Pins 1. Remove temperature gauge assembly from the cluster. 2. Check for continuity in wire between temperature sending unit and gauge (sensor input pin). 3. With ignition switch in On position, check for battery voltage across B+ pin and ground pin. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair Thermostat: Service and Repair Fig. 17 Engine Thermostat NOTE: The thermostat is located in a water box, formed in the timing belt end of the intake manifold. This thermostat has an air bleed valve, located in the thermostat flange. It is designed to provide the fastest warm up possible by preventing leakage through it and to guarantee a minimum engine operating temperature of 88 to 93°C (192 to 199°F). They also automatically reach wide open so they do not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104°C (220°F). Above this temperature the coolant temperature is controlled by the radiator, fan, and ambient temperature, not the thermostat. REMOVAL 1. Drain cooling system down to thermostat level or below. 2. Remove thermostat housing bolts and housing. 3. Remove thermostat, discard gasket and clean both gasket sealing surfaces. Fig. 18 Engine Thermostat Installed INSTALLATION Center thermostat in water box pocket. Check that the flange is seated correctly in the countersunk portion of the intake manifold water box. Install new gasket on water box. Install housing over gasket and thermostat and torque bolts to 12 Nm (133 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem Water Pump: Testing and Inspection Verifying Water Pump Problem VERIFYING WATER PUMP PROBLEM Check for Loose Water Pump Pulley As the pump shaft seals and bearings wear with age the pulley/shaft may develop a wobble or lateral runout. With the engine off and the key removed from the ignition, attempt to move the pulley from side to side and back and forth. There should be no detectable movement. The pulley should turn smoothly, with no rough spots. The water pump should be replaced if any pulley wobble is detected. If the water pump is not replaced the pump shaft may eventually seize or break. NOTE: Incorrect belt tension (too tight) may cause premature wear of the bearings and seals. WARNING: Never remove a radiator cap while the engine is hot. Severe personal injury may result. Inspect for Leakage 1. With the engine "OFF" and cold: - Check coolant level and refill if necessary. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 1627 - Inspect the water pump for leakage. Closely check the following areas: - Inspection (weep) hole. - Pump shaft. - Gasket. 2. Pressurize the cooling system with a pressure tester and again check for leaks. Do not exceed the rated pressure of the radiator cap. NOTE: If any leaks are found, verify that they are not originating from a component near or above the water pump (i.e. thermostat, loose radiator hoses, intake gasket, engine coolant temperature sensor) CAUTION: When finished, immediately re-install the radiator cap. 3. If no leaks are found, start and warm the engine until the thermostat opens. Stop the engine and check for fresh leakage around the water pump shaft. NOTE: Occasionally water pumps will only leak around the shaft seals while the shaft is rotating. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 1628 Water Pump: Testing and Inspection After Repairs Operational Check COOLING SYSTEM OPERATIONAL CHECK IMPORTANT: Always verify the operation of the thermostat and cooling fan prior to driving the vehicle after a cooling system repair. HOW - With the cooling system filled with coolant and the radiator cap installed, start the engine and allow the coolant to warm up. - The upper radiator hose should remain cool to the touch until the coolant within the engine block and head has reached the thermostat opening temperature. The thermostat opening should be indicated by a rapid warm up of the upper radiator hose. - If upper hose gradually warms up, the thermostat may be stuck open (assuming the engine is started cold) - If the coolant temperature reaches the normal operating temperature (as indicated by the temperature gauge) before the upper hose becomes warm, the engine should be turned off, and the cooling system allowed to cool down. The thermostat may be stuck closed and should be removed and tested. WARNING: Never remove the radiator cap, or disconnect a coolant hose on a warm engine. A warm cooling system may contain a large amount of stored energy in the form of steam and high pressure, which could seriously injure you. - If the thermostat opened properly, continue to allow the cooling system to warm up. As the coolant temperature reaches its maximum operating temperature the electrical cooling fan should energize. Verify the fan energizes and de-energizes. WHY Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 1629 Thermostat Closed, Cold Engine - With the thermostat closed, coolant flow through the radiator is blocked forcing the coolant to re-circulate through the block and head. This allows for a rapid warm up. During this time there should be little or no coolant flow through the upper radiator hose. Thermostat Open, Warm Engine - Once the coolant has reached normal operating temperature, the thermostat begins to open, allowing coolant flow through the upper hose and into the radiator. The thermostat will continue to regulate the amount of coolant flow to the radiator to maintain a "Minimum" operating temperature. Electric Cooling Fan Operation The cooling fan ground circuit is controlled by the cooling fan relay. The relay opens and closes to supply or remove ground (-) from the fan. With the ignition key "ON" positive (+) voltage is constantly supplied to the motor. The relay is controlled by the cooling fan temperature switch. The switch supplies the ground path for the operating coil within the cooling fan relay. When the coolant temperature reaches the maximum set point, the coolant switch closes and grounds the operating coil within the fan relay. The coil then closes the relay contacts, supplying ground to the fan motor. When the coolant temperature fails to the lower set point, the coolant switch opens, removing ground from the fan relay. The fan relay then opens and de-energizes the cooling fan. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 1630 Water Pump: Testing and Inspection After Repairs Leak Check AFTER REPAIRS LEAK CHECK PURPOSE Initially fill the cooling system and check for leaks prior to starting the engine and bleeding the system. Although the system will not be completely full, any leaks which are detected may be fixed before the engine and cooling system are hot. NOTE: It is much easier to repair a leak on a cold engine than on a hot engine. HOW - Fill the cooling system until the radiator is full. - Apply pressure to the system with a pressure tester. - Carefully check for leaks around: All hoses and clamps. - Water pump sealing surfaces. - Any cooling system component which was removed or replaced. - If no leaks are detected continue with the fill and bleed procedure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Page 1631 Water Pump: Service and Repair Water Pump And Coolant Tube Fig. 32 Water Pump Removal & Installation NOTE: The water pump bolts directly to the engine block, using a gasket for pump-to-block sealing, Fig. 32. The water pump is driven by the timing belt and is serviced as a unit. 1. Disconnect battery ground cable. Fig. 13 Crankshaft Pulley Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Page 1632 2. Remove crankshaft drive pulleys and torsional damper, Fig. 13. Fig. 14 Right Engine Mount & Bracket 3. Place a jack under engine to support and slightly raise engine, then remove engine mount bracket, Fig. 14. Fig. 15 Timing Belt Cover 4. Remove timing belt cover, Fig. 15, then mark belt running direction for reinstallation. 5. Loosen timing belt tensioner, then remove belt and crankshaft sprocket flange shield. 6. Drain cooling system. 7. Remove water pump mounting bolts. 8. Separate water pump from water inlet pipe Fig. 32, then remove water pump. 9. Reverse procedure to install, noting the following: a. Use a new O-ring on water inlet pipe. b. Torque water pump mounting bolts to 27 Nm (20 ft. lbs.). c. Refer to Engine/Timing Components/Timing Belt/Service and Repair for timing belt installation and tensioning procedure. See: Engine/Timing Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Page 1633 Water Pump: Tools and Equipment RECOMMENDED TOOLS - Drip pan - For draining coolant. - Gasket scraper. - Torque Wrenches: Low Range (0-50 ft-lb) for covers and brackets. - High Range (0-150 ft-lb) for crankshaft pulley bolt. - Full set of Metric sockets and wrenches. Timing Belt Removal Is Required Timing light (for measuring timing before and after). - Vacuum gauge (for measuring engine vacuum levels before and after). Crankshaft Pulley Removal Crankshaft Holding Tool MD998784 (used in conjunction with an old drive belt), or an air powered impact gun (for removing the crankshaft bolt). Timing Belt Tensioner Release - Large flat blade screw driver (for moving timing belt tensioner). - Fender covers. OPTIONAL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Page 1634 - Radiator hose removal tool. - Cooling system pressure tester. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations Water Pump: Fundamentals and Basics Initial Preparations INITIAL PREPARATIONS Disconnect Battery When working near or around the cooling fan or drive belts, accidentally engaging the starter or cooling fan can result in serious personal injury. The negative battery terminal should be disconnected prior to commencing work and should not be reconnected until after the water pump is installed and the engine is ready to restart. Fender Covers Fender covers will prevent damage to the vehicles finish while performing the job. Coolant Drip Pan Pre-position a drip pan under the vehicle to prevent any incidental spills Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 1637 Water Pump: Fundamentals and Basics Removal Tips and Hints WATER PUMP REMOVAL TIPS AND HINTS FROZEN AND BROKEN BOLTS Frozen and broken bolts are often a major problem when removing water pumps. Coolant can seep into the bolt holes resulting in corrosion and frozen bolts. Prior to starting the job, spray all water pump retaining bolts with a penetrating oil. Upon removal, any bolt or nut which shows signs of corrosion should be replaced. The threads of the associated bolt hole should be re-tapped or chased. Inspect the coolant hoses, drive belts, and associated pulleys. Since these components will need to be removed to replace the timing belt it would be convenient/time saving to have any necessary replacement parts on hand prior to removing the pump. COOLANT HOSES Inspect the hoses for the following: Cracks, especially near the hose clamps. - Swelling, look for areas of the hose that appear unnaturally bulged outwards. NOTE: This is often caused by improper removal techniques, see Hose Removal in this article. - Oil contamination, soft spots, oil contamination breaks down the structure of the rubber and significantly weakens the hose. NOTE: The oil leak should be fixed prior to replacing the hose. - Hard or brittle hoses, as the hoses age the rubber looses its resiliency and becomes brittle. The hoses need to be able to flex to compensate for the movement of the engine. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 1638 DRIVE BELTS Small cracks that run across that run across the ribbed surface of the belt from rib to rib , are considered normal, These are not reasons to replace the belt. If chunks of belt material are missing between the cracks, the belt should be replaced. Cracks running along the rib (not across) are not normal. Any belts with cracks running along the rib should be replaced. Replace the belt if it has excessive wear, frayed cords or severe glazing. Drive Pulleys - Verify the pulleys have no side to side wobble, and rotate freely. Replace if necessary. - Verify the pulleys are properly aligned. Adjust or replace as necessary. Belt Removal Do not attempt to bump the drive belts off with the starter. This practice can damage the belt, pulley, and technician. Removing the belt by relaxing the tension will allow you to correctly adjust the tension when installing the belt. DRIP PAN Prior to removing any hose or the water pump, place a large drip pan under the engine. Although the coolant may be drained from the radiator, there is still a large amount of residual coolant trapped in the hoses and water pump. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 1639 HOSE REMOVAL Prior to pulling the hose from the fitting, rotate/twist the hose on the fitting to break the grip of any corrosion present. If the hose is to be replaced, it may be quicker to cut hose from the fitting. CAUTION: When cutting the hose be careful not to damage the fitting. A radiator hose removal tool may help free up stubborn hoses. CAUTION: Do not use any device to pry the hose off of the fitting. - If at any time a tearing or ripping sound is heard (though the hose appears fine) the hose should be replaced. The sound is coming from the internal reinforcing fibers embedded in the hose. Once the fibers have been broken the hose will be subject to swelling and rupture when pressure is applied. WATER PUMP REMOVAL After removing the retaining bolts the water pump may still be stuck to the engine. The original gasket sealant may cause the pump to firmly stick to engine. A few soft blows from a rubber mallet or block of wood will generally loosen the pump. CAUTION: Verify that ALL of the retaining bolts are removed. - Do not pry between the pump and the gasket. This may damage the pump sealing surface. - Upon breaking the seal, a large amount of coolant trapped in the block will generally pour out from the water pump opening. Be sure to have a drip pan prepositioned. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 1640 Water Pump: Fundamentals and Basics Gasket Removal and Inspection GASKET REMOVAL - Remove all traces of the old gasket material. It only takes a very small amount of left over material to cause the new gasket to leak. - Never reuse gaskets. After a gasket has been initially installed and removed it will no longer be able to compensate for the varying expansion rates of the water pump and block. An old gasket may seal initially but as the engine heats up cools down, the old gasket will be prone to leakage. - When removing the gasket with a gasket scraper, be very careful not to gouge the sealing surface. Very small scratches in the sealing surface are likely to leak. HINT: Always sharpen your gasket scraper prior to starting a job. A dull scraper is more likely to slip and gouge the sealing surface. - If you are using a buffing wheel to clean the gasket surface, be very careful not to burn the surface. CAUTION: Buffing wheels can rapidly remove metal from the sealing surface, be very careful and check your work frequently. INSPECTION - Verify the gasket sealing surfaces are free of all gasket material, dirt, gouges, and contaminants (such as coolant or oil) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 1641 Water Pump: Fundamentals and Basics Installation Tips and Hints WATER PUMP INSTALLATION TIPS AND HINTS - Compare the old pump to the new pump and verify: Shaft lengths match exactly. - Retaining bolt holes match exactly. - Prior to applying the sealant to the gasket and pump, practice installing the pump to the engine. If any problems are encountered they will be easier to solve without the silicone applied. - Verify the retaining bolts and bolt holes have clean threads. Re-tap or chase the threads as necessary. - To simply the gasket installation process and minimize errors, install the gasket as follows: 1. Verify the gasket is correct. 2. Apply the sealant to the pump sealing surface and the gasket inner surface. Apply only a light film of sealant to the sealing surfaces. CAUTION: Excess sealant will squeeze out on the inside of the pump and may block the radiator or heater core coolant passages. 3. Install two retaining bolts through the pump. NOTE: This will help maintain the correct alignment of gasket in the next step. 4. While holding the bolts, place the gasket over the bolts and onto the pump sealing surface. 5. Install the pump and gasket onto the engine. - Do not over tighten the retaining bolts, use a torque wrench to properly tighten the bolts to the correct specification. CAUTION: Water pump retaining bolts may be easily broken or stripped, do not tighten the retaining bolts with an air wrench or impact gun. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 1642 - When tightening hose clamps: Position the hose squarely on the fitting. - Verify the hose clamp is clear of the retaining rim on the fitting. Do not over tighten the clamps. - While working on the cooling system it is a good habit to clean the radiator and A/C condenser fins of bugs and dirt. This build up of debris can seriously reduce the cooling ability of the system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 1643 Water Pump: Fundamentals and Basics Recommended Parts RECOMMENDED PARTS - New water pump, gasket and O-ring. - RTV sealant (for sealing water pump gasket, do not apply to O-ring). NOTE: Use only non-volatile oxygen sensor safe RTV sealant. This should be clearly indicated on the package. - Engine Coolant: Manual transmission - 8.9 qts. Automatic transmission- 8.8 qts NOTE: For optimum performance, use 50/50 mixture of high quality ethylene glycol coolant and water. - Intake gasket set (if intake manifold removal is necessary) NOTE: A coolant pipe runs from the back of the water pump, under the intake manifold and to the rear of the engine. This pipe has may leak and should be inspected. Replacing the pipe requires removing the intake manifold. OPTIONAL, PENDING INSPECTION - Timing belt - Radiator hoses. - Bypass hose. - Drive belts. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service Precautions > Customer Safety Information Catalytic Converter: Customer Safety Information 1. On vehicles equipped with catalytic converters the following conditions must be observed; a. Use only "UNLEADED FUEL." b. Avoid running out of fuel. c. In case of poor engine operation (misfiring), avoid driving the vehicle and correct the problem as soon as possible. d. Avoid push starting the vehicle. 2. Service vehicle on regular scheduled maintenance intervals to ensure proper engine performance and lower emission levels. 3. Always be conscious of fuel odors and excessive tailpipe emission (black smoke), these are problem indicators. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service Precautions > Customer Safety Information > Page 1649 Catalytic Converter: Technician Safety Information ELECTRICAL AND ELECTRONIC 1. Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. 2. Don't disconnect the battery when the engine is running. 3. Fully release locks prior to disconnecting connections, ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 4. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 5. In order to disable the ignition system, unplug the primary connections only. NEVER disconnect the secondary leads to disable the ignition system. 6. Do not use a self powered test lamp to check continuity. 7. Do not create any arcing to check the continuity of a circuit. 8. When charging battery, ensure battery cables are removed. 9. When replacing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, record stored trouble codes. ECM memory will be erased when ground cable is removed. 10. When measuring voltage at the control unit harness connector, disconnect harness connector first, then turn ignition "ON" as necessary. 11. To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. 12. Avoid getting water on any of the Fuel or Engine Control System Components. 13. Fuel and Engine Control System wiring should be at least 4 inches away from high tension cables. 14. Never pierce ignition leads or insulator boots to connect timing lights or analyzers. Use proper adapters. 15. When removing a spark plug wire twist the boot one quarter turn and pull on the boot only, never the lead itself. 16. Always use recommended power source in each testing procedure. 17. Never apply battery power to a component unless told to do so in a test procedure. 18. Do not try to disassemble the control unit. 19. Never use an auxiliary starting assist device which has a voltage rating above 12 volts to start engine. 20. In cases of electrical welding (for instance, spot welding), disconnect the climate control, injection, cruise control, ECU and radio. 21. In case of temperature above 176°F (80°C), (example: infra-red spray booth), remove all ECMs. 22. The battery produces a hazardous gas (hydrogen), avoid creating sparks near battery. FUEL SYSTEMS 1. Do not operate the fuel pump without fuel in the lines. 2. On fuel injected models do not depress the accelerator pedal while trying to start the car. 3. Handle all fuel injection related parts with care as they may easily be damaged. 4. Always use new gaskets or O-rings when installing fuel lines or injectors. 5. Lightly lubricate O-rings and flare connections with gasoline. Do not use engine oil, gear lubricant or brake fluid. 6. After servicing fuel system, check for leaks and correct as needed. ENGINE AND EXHAUST 1. On vehicles equipped with catalytic converters, the following conditions must be observed: a. Use only "UNLEADED FUEL". b. Avoid running out of fuel. c. In case of poor engine operation (misfiring), avoid driving the vehicle and correct the problem as soon as possible. d. Do not disconnect a spark plug wire with the engine running. e. Avoid push starting the vehicle. f. If running on a dynamometer, make sure the catalytic converter is well ventilated. g. Use caution when working near the catalytic converter to prevent the possibility of burns. 2. Do not use silicone based products on an oxygen sensor equipped vehicle to avoid damaging the sensor. 3. When performing a compression test, remove the fuel pump relay. (This will prevent fuel from being fed to the injectors). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service Precautions > Customer Safety Information > Page 1650 Catalytic Converter: Vehicle Damage Warnings ELECTRICAL AND ELECTRONIC 1. Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. 2. Don't disconnect the battery when the engine is running. 3. Fully release locks prior to disconnecting connections, ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 4. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 5. In order to disable the ignition system, unplug the primary connections only. NEVER disconnect the secondary leads to disable the ignition system. 6. Do not use a self powered test lamp to check continuity. 7. Do not create any arcing to check the continuity of a circuit. 8. When charging battery, ensure battery cables are removed. 9. When replacing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, record stored trouble codes. ECM memory will be erased when ground cable is removed. 10. When measuring voltage at the control unit harness connector, disconnect harness connector first, then turn ignition "ON" as necessary. 11. To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. 12. Avoid getting water on any of the Fuel or Engine Control System Components. 13. Fuel and Engine Control System wiring should be at least 4 inches away from high tension cables. 14. Never pierce ignition leads or insulator boots to connect timing lights or analyzers. Use proper adapters. 15. When removing a spark plug wire twist the boot one quarter turn and pull on the boot only, never the lead itself. 16. Always use recommended power source in each testing procedure. 17. Never apply battery power to a component unless told to do so in a test procedure. 18. Do not try to disassemble the control unit. 19. Never use an auxiliary starting assist device which has a voltage rating above 12 volts to start engine. 20. In cases of electrical welding (for instance, spot welding), disconnect the climate control, injection, cruise control, ECU and radio. 21. In case of temperature above 176°F (80°C), (example: infra-red spray booth), remove all ECMs. 22. The battery produces a hazardous gas (hydrogen), avoid creating sparks near battery. FUEL SYSTEMS 1. Do not operate the fuel pump without fuel in the lines. 2. On fuel injected models do not depress the accelerator pedal while trying to start the car. 3. Handle all fuel injection related parts with care as they may easily be damaged. 4. Always use new gaskets or O-rings when installing fuel lines or injectors. 5. Lightly lubricate O-rings and flare connections with gasoline. Do not use engine oil, gear lubricant or brake fluid. 6. After servicing fuel system, check for leaks and correct as needed. ENGINE AND EXHAUST 1. On vehicles equipped with catalytic converters, the following conditions must be observed: a. Use only "UNLEADED FUEL". b. Avoid running out of fuel. c. In case of poor engine operation (misfiring), avoid driving the vehicle and correct the problem as soon as possible. d. Do not disconnect a spark plug wire with the engine running. e. Avoid push starting the vehicle. f. If running on a dynamometer, make sure the catalytic converter is well ventilated. g. Use caution when working near the catalytic converter to prevent the possibility of burns. 2. Do not use silicone based products on an oxygen sensor equipped vehicle to avoid damaging the sensor. 3. When performing a compression test, remove the fuel pump relay. (This will prevent fuel from being fed to the injectors). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service Precautions > Page 1651 Catalytic Converter: Description and Operation Catalytic Converter THREE-WAY CATALYST This catalytic converter decreases HC, CO, and NOx emissions. The catalytic converter combines hydrocarbons (HC) and carbon monoxide (CO) with oxygen to form water (H2O) and carbon dioxide (CO2). The three-way catalytic converter contains rhodium which reduces or separates oxides of nitrogen (NOx) into nitrogen and oxygen. This action provides better exhaust emission control than is obtainable by using only exhaust gas recirculation, an oxidation catalyst or engine modifications. The three-way catalyst allows richer air/fuel mixtures, more spark advance and less exhaust gas recirculation. All these improve both driveability and fuel economy. Effective catalytic control of all three pollutants is possible when the correct level of CO is obtained, and excess oxygen is reduced. Therefore, it is necessary to maintain precise control of the air/fuel mixture entering the engine, keeping it very close to the stoichiometric point (chemically correct for theoretical complete combustion). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service Precautions > Page 1652 Catalytic Converter: Testing and Inspection The exhaust system should be checked for restriction before any components are replaced. Use the following procedures for diagnosis of the exhaust system: Check at Oxygen Sensor 1. Carefully remove O2 sensor with proper removal tool. 2. Install Exhaust Backpressure Tester in place of 02 sensor. 3. After completing test described below, be sure to coat threads of 02 sensor with antiseize compound prior to re-installation. Diagnosis: 1. With the engine at normal operating temperature and running at 2500 rpm, observe the exhaust system backpressure reading on the gauge. 2. If the backpressure exceeds 1 and 1/4 psi (8.62 kPa), a restricted exhaust system is indicated. 3. Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffler failure. 4. If there are no obvious reasons for the excessive backpressure, a restricted catalytic converter should be suspected, and replaced. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Nuts 191 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1656 Exhaust Manifold: Service and Repair EXHAUST MANIFOLD REMOVAL 1. Raise vehicle and disconnect exhaust pipe from rear cowl side.exhaust manifold at articulated joint. Fig. 18 Separate Articulated Joint, Disconnect Oxygen Sensor Wire 2. Disconnect Oxygen Sensor lead wire at the rear exhaust manifold. Fig. 19 Crossover Pipe 3. Remove bolts attaching cross-over pipe to manifold. 4. Remove nuts attaching rear manifold to cylinder head and remove manifold. 5. Lower vehicle and remove screws attaching front heat shield to front manifold. 6. Remove bolts fastening crossover pipe to front exhaust manifold and nuts fastening manifold to cylinder head. Remove assemblies. INSPECTION Fig. 20 Check Exhaust Manifold Mounting Surface Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1657 Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface and exhaust crossover mounting surface with a straightedge and thickness gauge. INSTALLATION Fig. 21 Identify Exhaust Manifold Gaskets NOTE: Install the gaskets with the numbers 1-3-5 embossed on the top on the rear bank and those with numbers 2-4-6 on the front, Radiator side, bank. 1. Install rear exhaust manifold and tighten attaching nuts to 20 Nm (175 in. lbs.). 2. Attach exhaust pipe to exhaust manifold and tighten shoulder bolt to 28 Nm (250 in. lbs.). 3. Attach crossover pipe to exhaust manifold and tighten bolt to 69 Nm 51 ft. lbs.). 4. Connect heated oxygen sensor lead. 5. Install front exhaust manifold and attach exhaust crossover. 6. Install front manifold heat shield and tighten attaching screws to 15 Nm (130 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe: > 110190A > Dec > 90 > Exhaust Flex Joint - Squeaking Exhaust Pipe: Customer Interest Exhaust Flex Joint - Squeaking SUBJECT: Exhaust Flex Joint Squeak - Vehicles With 2.2 Turbo, 2.5 Turbo, 3.0L EFI & 3.3L EFI NO.: 11-01-90 Rev. A GROUP: EXHAUST DATE: Dec. 21, 1990 MODELS: 1989-90 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/Convertible (AP) Sundance/Shadow (AS) Caravan/Grand Caravan/ Caravan C/V Voyager/Grand Voyager/Town & Country (AY) Imperial/New Yorker Fifth Avenue THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-01-90, WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ARE HIGHLIGHTED WITH >> ARROWS <<. "S" VEHICLE LINE (CARAVAN/VOYAGER) HAS BEEN ADDED TO THE LABOR OPERATION PAGES. SYMPTOM/CONDITION Vehicle exhibits a squeaking noise, coming from the exhaust-manifold-to-exhaust pipe coupling. Figure 1 DIAGNOSIS This noise is most noticeable when shifting from PARK/NEUTRAL to DRIVE or REVERSE. >> Before performing the repair procedure on Caravan/Voyager vehicles, verify that the washers for the muffler crossmember to frarne rail bolts (Figure Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe: > 110190A > Dec > 90 > Exhaust Flex Joint - Squeaking > Page 1666 1) are not contacting the crossmember. If washer-to-crossmember clearance is sufficient, and a squeak is still present, proceed with the following repair. << PARTS REQUIRED 1 Exhaust Seal Ring PN 4427699 2 Bolts, Flange to Manifold PN 5217003 2 Nuts, Flange to Manifold PN 4427610 REPAIR PROCEDURE This procedure involves replacement of the exhaust-manifold-to-exhaust-pipe sealing ring with a revised seal ring. 1. Using Figure 3 on Page 11-2 of the 1990 Front Wheel Drive Car Service Manual (Publication # 81-270-0101) for reference, disconnect the exhaust pipe from the exhaust manifold and remove the exhaust seal ring. 2. Install the revised seal ring, and connect the exhaust pipe to the exhaust manifold, using new bolts and nuts as called out in PARTS REQUIRED. Tighten to 28 N-m (250 in.lbs.) torque. NOTE: THE NEW SEAL RING WILL FIT LOOSELY ON THE PIPE. DO NOT RESIZE THE PIPE TO FIT THE SEAL RING TIGHTLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 11-20-05-92 . . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > 110190A > Dec > 90 > Exhaust Flex Joint Squeaking Exhaust Pipe: All Technical Service Bulletins Exhaust Flex Joint - Squeaking SUBJECT: Exhaust Flex Joint Squeak - Vehicles With 2.2 Turbo, 2.5 Turbo, 3.0L EFI & 3.3L EFI NO.: 11-01-90 Rev. A GROUP: EXHAUST DATE: Dec. 21, 1990 MODELS: 1989-90 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/Convertible (AP) Sundance/Shadow (AS) Caravan/Grand Caravan/ Caravan C/V Voyager/Grand Voyager/Town & Country (AY) Imperial/New Yorker Fifth Avenue THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-01-90, WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ARE HIGHLIGHTED WITH >> ARROWS <<. "S" VEHICLE LINE (CARAVAN/VOYAGER) HAS BEEN ADDED TO THE LABOR OPERATION PAGES. SYMPTOM/CONDITION Vehicle exhibits a squeaking noise, coming from the exhaust-manifold-to-exhaust pipe coupling. Figure 1 DIAGNOSIS This noise is most noticeable when shifting from PARK/NEUTRAL to DRIVE or REVERSE. >> Before performing the repair procedure on Caravan/Voyager vehicles, verify that the washers for the muffler crossmember to frarne rail bolts (Figure Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > 110190A > Dec > 90 > Exhaust Flex Joint Squeaking > Page 1672 1) are not contacting the crossmember. If washer-to-crossmember clearance is sufficient, and a squeak is still present, proceed with the following repair. << PARTS REQUIRED 1 Exhaust Seal Ring PN 4427699 2 Bolts, Flange to Manifold PN 5217003 2 Nuts, Flange to Manifold PN 4427610 REPAIR PROCEDURE This procedure involves replacement of the exhaust-manifold-to-exhaust-pipe sealing ring with a revised seal ring. 1. Using Figure 3 on Page 11-2 of the 1990 Front Wheel Drive Car Service Manual (Publication # 81-270-0101) for reference, disconnect the exhaust pipe from the exhaust manifold and remove the exhaust seal ring. 2. Install the revised seal ring, and connect the exhaust pipe to the exhaust manifold, using new bolts and nuts as called out in PARTS REQUIRED. Tighten to 28 N-m (250 in.lbs.) torque. NOTE: THE NEW SEAL RING WILL FIT LOOSELY ON THE PIPE. DO NOT RESIZE THE PIPE TO FIT THE SEAL RING TIGHTLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 11-20-05-92 . . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55 MPH Exhaust Pipe/Muffler Hanger: Customer Interest Exhaust System - Drone At 40-55 MPH Models 1987-90 S/AS Bodies With 2.5L & 3.0L Engines Subject Exhaust Drone At 40-55 MPH Index EXHAUST Date September 18, 1989 No. 11-02-89 (C11-01-9) P-3455 BODY CODE LEGEND S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH). DIAGNOSIS Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from under the floor pan area in front of the first bench seat. The vibration will also be present if the engine is run through the 2350-2450 RPM range with the transmission in neutral. PARTS REQUIRED 1 Crossmember Assembly PN 4427322 1 Muffler Support Bracket PN 4427295 1 Heat Shield PN 4401855 4 Screw & Washer Assembly PN 6501305 4 U-Nut PN 6101283 REPAIR PROCEDURE 1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the exhaust insulators to remain on the muffler. 2. Remove the muffler support bracket, crossmember, and heat shield. 3. Install new heat shield, using the fasteners just removed. 4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250 +/- 50 in. lbs., washer should bottom out on sleeve. 5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN 6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs. 6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs. 7. Road test vehicle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55 MPH > Page 1681 TIME ALLOWANCE: Labor Operation No. 11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55 MPH Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Exhaust System - Drone At 40-55 MPH Models 1987-90 S/AS Bodies With 2.5L & 3.0L Engines Subject Exhaust Drone At 40-55 MPH Index EXHAUST Date September 18, 1989 No. 11-02-89 (C11-01-9) P-3455 BODY CODE LEGEND S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH). DIAGNOSIS Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from under the floor pan area in front of the first bench seat. The vibration will also be present if the engine is run through the 2350-2450 RPM range with the transmission in neutral. PARTS REQUIRED 1 Crossmember Assembly PN 4427322 1 Muffler Support Bracket PN 4427295 1 Heat Shield PN 4401855 4 Screw & Washer Assembly PN 6501305 4 U-Nut PN 6101283 REPAIR PROCEDURE 1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the exhaust insulators to remain on the muffler. 2. Remove the muffler support bracket, crossmember, and heat shield. 3. Install new heat shield, using the fasteners just removed. 4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250 +/- 50 in. lbs., washer should bottom out on sleeve. 5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN 6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs. 6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs. 7. Road test vehicle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55 MPH > Page 1687 TIME ALLOWANCE: Labor Operation No. 11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 110289 > Sep > 89 > Exhaust System Drone At 40-55 MPH Heat Shield: Customer Interest Exhaust System - Drone At 40-55 MPH Models 1987-90 S/AS Bodies With 2.5L & 3.0L Engines Subject Exhaust Drone At 40-55 MPH Index EXHAUST Date September 18, 1989 No. 11-02-89 (C11-01-9) P-3455 BODY CODE LEGEND S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH). DIAGNOSIS Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from under the floor pan area in front of the first bench seat. The vibration will also be present if the engine is run through the 2350-2450 RPM range with the transmission in neutral. PARTS REQUIRED 1 Crossmember Assembly PN 4427322 1 Muffler Support Bracket PN 4427295 1 Heat Shield PN 4401855 4 Screw & Washer Assembly PN 6501305 4 U-Nut PN 6101283 REPAIR PROCEDURE 1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the exhaust insulators to remain on the muffler. 2. Remove the muffler support bracket, crossmember, and heat shield. 3. Install new heat shield, using the fasteners just removed. 4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250 +/- 50 in. lbs., washer should bottom out on sleeve. 5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN 6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs. 6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs. 7. Road test vehicle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 110289 > Sep > 89 > Exhaust System Drone At 40-55 MPH > Page 1696 TIME ALLOWANCE: Labor Operation No. 11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55 MPH Heat Shield: All Technical Service Bulletins Exhaust System - Drone At 40-55 MPH Models 1987-90 S/AS Bodies With 2.5L & 3.0L Engines Subject Exhaust Drone At 40-55 MPH Index EXHAUST Date September 18, 1989 No. 11-02-89 (C11-01-9) P-3455 BODY CODE LEGEND S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH). DIAGNOSIS Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from under the floor pan area in front of the first bench seat. The vibration will also be present if the engine is run through the 2350-2450 RPM range with the transmission in neutral. PARTS REQUIRED 1 Crossmember Assembly PN 4427322 1 Muffler Support Bracket PN 4427295 1 Heat Shield PN 4401855 4 Screw & Washer Assembly PN 6501305 4 U-Nut PN 6101283 REPAIR PROCEDURE 1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the exhaust insulators to remain on the muffler. 2. Remove the muffler support bracket, crossmember, and heat shield. 3. Install new heat shield, using the fasteners just removed. 4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250 +/- 50 in. lbs., washer should bottom out on sleeve. 5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN 6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs. 6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs. 7. Road test vehicle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55 MPH > Page 1702 TIME ALLOWANCE: Labor Operation No. 11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1710 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Engine Control Module: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 1719 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds Engine Control Module: Customer Interest ECM - Engine Die Out at Low Speeds NO.: 18-11-91 GROUP: DRIVEABILITY DATE: Aug. 26, 1991 SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L & 3.3L Engines MODELS: 1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON (AQ) CHRYSLER'S TC (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY (AY) IMPERIAL/NEW YORKER FIFTH AVENUE THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH >> ARROWS <<. SYMPTOM/CONDITION: Vehicle may exhibit either or both of the following conditions: Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine dies out when throttle is closed. Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM but fail to continue idling. Engine will run normally if throttle is held open. These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on for extended periods of time and only when the ambient temperature is above 40~ F (4~ C). DIAGNOSIS: Connect a DRB II tester to the vehicle diagnostic connector. 1. With the engine at normal operating temperature and with the AC on, record the AIS position while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following repair procedure. PARTS REQUIRED: 1 Single Module Engine Controller (SMEC) 1989 3.0L Engine AS Body, Federal 4639386 AS Body, California 4639001 AC Body, Federal 4639382 AC Body, California 4639384 1990 3.0L Engine >> AS Body, Federal (except Town & Country) 4639422 << >> AS Body, California (except Town & Country) 4639424 << AC & AY Bodies, Federal 4639398 AC & AY Bodies, California 4639400 AQ Body, Federal 4650386 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds > Page 1724 AQ Body, California 4650388 >> AS Body, Federal (except Town & Country) 4639386 << >> AS Body, California (except Town & Country) 4639001 << 1990 3.3L Engine AS Body, Federal 4672435 AS Body, California 4672438 AC & AY Bodies, Federal 4672440 AC & AY Bodies, California 4672431 1 Authorized Modification Label 4275086 REPAIR PROCEDURE: This repair involves the replacement of the engine controller with a revised one. 1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS REQUIRED. Figure 1 2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1, and attached near the VECI label. * INSERT PART NUMBER USED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Engine Control Module: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 1730 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds Engine Control Module: All Technical Service Bulletins ECM - Engine Die Out at Low Speeds NO.: 18-11-91 GROUP: DRIVEABILITY DATE: Aug. 26, 1991 SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L & 3.3L Engines MODELS: 1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON (AQ) CHRYSLER'S TC (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY (AY) IMPERIAL/NEW YORKER FIFTH AVENUE THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH >> ARROWS <<. SYMPTOM/CONDITION: Vehicle may exhibit either or both of the following conditions: Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine dies out when throttle is closed. Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM but fail to continue idling. Engine will run normally if throttle is held open. These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on for extended periods of time and only when the ambient temperature is above 40~ F (4~ C). DIAGNOSIS: Connect a DRB II tester to the vehicle diagnostic connector. 1. With the engine at normal operating temperature and with the AC on, record the AIS position while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following repair procedure. PARTS REQUIRED: 1 Single Module Engine Controller (SMEC) 1989 3.0L Engine AS Body, Federal 4639386 AS Body, California 4639001 AC Body, Federal 4639382 AC Body, California 4639384 1990 3.0L Engine >> AS Body, Federal (except Town & Country) 4639422 << >> AS Body, California (except Town & Country) 4639424 << AC & AY Bodies, Federal 4639398 AC & AY Bodies, California 4639400 AQ Body, Federal 4650386 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds > Page 1735 AQ Body, California 4650388 >> AS Body, Federal (except Town & Country) 4639386 << >> AS Body, California (except Town & Country) 4639001 << 1990 3.3L Engine AS Body, Federal 4672435 AS Body, California 4672438 AC & AY Bodies, Federal 4672440 AC & AY Bodies, California 4672431 1 Authorized Modification Label 4275086 REPAIR PROCEDURE: This repair involves the replacement of the engine controller with a revised one. 1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS REQUIRED. Figure 1 2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1, and attached near the VECI label. * INSERT PART NUMBER USED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations Engine Control Module: Component Locations Single Module Engine Controller The Single Module Engine Controller is located on the front left hand side of the engine compartment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 1738 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 Engine Control Module: Connector Views 14-Way Connector (1989 3.0) Single Module Engine Controller Connector(14-Way) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 Single Module Engine Controller Connector(60-Way) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 60 Way (SMEC) Wiring Connector Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 1745 Engine Control Module: Description and Operation Fig. 2 Single Module Engine Controller (SMEC) The SMEC, Fig. 2, is mounted in the engine compartment and contains circuits necessary to energize the ignition coil, fuel injectors and alternator field in order to minimize electrical noise in the passenger compartment. The SMEC contains a voltage converter which converts battery voltage into a regulated 8 volt output to energize the ignition pick up coil. The externally mounted Automatic Shut Down (ASD) relay which interrupts power to the fuel pump, ignition coil and injector when necessary is controlled by the SMEC. The ASD relay is turned on and off by the SMEC in response to distributor reference pulses. When distributor reference pulses are transmitted to the SMEC, the SMEC activates the ASD relay. However, when no reference pulse is transmitted to the SMEC, the ASD relay is deactivated and power is shut off to the fuel control system and ignition coil. The SMEC has been programmed to monitor several different circuits of the fuel injection system in order to provide a self-diagnosis function. In conjunction with the self-diagnosis function, a check engine lamp is wired into the system to indicate a failure in the monitored circuits. The check engine lamp is illuminated for 3 seconds whenever the engine is started as a `bulb test.' However, if the SMEC detects a malfunction in one of the monitored circuits the check engine lamp will be illuminated and will remain on as long as the ignition key remains in the on position. Illumination of the check engine lamp indicates that the system has entered the `limp-in' mode and signals an immediate need for system service. If vehicle performance or the check engine lamp indicate fuel injection system malfunctions, certain procedures should be followed. Prior to suspecting the fuel injection service as the cause for complaints, ensure that the engine and all related systems are in proper operating condition. After checking related systems, inspect fuel injection components and connecting harnesses as outlined in Visual Inspection, repair system as indicated, then road test vehicle to check system operation. If service performed during visual inspection does not correct observed malfunctions, or if check engine lamp remains illuminated, refer to `Obtaining fault codes' to call up fault codes stored in the SMEC memory and correct as needed. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 1746 Engine Control Module: Service and Repair 1. Remove air cleaner duct from SMEC. 2. Remove battery. 3. Remove two SMEC mounting screws. 4. Remove SMEC electrical connectors. 5. Remove SMEC. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Relay Locations--next To Battery The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the inner fender. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 1751 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions Main Relay (Computer/Fuel System): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Page 1755 Main Relay (Computer/Fuel System): Description and Operation Relay Locations--next To Battery The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel injectors, and electric fuel pump at all times when the ignition switch is in the START position. When the ignition switch is in the RUN position and the engine control module is receiving reference signals from the distributor, power will also be supplied. If there is no reference signal after two seconds the engine control module will de-energize the ASD and no power will be supplied to the ignition coil, fuel injectors, or electric fuel pump. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay Relay Terminal Identification ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with circuit codes, and color codes, and their function: Circuit No. Terminal No. Color Code Description J1 30 Red Has battery input voltage supplied through fusible link. Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output voltage to fuel pump, O2 sensor, fuel injectors, and coil. K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine Controller (SMEC). The SMEC provides input voltage to relay. K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when distributor signal is present. N/A 87A N/A Not used in these applications. ASD RELAY TEST NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent. Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no scanner is available proceed with the following test. 1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage. If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present proceed to step 2. 2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to the START position and crank the engine. If Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 1758 output voltage is present during cranking, the ASD relay is functioning normally and no further testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3. 3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86) wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD relay, and test operation. 4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning, and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14 (terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists replace and ASD relay and test operation. 5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58 of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Polarity Protection Relay, ECM > Component Information > Locations Polarity Protection Relay: Locations Relay Identification The ASD relay is found on the left inner fender apron near the left strut tower and the diagnostic connector. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Engine Compartment Components This vehicle utilizes the Automatic Shutdown (ASD) Relay to control the Fuel Pump operation. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Relay Locations--next To Battery The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the inner fender. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 1770 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions Main Relay (Computer/Fuel System): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions > Page 1773 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Page 1774 Main Relay (Computer/Fuel System): Description and Operation Relay Locations--next To Battery The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel injectors, and electric fuel pump at all times when the ignition switch is in the START position. When the ignition switch is in the RUN position and the engine control module is receiving reference signals from the distributor, power will also be supplied. If there is no reference signal after two seconds the engine control module will de-energize the ASD and no power will be supplied to the ignition coil, fuel injectors, or electric fuel pump. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay Relay Terminal Identification ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with circuit codes, and color codes, and their function: Circuit No. Terminal No. Color Code Description J1 30 Red Has battery input voltage supplied through fusible link. Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output voltage to fuel pump, O2 sensor, fuel injectors, and coil. K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine Controller (SMEC). The SMEC provides input voltage to relay. K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when distributor signal is present. N/A 87A N/A Not used in these applications. ASD RELAY TEST NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent. Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no scanner is available proceed with the following test. 1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage. If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present proceed to step 2. 2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to the START position and crank the engine. If Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 1777 output voltage is present during cranking, the ASD relay is functioning normally and no further testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3. 3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86) wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD relay, and test operation. 4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning, and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14 (terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists replace and ASD relay and test operation. 5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58 of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1783 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Absolute Pressure Sensor: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 1794 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 Absolute Pressure Sensor: Customer Interest Check Engine Lamp Comes On and Fault Code 13 NO.: 18-09-91 GROUP: DRIVEABILITY DATE: Sept. 23, 1991 SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine MODELS: 1989 (AA) SPIRIT/ACCLAIM 1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON 1989 (AG) DAYTONA 1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE 1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER SYMPTOM/CONDITION: The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic Change" is set into the diagnostic system. DIAGNOSIS: Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the diagnostic manual to verify that the MAP sensor is operating properly. PARTS REQUIRED: 1 MAP Sensor Relocation Package 4638458 Package Contents: 1 Cap Plug (1987-88 vehicles) 3580172 1 Cap Plug (1989 vehicles) 4241618 1 Purge Jumper Assembly 4669038 Consisting of: 1 In-Line Vacuum Connector 4201275 1 Vacuum Tee 33000227 1 11" Vacuum Hose 4104272 1 Bleed/Hose Assembly 4669042 Consisting of: 1 Vent 53007494 1 1" Vacuum Hose 4713956 1 Vacuum Tee 4669041 2 Vacuum Hose With 90 Degree Bend 4669044 1 Bracket 4686013 1 Wiring Harness 4687141 5 Tie Wraps 6015756 REPAIR PROCEDURE: This repair involves relocation of the MAP sensor. 1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable. 2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its present location. 3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug (3580172 for 1987 and 1988 vehicles or 4241618 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 1799 for 1989 vehicles) in its place. 4. Loosen clamps and remove throttle body/air filter intake hose. 5. Wiring Harness Installation Procedure: If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted on the right side shock tower or on the bulkhead follow Step B. A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor connector. Route the harness along the backside of the intake manifold toward the throttle body. The harness should be secured to the fuel line and to the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps. B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length. Connect the FEMALE end of the harness to the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the harness to the right side of the motor mount and the two rear engine wiring support brackets. Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the supplied tie wraps. 6. Attach original MAP sensor to the bracket (4686013) supplied in the package. Figure 1 7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to slide over throttle body stud. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 1800 Figure 2 8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque nut to 25 N-m (225 in.lbs.). 9. Disconnect the intake manifold end of the formed purge hose that extends from the intake manifold nipple to the "F" shaped connector (Figure 2). Figure 3 10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to nipple on intake manifold. Position the MAP bleed valve as close to vertical as possible. Figure 4 11. Cut the existing PVC hose as shown in Figure 2. 12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the formed purge hose (disconnected in Step 9) and the PVC hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed purge hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 1801 Figure 5 NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE IT OVER THE TOP OF THROTTLE LINKAGE. 13. Connect vacuum hose to MAP sensor. 14. Connect wiring harness connector to MAP sensor. 15. Install throttle body/air filter intake hose and tighten clamps. 16. Use the DRB II to erase any fault codes and perform the applicable verification tests. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-14-15-94 . . . . . . . . . . . . . . . . . 0.8 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set Absolute Pressure Sensor: Customer Interest MAP Sensor - DTC's 13 or 14 Set Models 1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies Subject MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines Index DRIVEABILITY Date January 29, 1990 No. 18-03-90 (C18-20-9) P-164 BODY CODE LEGEND AA - ACCLAIM/,SPIRIT LEBARON LANDAU C/AC - DYNASTY/NEW YORKER LANDAU/SALON E - CARAVELLE/600 G/AG - DAYTONA H/AH - LANCER/LEBARON GTS J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE K/AK - ARIES/RELIANT P/AP - SHADOW/SUNDANCE S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle diagnostic memory. PARTS REQUIRED 1 MAP Sensor PN 5227351 1 Sensor Hose (3.0L Engine Only) PN 4557138 REPAIR PROCEDURE When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service Manual for replacement procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption Absolute Pressure Sensor: Customer Interest Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 1810 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Absolute Pressure Sensor: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 1816 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 Absolute Pressure Sensor: All Technical Service Bulletins Check Engine Lamp Comes On and Fault Code 13 NO.: 18-09-91 GROUP: DRIVEABILITY DATE: Sept. 23, 1991 SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine MODELS: 1989 (AA) SPIRIT/ACCLAIM 1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON 1989 (AG) DAYTONA 1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE 1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER SYMPTOM/CONDITION: The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic Change" is set into the diagnostic system. DIAGNOSIS: Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the diagnostic manual to verify that the MAP sensor is operating properly. PARTS REQUIRED: 1 MAP Sensor Relocation Package 4638458 Package Contents: 1 Cap Plug (1987-88 vehicles) 3580172 1 Cap Plug (1989 vehicles) 4241618 1 Purge Jumper Assembly 4669038 Consisting of: 1 In-Line Vacuum Connector 4201275 1 Vacuum Tee 33000227 1 11" Vacuum Hose 4104272 1 Bleed/Hose Assembly 4669042 Consisting of: 1 Vent 53007494 1 1" Vacuum Hose 4713956 1 Vacuum Tee 4669041 2 Vacuum Hose With 90 Degree Bend 4669044 1 Bracket 4686013 1 Wiring Harness 4687141 5 Tie Wraps 6015756 REPAIR PROCEDURE: This repair involves relocation of the MAP sensor. 1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable. 2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its present location. 3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug (3580172 for 1987 and 1988 vehicles or 4241618 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 1821 for 1989 vehicles) in its place. 4. Loosen clamps and remove throttle body/air filter intake hose. 5. Wiring Harness Installation Procedure: If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted on the right side shock tower or on the bulkhead follow Step B. A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor connector. Route the harness along the backside of the intake manifold toward the throttle body. The harness should be secured to the fuel line and to the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps. B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length. Connect the FEMALE end of the harness to the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the harness to the right side of the motor mount and the two rear engine wiring support brackets. Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the supplied tie wraps. 6. Attach original MAP sensor to the bracket (4686013) supplied in the package. Figure 1 7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to slide over throttle body stud. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 1822 Figure 2 8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque nut to 25 N-m (225 in.lbs.). 9. Disconnect the intake manifold end of the formed purge hose that extends from the intake manifold nipple to the "F" shaped connector (Figure 2). Figure 3 10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to nipple on intake manifold. Position the MAP bleed valve as close to vertical as possible. Figure 4 11. Cut the existing PVC hose as shown in Figure 2. 12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the formed purge hose (disconnected in Step 9) and the PVC hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed purge hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 1823 Figure 5 NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE IT OVER THE TOP OF THROTTLE LINKAGE. 13. Connect vacuum hose to MAP sensor. 14. Connect wiring harness connector to MAP sensor. 15. Install throttle body/air filter intake hose and tighten clamps. 16. Use the DRB II to erase any fault codes and perform the applicable verification tests. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-14-15-94 . . . . . . . . . . . . . . . . . 0.8 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set Absolute Pressure Sensor: All Technical Service Bulletins MAP Sensor - DTC's 13 or 14 Set Models 1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies Subject MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines Index DRIVEABILITY Date January 29, 1990 No. 18-03-90 (C18-20-9) P-164 BODY CODE LEGEND AA - ACCLAIM/,SPIRIT LEBARON LANDAU C/AC - DYNASTY/NEW YORKER LANDAU/SALON E - CARAVELLE/600 G/AG - DAYTONA H/AH - LANCER/LEBARON GTS J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE K/AK - ARIES/RELIANT P/AP - SHADOW/SUNDANCE S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle diagnostic memory. PARTS REQUIRED 1 MAP Sensor PN 5227351 1 Sensor Hose (3.0L Engine Only) PN 4557138 REPAIR PROCEDURE When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service Manual for replacement procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption Absolute Pressure Sensor: All Technical Service Bulletins Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 1832 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Barometric Pressure Sensor: Locations Engine Compartment Components. RH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1840 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Top RH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 1846 Engine Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1847 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 5 Coolant & charge temperature sensors The coolant temperature sensor, Fig. 5, is mounted in the thermostat housing and allows the SMEC to monitor engine operating temperature in order to provide proper air/fuel mixtures. The sensor provides a variable resistance which is proportional to coolant temperature. When the engine is cold and sensor resistance is low, the SMEC provides richer air/fuel mixtures and increases engine idle speed to provide acceptable cold engine performance and allow quick warm up. When coolant temperature and sensor resistance increase, the SMEC provides leaner air/fuel mixtures and lowers engine idle speed to provide proper exhaust emission control and increased fuel economy. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Senior 105 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1853 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 1854 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect distributor lead wire at wiring harness connector. 2. Remove distributor cap retaining screws and remove distributor cap. 3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum. Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when reinstalling the distributor. 4. Remove the distributor hold down nut and remove the distributor from the engine. DISASSEMBLY 1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and remove lead wire. 2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or damaged slots. 3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing. 4. Remove 2 bearing retainer screws. 5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the distributor drive gear roll pin. 6. Remove distributor drive gear, remove distributor shaft and bearing assembly. REASSEMBLY 1. Install shaft and bearing assembly in distributor housing. 2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference marks made during disassembly, and install roll pin. 3. Install distributor shaft bearing retaining screws. 4. Install the photo optic sensing unit and bushing and tighten with 3 screws. 5. Install disk spacers and disk. Install disk assembly screw. 6. Install lead wire, and lead wire clamp screw. 7. Install protective cover on distributor housing. INSTALLATION 1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If engine has been cranked with distributor removed proceed to step 3 for installation. 2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the distributor is installed, the rotor will be in line with the previously scribed line on the air intake plenum. Proceed to step 4. 3. If the engine has been cranked with the distributor removed perform the following procedure: a. Rotate the crankshaft until the number one piston is at the top of its compression stroke. Distributor Cap Terminal Routing b. Rotate the distributor shaft until the rotor points to number one terminal. c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam shaft. With the distributor fully seated the rotor should be under the number one terminal. 4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers. Install hold down nut finger tight. 5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to ADJUSTMENT PROCEDURES for timing adjustment. . Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Engine Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1858 Intake Air Temperature Sensor: Description and Operation Fig. 5 Coolant & charge temperature sensors The charge temperature switch, Fig. 5, is mounted in the intake manifold and measures the temperature of the air/fuel mixture. This information is used by the SMEC to modify the air/fuel mixture. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Switch > Component Information > Locations Intake Air Temperature Switch: Locations RH Side Of Air Cleaner Assembly Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations Engine Compartment Components. RH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 1866 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1867 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 3 Manifold Absolute Pressure (MAP) sensor location The MAP sensor, Fig. 3, is mounted in the engine compartment on the dash panel and monitors intake manifold vacuum through a line connected to the intake plenum. The sensor converts manifold vacuum (negative pressure) and barometric pressure into electrical signals and transmits these signals to the SMEC. The SMEC uses these signals to monitor engine load and atmospheric conditions in order to determine the correct air/fuel mixture for vehicle operating conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1868 Manifold Pressure/Vacuum Sensor: Service and Repair 1. Remove vacuum hose from sensor. 2. Remove sensor attaching screws, then the sensor. 3. Reverse procedure to install. Ensure proper installation of vacuum hose to sensor and sensor to dash panel. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations On Exhaust Manifold Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1875 Oxygen Sensor: Description and Operation Fig. 4 Oxygen sensor The oxygen sensor, Fig. 4, produces voltage signals when exposed to oxygen in the exhaust gasses. The oxygen content in the exhaust gasses is directly proportional to the air/fuel mixture entering the engine, and the voltage signal produced by the sensor is inversely proportional to the amount of oxygen remaining in the exhaust gasses. The SMEC uses these signals to determine air/fuel mixtures entering the engine. The oxygen sensor is mounted in the rear exhaust manifold, and the sensing element must be heated by exhaust gasses before the sensor begins to produce voltage signals. When exhaust gas oxygen content is high (lean mixtures), the sensor produces a low voltage. When oxygen content is low (rich mixtures), the sensor produces a higher voltage. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1876 Oxygen Sensor: Service and Repair The oxygen sensor is to be removed using tool No. C-4907 or equivalent. After removal, clean threads in exhaust manifold using an 18mm x 1.5 x 6E tap. If reinstalling the same sensor, apply a suitable anti-seize to threads of sensor. New sensors are packaged with an anti-seize compound already applied to the threads and no further application is required. When installing sensor, torque to 20 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure Revision Models 1989 AS Subject Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI Index MISCELLANEOUS Date December 29, 1989 No. 26-34-89 P-13 (C26-34-9) BODY CODE LEGEND AS - 1989 RAM VAN, CARAVAN, VOYAGER Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 1881 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 1882 DIAGNOSTIC MANUAL REVISION Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH. 1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No. 81-699-9017. Pages 136 and 137. Please affix these revised pages in your manual. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1883 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1884 Throttle Position Sensor: Locations LH Rear Corner Of Cylinder Head Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1887 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1888 Throttle Position Sensor: Description and Operation The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The sensor produces a voltage signal which increases and decreases according to throttle position. The SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide open throttle, acceleration and deceleration. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1889 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle body mounting screws. 3. Lift TPS from throttle shaft, then remove O-ring. 4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw to 20 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1898 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1899 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1900 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 1906 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 1907 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1912 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1913 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1914 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 1920 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 1921 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 1924 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 1925 Transmission Position Switch/Sensor: Locations 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 1926 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 1929 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 1932 Transmission Position Switch/Sensor: Description and Operation PRNDL The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. It may have been replaced by a transmission range sensor (TRS). Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 1935 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 1936 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 1937 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations LH Side Of Engine Compartment. Upper LH Corner Of Transaxle Applicable to: 1989 w/Electronic Transaxle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1943 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1944 Vehicle Speed Sensor: Description and Operation The distance sensor is located in the transaxle extension housing and signals vehicle motion to the SMEC by generating eight pulses per axle shaft revolution. The SMEC uses this signal along with signals from the throttle position sensor to determine between a closed throttle deceleration and a normal idle condition, thereby allowing the SMEC to maintain desired control of the AIS motor. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure Revision Models 1989 AS Subject Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI Index MISCELLANEOUS Date December 29, 1989 No. 26-34-89 P-13 (C26-34-9) BODY CODE LEGEND AS - 1989 RAM VAN, CARAVAN, VOYAGER Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 1950 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 1951 DIAGNOSTIC MANUAL REVISION Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH. 1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No. 81-699-9017. Pages 136 and 137. Please affix these revised pages in your manual. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1952 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1953 Throttle Position Sensor: Locations LH Rear Corner Of Cylinder Head Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1956 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1957 Throttle Position Sensor: Description and Operation The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The sensor produces a voltage signal which increases and decreases according to throttle position. The SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide open throttle, acceleration and deceleration. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1958 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle body mounting screws. 3. Lift TPS from throttle shaft, then remove O-ring. 4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw to 20 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1964 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Senior 105 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1970 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1971 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect distributor lead wire at wiring harness connector. 2. Remove distributor cap retaining screws and remove distributor cap. 3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum. Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when reinstalling the distributor. 4. Remove the distributor hold down nut and remove the distributor from the engine. DISASSEMBLY 1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and remove lead wire. 2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or damaged slots. 3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing. 4. Remove 2 bearing retainer screws. 5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the distributor drive gear roll pin. 6. Remove distributor drive gear, remove distributor shaft and bearing assembly. REASSEMBLY 1. Install shaft and bearing assembly in distributor housing. 2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference marks made during disassembly, and install roll pin. 3. Install distributor shaft bearing retaining screws. 4. Install the photo optic sensing unit and bushing and tighten with 3 screws. 5. Install disk spacers and disk. Install disk assembly screw. 6. Install lead wire, and lead wire clamp screw. 7. Install protective cover on distributor housing. INSTALLATION 1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If engine has been cranked with distributor removed proceed to step 3 for installation. 2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the distributor is installed, the rotor will be in line with the previously scribed line on the air intake plenum. Proceed to step 4. 3. If the engine has been cranked with the distributor removed perform the following procedure: a. Rotate the crankshaft until the number one piston is at the top of its compression stroke. Distributor Cap Terminal Routing b. Rotate the distributor shaft until the rotor points to number one terminal. c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam shaft. With the distributor fully seated the rotor should be under the number one terminal. 4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers. Install hold down nut finger tight. 5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to ADJUSTMENT PROCEDURES for timing adjustment. . Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations Ignition Switch: Locations I/P, Cowl & Steering Column Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations > Page 1975 Steering Column Components Top Of Steering Column Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations > Page 1976 Ignition Switch: Service and Repair Fig. 10 Ignition switch replacement 1. If equipped, disarm airbag system, refer to MAINTENANCE PROCEDURES. 2. Remove left lower instrument panel cover. 3. Position gear selector to D and disconnect indicator cable, if equipped with automatic transaxle. 4. Remove lower panel reinforcement, then five steering column to support bracket attaching nuts. 5. Lower column and disconnect ignition switch electrical connector. 6. Position ignition lock cylinder in Lock position. 7. Tape ignition switch rod to steering column to prevent rod from falling out of lock cylinder assembly. 8. Remove two ignition switch attaching screws, then the switch. 9. Reverse procedure to install. Rearm airbag system, refer to MAINTENANCE PROCEDURES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations System not equipped with fuel pressure test port. (To test fuel pressure tee into system with adapter.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle mixture using this screw! Idle mixture is electronically controlled by the Powertrain Control Module (PCM), and is not adjustable. If an idle mixture problem is suspected, check oxygen sensor and feedback system. SEE Computers and Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications IDLE SPEED Idle speed adjustment is electronically controlled by the Automatic Idle Speed (AIS) Motor and is not adjustable. For diagnosis of incorrect idle speed, refer to COMPUTERIZED ENGINE CONTROLS. IDLE SPEED Automatic ............................................................................................................................................. .................................................................. 800 RPM Manual .............................................................. ...................................................................................................................................................... 800 RPM Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1988 Idle Speed: Testing and Inspection 1. Remove air cleaner assembly, then plug heated air door vacuum hose. 2. With vehicle in PARK for A/T, or NEUTRAL for M/T, START engine and warm until cooling fan cycles ON and OFF at least once. STOP engine. 3. Connect suitable timing light, then disconnect coolant temperature sensor. START engine, and ensure basic timing is set to 12° BTDC. 4. STOP engine and reconnect coolant temperature sensor wire. 5. Disconnect PCV valve hose from intake manifold nipple. 6. Attach tool No. C-5004 or equivalent (.125 inch orifice in attached hose) to intake manifold PCV nipple. 7. Connect DRB II or equivalent scanner, then START engine and allow to idle for at least 1 minute. 8. Using scanner, place read/hold switch in read position and depress ATM button until code 70 appears. 9. Place read/hold switch to hold position, then the following should occur: a. AIS motor will fully close. b. Idle spark advance will become fixed. c. Idle fuel will become enriched. d. Engine rpm will be displayed on diagnostic read-out tool in units of rpm x 10. For example, display 95 equals 95 x 10 which indicates 950 rpm. 10. Check idle rpm. If idle rpm is within 850-1250 rpm then throttle body minimum air flow is satisfactory. If idle rpm is not as specified, clean or replace throttle body, refer to MAINTENANCE PROCEDURES. Retest minimum air flow after throttle body cleaning. 11. STOP engine, then remove tool No. C-5004 (orifice) from intake manifold PCV nipple. Install PCV valve hose. 12 Erase fault codes. Remove scanner, then install air cleaner assembly and heated air door vacuum hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1989 Idle Speed: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle speed using this screw, unless directed to do so in a service procedure. Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air Control (IAC) motor, and is not adjustable. If idle is outside of specified RPM, or is rough, or unstable, inspect and clean throttle body if deposits are visible. Perform Minimum Idle Air Flow Test if applicable. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair 1. Loosen gas cap and allow tank pressure to release. 2. Remove wiring harness connector from any injector, then ground one injector terminal. 3. Connect a suitable jumper wire to a second terminal, then touch the positive post of the battery for approximately 10 seconds and release system pressure. 4. Remove jumper wires and service fuel system as required. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Cylinder Location 1988-1996 3.0L (182) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Cylinder Location > Page 1998 Distributor Cap From The Top - Includes Connections Inside The Cap. (Round Terminals Are Plug Wire Connections On The Top Of The Cap.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations 1988-1996 3.0L (182) 3.0L Except Stealth Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Marks and Indicators: Diagrams TIMING MARK 3.0L Timing Scale Above Crank Pulley--Viewed From Front Of Car Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications Distributor: Specifications Distributer Adapter ............................................................................................................................... .......................................... 14 Nm (120 in lbs) Distributer Housing Bolt ............................................. .................................................................................................................... 15 Nm (130 in lbs) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications > Page 2012 Distributor: Locations Distributor Hold-Down The Optical Distributor is located at the back of the engine, behind the right-hand cylinder head. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications > Page 2013 Distributor: Service and Repair REMOVAL 1. Disconnect distributor lead wire at wiring harness connector. 2. Remove distributor cap retaining screws and remove distributor cap. 3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum. Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when reinstalling the distributor. 4. Remove the distributor hold down nut and remove the distributor from the engine. DISASSEMBLY 1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and remove lead wire. 2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or damaged slots. 3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing. 4. Remove 2 bearing retainer screws. 5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the distributor drive gear roll pin. 6. Remove distributor drive gear, remove distributor shaft and bearing assembly. REASSEMBLY 1. Install shaft and bearing assembly in distributor housing. 2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference marks made during disassembly, and install roll pin. 3. Install distributor shaft bearing retaining screws. 4. Install the photo optic sensing unit and bushing and tighten with 3 screws. 5. Install disk spacers and disk. Install disk assembly screw. 6. Install lead wire, and lead wire clamp screw. 7. Install protective cover on distributor housing. INSTALLATION 1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If engine has been cranked with distributor removed proceed to step 3 for installation. 2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the distributor is installed, the rotor will be in line with the previously scribed line on the air intake plenum. Proceed to step 4. 3. If the engine has been cranked with the distributor removed perform the following procedure: a. Rotate the crankshaft until the number one piston is at the top of its compression stroke. Distributor Cap Terminal Routing b. Rotate the distributor shaft until the rotor points to number one terminal. c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam shaft. With the distributor fully seated the rotor should be under the number one terminal. 4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers. Install hold down nut finger tight. 5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to ADJUSTMENT PROCEDURES for timing adjustment. . Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. .................... 0.9 to 1.1 mm (0.039 to 0.044 in) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 2018 Spark Plug: Specifications Tightening Specifications Spark Plug Torque ............................................................................................................................... ...................................................... 28 Nm (20 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications SERVICE SPECIFICATIONS Compression pressure ..................................................................................................................... 840 kPa (178 psi) +/- 100 kPa (14 psi) @ 250-400 rpm Maximum variation ....................................... .............................................................................................................................................................. .... 25% Manifold vacuum .................................................................................................................... ........................................................... 520 mmHg (20 in.Hg.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2022 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. NOTE: Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. NOTE: Correct engine compression pressures should be 178 psi +/- 14 psi, Maximum cylinder deviation 25% Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2026 Valve Clearance: Adjustments This engine uses hydraulic lash adjusters. No provision for adjustment is provided. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Absolute Pressure Sensor: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 2036 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 Absolute Pressure Sensor: Customer Interest Check Engine Lamp Comes On and Fault Code 13 NO.: 18-09-91 GROUP: DRIVEABILITY DATE: Sept. 23, 1991 SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine MODELS: 1989 (AA) SPIRIT/ACCLAIM 1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON 1989 (AG) DAYTONA 1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE 1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER SYMPTOM/CONDITION: The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic Change" is set into the diagnostic system. DIAGNOSIS: Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the diagnostic manual to verify that the MAP sensor is operating properly. PARTS REQUIRED: 1 MAP Sensor Relocation Package 4638458 Package Contents: 1 Cap Plug (1987-88 vehicles) 3580172 1 Cap Plug (1989 vehicles) 4241618 1 Purge Jumper Assembly 4669038 Consisting of: 1 In-Line Vacuum Connector 4201275 1 Vacuum Tee 33000227 1 11" Vacuum Hose 4104272 1 Bleed/Hose Assembly 4669042 Consisting of: 1 Vent 53007494 1 1" Vacuum Hose 4713956 1 Vacuum Tee 4669041 2 Vacuum Hose With 90 Degree Bend 4669044 1 Bracket 4686013 1 Wiring Harness 4687141 5 Tie Wraps 6015756 REPAIR PROCEDURE: This repair involves relocation of the MAP sensor. 1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable. 2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its present location. 3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug (3580172 for 1987 and 1988 vehicles or 4241618 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2041 for 1989 vehicles) in its place. 4. Loosen clamps and remove throttle body/air filter intake hose. 5. Wiring Harness Installation Procedure: If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted on the right side shock tower or on the bulkhead follow Step B. A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor connector. Route the harness along the backside of the intake manifold toward the throttle body. The harness should be secured to the fuel line and to the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps. B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length. Connect the FEMALE end of the harness to the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the harness to the right side of the motor mount and the two rear engine wiring support brackets. Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the supplied tie wraps. 6. Attach original MAP sensor to the bracket (4686013) supplied in the package. Figure 1 7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to slide over throttle body stud. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2042 Figure 2 8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque nut to 25 N-m (225 in.lbs.). 9. Disconnect the intake manifold end of the formed purge hose that extends from the intake manifold nipple to the "F" shaped connector (Figure 2). Figure 3 10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to nipple on intake manifold. Position the MAP bleed valve as close to vertical as possible. Figure 4 11. Cut the existing PVC hose as shown in Figure 2. 12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the formed purge hose (disconnected in Step 9) and the PVC hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed purge hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2043 Figure 5 NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE IT OVER THE TOP OF THROTTLE LINKAGE. 13. Connect vacuum hose to MAP sensor. 14. Connect wiring harness connector to MAP sensor. 15. Install throttle body/air filter intake hose and tighten clamps. 16. Use the DRB II to erase any fault codes and perform the applicable verification tests. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-14-15-94 . . . . . . . . . . . . . . . . . 0.8 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set Absolute Pressure Sensor: Customer Interest MAP Sensor - DTC's 13 or 14 Set Models 1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies Subject MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines Index DRIVEABILITY Date January 29, 1990 No. 18-03-90 (C18-20-9) P-164 BODY CODE LEGEND AA - ACCLAIM/,SPIRIT LEBARON LANDAU C/AC - DYNASTY/NEW YORKER LANDAU/SALON E - CARAVELLE/600 G/AG - DAYTONA H/AH - LANCER/LEBARON GTS J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE K/AK - ARIES/RELIANT P/AP - SHADOW/SUNDANCE S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle diagnostic memory. PARTS REQUIRED 1 MAP Sensor PN 5227351 1 Sensor Hose (3.0L Engine Only) PN 4557138 REPAIR PROCEDURE When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service Manual for replacement procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption Absolute Pressure Sensor: Customer Interest Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 2052 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Absolute Pressure Sensor: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 2058 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 Absolute Pressure Sensor: All Technical Service Bulletins Check Engine Lamp Comes On and Fault Code 13 NO.: 18-09-91 GROUP: DRIVEABILITY DATE: Sept. 23, 1991 SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine MODELS: 1989 (AA) SPIRIT/ACCLAIM 1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON 1989 (AG) DAYTONA 1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE 1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER SYMPTOM/CONDITION: The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic Change" is set into the diagnostic system. DIAGNOSIS: Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the diagnostic manual to verify that the MAP sensor is operating properly. PARTS REQUIRED: 1 MAP Sensor Relocation Package 4638458 Package Contents: 1 Cap Plug (1987-88 vehicles) 3580172 1 Cap Plug (1989 vehicles) 4241618 1 Purge Jumper Assembly 4669038 Consisting of: 1 In-Line Vacuum Connector 4201275 1 Vacuum Tee 33000227 1 11" Vacuum Hose 4104272 1 Bleed/Hose Assembly 4669042 Consisting of: 1 Vent 53007494 1 1" Vacuum Hose 4713956 1 Vacuum Tee 4669041 2 Vacuum Hose With 90 Degree Bend 4669044 1 Bracket 4686013 1 Wiring Harness 4687141 5 Tie Wraps 6015756 REPAIR PROCEDURE: This repair involves relocation of the MAP sensor. 1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable. 2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its present location. 3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug (3580172 for 1987 and 1988 vehicles or 4241618 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2063 for 1989 vehicles) in its place. 4. Loosen clamps and remove throttle body/air filter intake hose. 5. Wiring Harness Installation Procedure: If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted on the right side shock tower or on the bulkhead follow Step B. A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor connector. Route the harness along the backside of the intake manifold toward the throttle body. The harness should be secured to the fuel line and to the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps. B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length. Connect the FEMALE end of the harness to the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the harness to the right side of the motor mount and the two rear engine wiring support brackets. Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the supplied tie wraps. 6. Attach original MAP sensor to the bracket (4686013) supplied in the package. Figure 1 7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to slide over throttle body stud. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2064 Figure 2 8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque nut to 25 N-m (225 in.lbs.). 9. Disconnect the intake manifold end of the formed purge hose that extends from the intake manifold nipple to the "F" shaped connector (Figure 2). Figure 3 10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to nipple on intake manifold. Position the MAP bleed valve as close to vertical as possible. Figure 4 11. Cut the existing PVC hose as shown in Figure 2. 12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the formed purge hose (disconnected in Step 9) and the PVC hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed purge hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2065 Figure 5 NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE IT OVER THE TOP OF THROTTLE LINKAGE. 13. Connect vacuum hose to MAP sensor. 14. Connect wiring harness connector to MAP sensor. 15. Install throttle body/air filter intake hose and tighten clamps. 16. Use the DRB II to erase any fault codes and perform the applicable verification tests. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-14-15-94 . . . . . . . . . . . . . . . . . 0.8 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set Absolute Pressure Sensor: All Technical Service Bulletins MAP Sensor - DTC's 13 or 14 Set Models 1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies Subject MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines Index DRIVEABILITY Date January 29, 1990 No. 18-03-90 (C18-20-9) P-164 BODY CODE LEGEND AA - ACCLAIM/,SPIRIT LEBARON LANDAU C/AC - DYNASTY/NEW YORKER LANDAU/SALON E - CARAVELLE/600 G/AG - DAYTONA H/AH - LANCER/LEBARON GTS J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE K/AK - ARIES/RELIANT P/AP - SHADOW/SUNDANCE S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle diagnostic memory. PARTS REQUIRED 1 MAP Sensor PN 5227351 1 Sensor Hose (3.0L Engine Only) PN 4557138 REPAIR PROCEDURE When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service Manual for replacement procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption Absolute Pressure Sensor: All Technical Service Bulletins Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 2074 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Engine Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2078 Intake Air Temperature Sensor: Description and Operation Fig. 5 Coolant & charge temperature sensors The charge temperature switch, Fig. 5, is mounted in the intake manifold and measures the temperature of the air/fuel mixture. This information is used by the SMEC to modify the air/fuel mixture. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Switch > Component Information > Locations Intake Air Temperature Switch: Locations RH Side Of Air Cleaner Assembly Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 182188 > Dec > 88 > AIS Motor - Erratic Idle Speed In Cold Ambients Auxiliary Air Valve (Idle Speed): Customer Interest AIS Motor - Erratic Idle Speed In Cold Ambients Models 1987-1989 C- & SBody Vehicles Equipped With 3.0L Engines Subject Erratic Idle Speed in Cold Ambients Index DRIVEABILITY Date December 12, 1988 No. 18-21-88 (C18-26) SYMPTOM/CONDITION Vehicles driven consistently in cold ambients may exhibit an erratic idle due to an A.I.S. motor failure. A revised A.I.S. motor is now available for those areas. NOTE: ERRATIC IDLE CONDITION MAY NOT SHOW UP WHEN USING THE DIAGNOSTIC TEST PROCEDURE, DUE TO THE WARM IN-SHOP AMBIENT TEMPERATURES. PARTS REQUIRED 1987-1988 3.0L VEHICLES 1 A.I.S. Motor PN 4458366 1989 3.0L VEHICLES 1 A.I.S. Motor PN 4458355 REPAIR PROCEDURE This repair involves replacing the A.I.S. motor with a revised A.I.S. motor. 1. Remove A.I.S. motor as outlined in the service manual. NOTE: FOR DIFFICULTY IN REMOVING A.I.S. MOTOR ATTACHING SCREWS, REFER TO TECHNICAL SERVICE BULLETIN 14-07-88. 2. Install new A.I.S. motor as outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-30-23-93 . . . . . . . . . 0.5 Hrs. FAILURE CODE: 61 - Intermittent Operation Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 182188 > Dec > 88 > AIS Motor - Erratic Idle Speed In Cold Ambients Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins AIS Motor - Erratic Idle Speed In Cold Ambients Models 1987-1989 C- & SBody Vehicles Equipped With 3.0L Engines Subject Erratic Idle Speed in Cold Ambients Index DRIVEABILITY Date December 12, 1988 No. 18-21-88 (C18-26) SYMPTOM/CONDITION Vehicles driven consistently in cold ambients may exhibit an erratic idle due to an A.I.S. motor failure. A revised A.I.S. motor is now available for those areas. NOTE: ERRATIC IDLE CONDITION MAY NOT SHOW UP WHEN USING THE DIAGNOSTIC TEST PROCEDURE, DUE TO THE WARM IN-SHOP AMBIENT TEMPERATURES. PARTS REQUIRED 1987-1988 3.0L VEHICLES 1 A.I.S. Motor PN 4458366 1989 3.0L VEHICLES 1 A.I.S. Motor PN 4458355 REPAIR PROCEDURE This repair involves replacing the A.I.S. motor with a revised A.I.S. motor. 1. Remove A.I.S. motor as outlined in the service manual. NOTE: FOR DIFFICULTY IN REMOVING A.I.S. MOTOR ATTACHING SCREWS, REFER TO TECHNICAL SERVICE BULLETIN 14-07-88. 2. Install new A.I.S. motor as outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-30-23-93 . . . . . . . . . 0.5 Hrs. FAILURE CODE: 61 - Intermittent Operation Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Barometric Pressure Sensor: Locations Engine Compartment Components. RH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2102 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2107 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Top RH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 2113 Engine Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2114 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 5 Coolant & charge temperature sensors The coolant temperature sensor, Fig. 5, is mounted in the thermostat housing and allows the SMEC to monitor engine operating temperature in order to provide proper air/fuel mixtures. The sensor provides a variable resistance which is proportional to coolant temperature. When the engine is cold and sensor resistance is low, the SMEC provides richer air/fuel mixtures and increases engine idle speed to provide acceptable cold engine performance and allow quick warm up. When coolant temperature and sensor resistance increase, the SMEC provides leaner air/fuel mixtures and lowers engine idle speed to provide proper exhaust emission control and increased fuel economy. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Senior 105 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2120 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2121 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect distributor lead wire at wiring harness connector. 2. Remove distributor cap retaining screws and remove distributor cap. 3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum. Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when reinstalling the distributor. 4. Remove the distributor hold down nut and remove the distributor from the engine. DISASSEMBLY 1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and remove lead wire. 2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or damaged slots. 3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing. 4. Remove 2 bearing retainer screws. 5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the distributor drive gear roll pin. 6. Remove distributor drive gear, remove distributor shaft and bearing assembly. REASSEMBLY 1. Install shaft and bearing assembly in distributor housing. 2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference marks made during disassembly, and install roll pin. 3. Install distributor shaft bearing retaining screws. 4. Install the photo optic sensing unit and bushing and tighten with 3 screws. 5. Install disk spacers and disk. Install disk assembly screw. 6. Install lead wire, and lead wire clamp screw. 7. Install protective cover on distributor housing. INSTALLATION 1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If engine has been cranked with distributor removed proceed to step 3 for installation. 2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the distributor is installed, the rotor will be in line with the previously scribed line on the air intake plenum. Proceed to step 4. 3. If the engine has been cranked with the distributor removed perform the following procedure: a. Rotate the crankshaft until the number one piston is at the top of its compression stroke. Distributor Cap Terminal Routing b. Rotate the distributor shaft until the rotor points to number one terminal. c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam shaft. With the distributor fully seated the rotor should be under the number one terminal. 4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers. Install hold down nut finger tight. 5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to ADJUSTMENT PROCEDURES for timing adjustment. . Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Engine Compartment Components The Diagnostic Connector is found on the left side of the engine compartment, behind the battery, and near the left strut tower. It is also near the Auto Shut Down (ASD) Relay. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Engine Control Module: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 2133 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds Engine Control Module: Customer Interest ECM - Engine Die Out at Low Speeds NO.: 18-11-91 GROUP: DRIVEABILITY DATE: Aug. 26, 1991 SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L & 3.3L Engines MODELS: 1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON (AQ) CHRYSLER'S TC (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY (AY) IMPERIAL/NEW YORKER FIFTH AVENUE THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH >> ARROWS <<. SYMPTOM/CONDITION: Vehicle may exhibit either or both of the following conditions: Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine dies out when throttle is closed. Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM but fail to continue idling. Engine will run normally if throttle is held open. These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on for extended periods of time and only when the ambient temperature is above 40~ F (4~ C). DIAGNOSIS: Connect a DRB II tester to the vehicle diagnostic connector. 1. With the engine at normal operating temperature and with the AC on, record the AIS position while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following repair procedure. PARTS REQUIRED: 1 Single Module Engine Controller (SMEC) 1989 3.0L Engine AS Body, Federal 4639386 AS Body, California 4639001 AC Body, Federal 4639382 AC Body, California 4639384 1990 3.0L Engine >> AS Body, Federal (except Town & Country) 4639422 << >> AS Body, California (except Town & Country) 4639424 << AC & AY Bodies, Federal 4639398 AC & AY Bodies, California 4639400 AQ Body, Federal 4650386 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds > Page 2138 AQ Body, California 4650388 >> AS Body, Federal (except Town & Country) 4639386 << >> AS Body, California (except Town & Country) 4639001 << 1990 3.3L Engine AS Body, Federal 4672435 AS Body, California 4672438 AC & AY Bodies, Federal 4672440 AC & AY Bodies, California 4672431 1 Authorized Modification Label 4275086 REPAIR PROCEDURE: This repair involves the replacement of the engine controller with a revised one. 1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS REQUIRED. Figure 1 2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1, and attached near the VECI label. * INSERT PART NUMBER USED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Engine Control Module: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 2144 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds Engine Control Module: All Technical Service Bulletins ECM - Engine Die Out at Low Speeds NO.: 18-11-91 GROUP: DRIVEABILITY DATE: Aug. 26, 1991 SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L & 3.3L Engines MODELS: 1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON (AQ) CHRYSLER'S TC (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY (AY) IMPERIAL/NEW YORKER FIFTH AVENUE THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH >> ARROWS <<. SYMPTOM/CONDITION: Vehicle may exhibit either or both of the following conditions: Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine dies out when throttle is closed. Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM but fail to continue idling. Engine will run normally if throttle is held open. These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on for extended periods of time and only when the ambient temperature is above 40~ F (4~ C). DIAGNOSIS: Connect a DRB II tester to the vehicle diagnostic connector. 1. With the engine at normal operating temperature and with the AC on, record the AIS position while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following repair procedure. PARTS REQUIRED: 1 Single Module Engine Controller (SMEC) 1989 3.0L Engine AS Body, Federal 4639386 AS Body, California 4639001 AC Body, Federal 4639382 AC Body, California 4639384 1990 3.0L Engine >> AS Body, Federal (except Town & Country) 4639422 << >> AS Body, California (except Town & Country) 4639424 << AC & AY Bodies, Federal 4639398 AC & AY Bodies, California 4639400 AQ Body, Federal 4650386 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds > Page 2149 AQ Body, California 4650388 >> AS Body, Federal (except Town & Country) 4639386 << >> AS Body, California (except Town & Country) 4639001 << 1990 3.3L Engine AS Body, Federal 4672435 AS Body, California 4672438 AC & AY Bodies, Federal 4672440 AC & AY Bodies, California 4672431 1 Authorized Modification Label 4275086 REPAIR PROCEDURE: This repair involves the replacement of the engine controller with a revised one. 1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS REQUIRED. Figure 1 2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1, and attached near the VECI label. * INSERT PART NUMBER USED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations Engine Control Module: Component Locations Single Module Engine Controller The Single Module Engine Controller is located on the front left hand side of the engine compartment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 2152 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2155 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2156 Engine Control Module: Connector Views 14-Way Connector (1989 3.0) Single Module Engine Controller Connector(14-Way) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2157 Single Module Engine Controller Connector(60-Way) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2158 60 Way (SMEC) Wiring Connector Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2159 Engine Control Module: Description and Operation Fig. 2 Single Module Engine Controller (SMEC) The SMEC, Fig. 2, is mounted in the engine compartment and contains circuits necessary to energize the ignition coil, fuel injectors and alternator field in order to minimize electrical noise in the passenger compartment. The SMEC contains a voltage converter which converts battery voltage into a regulated 8 volt output to energize the ignition pick up coil. The externally mounted Automatic Shut Down (ASD) relay which interrupts power to the fuel pump, ignition coil and injector when necessary is controlled by the SMEC. The ASD relay is turned on and off by the SMEC in response to distributor reference pulses. When distributor reference pulses are transmitted to the SMEC, the SMEC activates the ASD relay. However, when no reference pulse is transmitted to the SMEC, the ASD relay is deactivated and power is shut off to the fuel control system and ignition coil. The SMEC has been programmed to monitor several different circuits of the fuel injection system in order to provide a self-diagnosis function. In conjunction with the self-diagnosis function, a check engine lamp is wired into the system to indicate a failure in the monitored circuits. The check engine lamp is illuminated for 3 seconds whenever the engine is started as a `bulb test.' However, if the SMEC detects a malfunction in one of the monitored circuits the check engine lamp will be illuminated and will remain on as long as the ignition key remains in the on position. Illumination of the check engine lamp indicates that the system has entered the `limp-in' mode and signals an immediate need for system service. If vehicle performance or the check engine lamp indicate fuel injection system malfunctions, certain procedures should be followed. Prior to suspecting the fuel injection service as the cause for complaints, ensure that the engine and all related systems are in proper operating condition. After checking related systems, inspect fuel injection components and connecting harnesses as outlined in Visual Inspection, repair system as indicated, then road test vehicle to check system operation. If service performed during visual inspection does not correct observed malfunctions, or if check engine lamp remains illuminated, refer to `Obtaining fault codes' to call up fault codes stored in the SMEC memory and correct as needed. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2160 Engine Control Module: Service and Repair 1. Remove air cleaner duct from SMEC. 2. Remove battery. 3. Remove two SMEC mounting screws. 4. Remove SMEC electrical connectors. 5. Remove SMEC. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations Idle Speed/Throttle Actuator - Electronic: Component Locations LH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations > Page 2165 Engine Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2166 Idle Speed/Throttle Actuator - Electronic: Description and Operation The AIS motor is operated by the SMEC and controls engine idle speed by controlling air flow through the throttle body by-pass channel. The SMEC computes proper idle speed based in signals from vehicle and engine sensors and the switch inputs, and transmits voltage signals to the AIS motor to open or close the by-pass channel in order to maintain the proper engine speed. Basic, no-load idle speed is determined by the amount of air flowing through the throttle body past the closed throttle plate. The AIS motor alters idle speed by allowing increased air flow through the by-pass channel; increasing idle speed when the channel is opened and decreasing idle speed when the channel is closed. In addition, the AIS motor is signaled to open the by-pass channel during deceleration to prevent stalling and mixture enrichment caused by sudden closing of the throttle plate. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2167 Idle Speed/Throttle Actuator - Electronic: Service and Repair 1. Disconnect battery ground cable, then remove air cleaner assembly. 2. Disconnect four pin connector from AIS, then remove temperature sending unit from throttle body housing. 3. Remove two AIS to throttle body torx head retaining screws. 4. Remove AIS from throttle body housing with O-ring. 5. Reverse procedure to install. Install new O-ring and torque retaining screws to 20 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Relay Locations--next To Battery The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the inner fender. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 2172 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions Main Relay (Computer/Fuel System): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions > Page 2175 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Page 2176 Main Relay (Computer/Fuel System): Description and Operation Relay Locations--next To Battery The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel injectors, and electric fuel pump at all times when the ignition switch is in the START position. When the ignition switch is in the RUN position and the engine control module is receiving reference signals from the distributor, power will also be supplied. If there is no reference signal after two seconds the engine control module will de-energize the ASD and no power will be supplied to the ignition coil, fuel injectors, or electric fuel pump. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay Relay Terminal Identification ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with circuit codes, and color codes, and their function: Circuit No. Terminal No. Color Code Description J1 30 Red Has battery input voltage supplied through fusible link. Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output voltage to fuel pump, O2 sensor, fuel injectors, and coil. K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine Controller (SMEC). The SMEC provides input voltage to relay. K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when distributor signal is present. N/A 87A N/A Not used in these applications. ASD RELAY TEST NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent. Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no scanner is available proceed with the following test. 1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage. If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present proceed to step 2. 2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to the START position and crank the engine. If Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2179 output voltage is present during cranking, the ASD relay is functioning normally and no further testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3. 3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86) wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD relay, and test operation. 4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning, and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14 (terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists replace and ASD relay and test operation. 5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58 of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Malfunction Indicator Lamp Driver Module > Component Information > Locations Malfunction Indicator Lamp Driver Module: Locations Upper I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations Engine Compartment Components. RH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 2188 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2189 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 3 Manifold Absolute Pressure (MAP) sensor location The MAP sensor, Fig. 3, is mounted in the engine compartment on the dash panel and monitors intake manifold vacuum through a line connected to the intake plenum. The sensor converts manifold vacuum (negative pressure) and barometric pressure into electrical signals and transmits these signals to the SMEC. The SMEC uses these signals to monitor engine load and atmospheric conditions in order to determine the correct air/fuel mixture for vehicle operating conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2190 Manifold Pressure/Vacuum Sensor: Service and Repair 1. Remove vacuum hose from sensor. 2. Remove sensor attaching screws, then the sensor. 3. Reverse procedure to install. Ensure proper installation of vacuum hose to sensor and sensor to dash panel. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations On Exhaust Manifold Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2196 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2197 Oxygen Sensor: Description and Operation Fig. 4 Oxygen sensor The oxygen sensor, Fig. 4, produces voltage signals when exposed to oxygen in the exhaust gasses. The oxygen content in the exhaust gasses is directly proportional to the air/fuel mixture entering the engine, and the voltage signal produced by the sensor is inversely proportional to the amount of oxygen remaining in the exhaust gasses. The SMEC uses these signals to determine air/fuel mixtures entering the engine. The oxygen sensor is mounted in the rear exhaust manifold, and the sensing element must be heated by exhaust gasses before the sensor begins to produce voltage signals. When exhaust gas oxygen content is high (lean mixtures), the sensor produces a low voltage. When oxygen content is low (rich mixtures), the sensor produces a higher voltage. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2198 Oxygen Sensor: Service and Repair The oxygen sensor is to be removed using tool No. C-4907 or equivalent. After removal, clean threads in exhaust manifold using an 18mm x 1.5 x 6E tap. If reinstalling the same sensor, apply a suitable anti-seize to threads of sensor. New sensors are packaged with an anti-seize compound already applied to the threads and no further application is required. When installing sensor, torque to 20 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2204 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Engine Control Module: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 2213 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds Engine Control Module: Customer Interest ECM - Engine Die Out at Low Speeds NO.: 18-11-91 GROUP: DRIVEABILITY DATE: Aug. 26, 1991 SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L & 3.3L Engines MODELS: 1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON (AQ) CHRYSLER'S TC (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY (AY) IMPERIAL/NEW YORKER FIFTH AVENUE THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH >> ARROWS <<. SYMPTOM/CONDITION: Vehicle may exhibit either or both of the following conditions: Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine dies out when throttle is closed. Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM but fail to continue idling. Engine will run normally if throttle is held open. These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on for extended periods of time and only when the ambient temperature is above 40~ F (4~ C). DIAGNOSIS: Connect a DRB II tester to the vehicle diagnostic connector. 1. With the engine at normal operating temperature and with the AC on, record the AIS position while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following repair procedure. PARTS REQUIRED: 1 Single Module Engine Controller (SMEC) 1989 3.0L Engine AS Body, Federal 4639386 AS Body, California 4639001 AC Body, Federal 4639382 AC Body, California 4639384 1990 3.0L Engine >> AS Body, Federal (except Town & Country) 4639422 << >> AS Body, California (except Town & Country) 4639424 << AC & AY Bodies, Federal 4639398 AC & AY Bodies, California 4639400 AQ Body, Federal 4650386 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds > Page 2218 AQ Body, California 4650388 >> AS Body, Federal (except Town & Country) 4639386 << >> AS Body, California (except Town & Country) 4639001 << 1990 3.3L Engine AS Body, Federal 4672435 AS Body, California 4672438 AC & AY Bodies, Federal 4672440 AC & AY Bodies, California 4672431 1 Authorized Modification Label 4275086 REPAIR PROCEDURE: This repair involves the replacement of the engine controller with a revised one. 1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS REQUIRED. Figure 1 2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1, and attached near the VECI label. * INSERT PART NUMBER USED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Engine Control Module: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 2224 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds Engine Control Module: All Technical Service Bulletins ECM - Engine Die Out at Low Speeds NO.: 18-11-91 GROUP: DRIVEABILITY DATE: Aug. 26, 1991 SUBJECT: Start-Stall and/or Decel Dieout During Parking Lot (Low Speed) Maneuvers - 3.0L & 3.3L Engines MODELS: 1989-90 (AC) DYNASTY/NEW YORKER LANDAU/SALON (AQ) CHRYSLER'S TC (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY (AY) IMPERIAL/NEW YORKER FIFTH AVENUE THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-31-90, DATED 12/17/90 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH >> ARROWS <<. SYMPTOM/CONDITION: Vehicle may exhibit either or both of the following conditions: Parking lot (low speed) maneuvering dieout: Throttle is opened briefly to move vehicle and engine dies out when throttle is closed. Start up dieout: Engine will start but fail to run up to idle RPM, or it will initially run up to idle RPM but fail to continue idling. Engine will run normally if throttle is held open. These conditions will occur only on vehicles with non-cycling AC compressor when the AC is left on for extended periods of time and only when the ambient temperature is above 40~ F (4~ C). DIAGNOSIS: Connect a DRB II tester to the vehicle diagnostic connector. 1. With the engine at normal operating temperature and with the AC on, record the AIS position while idling in DRIVE. Then, with the left foot on the brake and parking brake engaged, open throttle slightly (less than 1/4 throttle) and again record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 2. With the engine at normal operating temperature and the AC off, idle in DRIVE for five minutes to allow AIS to update itself. Again, with left foot on the brake and the parking brake engaged, open throttle slightly and record the AIS position. Is the AIS position with the throttle open less than the AIS position at idle in DRIVE? 3. If the answer to Step 1 is "Yes" and the answer to Step 2 is "No", proceed with the following repair procedure. PARTS REQUIRED: 1 Single Module Engine Controller (SMEC) 1989 3.0L Engine AS Body, Federal 4639386 AS Body, California 4639001 AC Body, Federal 4639382 AC Body, California 4639384 1990 3.0L Engine >> AS Body, Federal (except Town & Country) 4639422 << >> AS Body, California (except Town & Country) 4639424 << AC & AY Bodies, Federal 4639398 AC & AY Bodies, California 4639400 AQ Body, Federal 4650386 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 181191 > Aug > 91 > ECM - Engine Die Out at Low Speeds > Page 2229 AQ Body, California 4650388 >> AS Body, Federal (except Town & Country) 4639386 << >> AS Body, California (except Town & Country) 4639001 << 1990 3.3L Engine AS Body, Federal 4672435 AS Body, California 4672438 AC & AY Bodies, Federal 4672440 AC & AY Bodies, California 4672431 1 Authorized Modification Label 4275086 REPAIR PROCEDURE: This repair involves the replacement of the engine controller with a revised one. 1. Replace the engine controller (SMEC/SBEC) with the appropriate unit called out in PARTS REQUIRED. Figure 1 2. Type the required information on the Authorized Modification Label, as illustrated in Figure 1, and attached near the VECI label. * INSERT PART NUMBER USED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-90-93 . . . . . . . . . . . . . . . . . 0.5 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations Engine Control Module: Component Locations Single Module Engine Controller The Single Module Engine Controller is located on the front left hand side of the engine compartment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 2232 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2235 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2236 Engine Control Module: Connector Views 14-Way Connector (1989 3.0) Single Module Engine Controller Connector(14-Way) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2237 Single Module Engine Controller Connector(60-Way) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2238 60 Way (SMEC) Wiring Connector Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2239 Engine Control Module: Description and Operation Fig. 2 Single Module Engine Controller (SMEC) The SMEC, Fig. 2, is mounted in the engine compartment and contains circuits necessary to energize the ignition coil, fuel injectors and alternator field in order to minimize electrical noise in the passenger compartment. The SMEC contains a voltage converter which converts battery voltage into a regulated 8 volt output to energize the ignition pick up coil. The externally mounted Automatic Shut Down (ASD) relay which interrupts power to the fuel pump, ignition coil and injector when necessary is controlled by the SMEC. The ASD relay is turned on and off by the SMEC in response to distributor reference pulses. When distributor reference pulses are transmitted to the SMEC, the SMEC activates the ASD relay. However, when no reference pulse is transmitted to the SMEC, the ASD relay is deactivated and power is shut off to the fuel control system and ignition coil. The SMEC has been programmed to monitor several different circuits of the fuel injection system in order to provide a self-diagnosis function. In conjunction with the self-diagnosis function, a check engine lamp is wired into the system to indicate a failure in the monitored circuits. The check engine lamp is illuminated for 3 seconds whenever the engine is started as a `bulb test.' However, if the SMEC detects a malfunction in one of the monitored circuits the check engine lamp will be illuminated and will remain on as long as the ignition key remains in the on position. Illumination of the check engine lamp indicates that the system has entered the `limp-in' mode and signals an immediate need for system service. If vehicle performance or the check engine lamp indicate fuel injection system malfunctions, certain procedures should be followed. Prior to suspecting the fuel injection service as the cause for complaints, ensure that the engine and all related systems are in proper operating condition. After checking related systems, inspect fuel injection components and connecting harnesses as outlined in Visual Inspection, repair system as indicated, then road test vehicle to check system operation. If service performed during visual inspection does not correct observed malfunctions, or if check engine lamp remains illuminated, refer to `Obtaining fault codes' to call up fault codes stored in the SMEC memory and correct as needed. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2240 Engine Control Module: Service and Repair 1. Remove air cleaner duct from SMEC. 2. Remove battery. 3. Remove two SMEC mounting screws. 4. Remove SMEC electrical connectors. 5. Remove SMEC. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Relay Locations--next To Battery The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the inner fender. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 2245 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions Main Relay (Computer/Fuel System): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions > Page 2248 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Page 2249 Main Relay (Computer/Fuel System): Description and Operation Relay Locations--next To Battery The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel injectors, and electric fuel pump at all times when the ignition switch is in the START position. When the ignition switch is in the RUN position and the engine control module is receiving reference signals from the distributor, power will also be supplied. If there is no reference signal after two seconds the engine control module will de-energize the ASD and no power will be supplied to the ignition coil, fuel injectors, or electric fuel pump. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay Relay Terminal Identification ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with circuit codes, and color codes, and their function: Circuit No. Terminal No. Color Code Description J1 30 Red Has battery input voltage supplied through fusible link. Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output voltage to fuel pump, O2 sensor, fuel injectors, and coil. K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine Controller (SMEC). The SMEC provides input voltage to relay. K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when distributor signal is present. N/A 87A N/A Not used in these applications. ASD RELAY TEST NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent. Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no scanner is available proceed with the following test. 1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage. If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present proceed to step 2. 2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to the START position and crank the engine. If Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2252 output voltage is present during cranking, the ASD relay is functioning normally and no further testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3. 3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86) wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD relay, and test operation. 4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning, and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14 (terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists replace and ASD relay and test operation. 5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58 of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Polarity Protection Relay, ECM > Component Information > Locations Polarity Protection Relay: Locations Relay Identification The ASD relay is found on the left inner fender apron near the left strut tower and the diagnostic connector. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Polarity Protection Relay, ECM > Component Information > Locations Polarity Protection Relay: Locations Relay Identification The ASD relay is found on the left inner fender apron near the left strut tower and the diagnostic connector. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Absolute Pressure Sensor: Customer Interest PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 2268 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 Absolute Pressure Sensor: Customer Interest Check Engine Lamp Comes On and Fault Code 13 NO.: 18-09-91 GROUP: DRIVEABILITY DATE: Sept. 23, 1991 SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine MODELS: 1989 (AA) SPIRIT/ACCLAIM 1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON 1989 (AG) DAYTONA 1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE 1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER SYMPTOM/CONDITION: The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic Change" is set into the diagnostic system. DIAGNOSIS: Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the diagnostic manual to verify that the MAP sensor is operating properly. PARTS REQUIRED: 1 MAP Sensor Relocation Package 4638458 Package Contents: 1 Cap Plug (1987-88 vehicles) 3580172 1 Cap Plug (1989 vehicles) 4241618 1 Purge Jumper Assembly 4669038 Consisting of: 1 In-Line Vacuum Connector 4201275 1 Vacuum Tee 33000227 1 11" Vacuum Hose 4104272 1 Bleed/Hose Assembly 4669042 Consisting of: 1 Vent 53007494 1 1" Vacuum Hose 4713956 1 Vacuum Tee 4669041 2 Vacuum Hose With 90 Degree Bend 4669044 1 Bracket 4686013 1 Wiring Harness 4687141 5 Tie Wraps 6015756 REPAIR PROCEDURE: This repair involves relocation of the MAP sensor. 1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable. 2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its present location. 3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug (3580172 for 1987 and 1988 vehicles or 4241618 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2273 for 1989 vehicles) in its place. 4. Loosen clamps and remove throttle body/air filter intake hose. 5. Wiring Harness Installation Procedure: If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted on the right side shock tower or on the bulkhead follow Step B. A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor connector. Route the harness along the backside of the intake manifold toward the throttle body. The harness should be secured to the fuel line and to the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps. B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length. Connect the FEMALE end of the harness to the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the harness to the right side of the motor mount and the two rear engine wiring support brackets. Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the supplied tie wraps. 6. Attach original MAP sensor to the bracket (4686013) supplied in the package. Figure 1 7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to slide over throttle body stud. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2274 Figure 2 8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque nut to 25 N-m (225 in.lbs.). 9. Disconnect the intake manifold end of the formed purge hose that extends from the intake manifold nipple to the "F" shaped connector (Figure 2). Figure 3 10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to nipple on intake manifold. Position the MAP bleed valve as close to vertical as possible. Figure 4 11. Cut the existing PVC hose as shown in Figure 2. 12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the formed purge hose (disconnected in Step 9) and the PVC hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed purge hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2275 Figure 5 NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE IT OVER THE TOP OF THROTTLE LINKAGE. 13. Connect vacuum hose to MAP sensor. 14. Connect wiring harness connector to MAP sensor. 15. Install throttle body/air filter intake hose and tighten clamps. 16. Use the DRB II to erase any fault codes and perform the applicable verification tests. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-14-15-94 . . . . . . . . . . . . . . . . . 0.8 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set Absolute Pressure Sensor: Customer Interest MAP Sensor - DTC's 13 or 14 Set Models 1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies Subject MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines Index DRIVEABILITY Date January 29, 1990 No. 18-03-90 (C18-20-9) P-164 BODY CODE LEGEND AA - ACCLAIM/,SPIRIT LEBARON LANDAU C/AC - DYNASTY/NEW YORKER LANDAU/SALON E - CARAVELLE/600 G/AG - DAYTONA H/AH - LANCER/LEBARON GTS J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE K/AK - ARIES/RELIANT P/AP - SHADOW/SUNDANCE S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle diagnostic memory. PARTS REQUIRED 1 MAP Sensor PN 5227351 1 Sensor Hose (3.0L Engine Only) PN 4557138 REPAIR PROCEDURE When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service Manual for replacement procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption Absolute Pressure Sensor: Customer Interest Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 2284 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Absolute Pressure Sensor: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 2290 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 Absolute Pressure Sensor: All Technical Service Bulletins Check Engine Lamp Comes On and Fault Code 13 NO.: 18-09-91 GROUP: DRIVEABILITY DATE: Sept. 23, 1991 SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine MODELS: 1989 (AA) SPIRIT/ACCLAIM 1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON 1989 (AG) DAYTONA 1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE 1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER SYMPTOM/CONDITION: The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic Change" is set into the diagnostic system. DIAGNOSIS: Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the diagnostic manual to verify that the MAP sensor is operating properly. PARTS REQUIRED: 1 MAP Sensor Relocation Package 4638458 Package Contents: 1 Cap Plug (1987-88 vehicles) 3580172 1 Cap Plug (1989 vehicles) 4241618 1 Purge Jumper Assembly 4669038 Consisting of: 1 In-Line Vacuum Connector 4201275 1 Vacuum Tee 33000227 1 11" Vacuum Hose 4104272 1 Bleed/Hose Assembly 4669042 Consisting of: 1 Vent 53007494 1 1" Vacuum Hose 4713956 1 Vacuum Tee 4669041 2 Vacuum Hose With 90 Degree Bend 4669044 1 Bracket 4686013 1 Wiring Harness 4687141 5 Tie Wraps 6015756 REPAIR PROCEDURE: This repair involves relocation of the MAP sensor. 1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable. 2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its present location. 3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug (3580172 for 1987 and 1988 vehicles or 4241618 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2295 for 1989 vehicles) in its place. 4. Loosen clamps and remove throttle body/air filter intake hose. 5. Wiring Harness Installation Procedure: If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted on the right side shock tower or on the bulkhead follow Step B. A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor connector. Route the harness along the backside of the intake manifold toward the throttle body. The harness should be secured to the fuel line and to the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps. B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length. Connect the FEMALE end of the harness to the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the harness to the right side of the motor mount and the two rear engine wiring support brackets. Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the supplied tie wraps. 6. Attach original MAP sensor to the bracket (4686013) supplied in the package. Figure 1 7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to slide over throttle body stud. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2296 Figure 2 8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque nut to 25 N-m (225 in.lbs.). 9. Disconnect the intake manifold end of the formed purge hose that extends from the intake manifold nipple to the "F" shaped connector (Figure 2). Figure 3 10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to nipple on intake manifold. Position the MAP bleed valve as close to vertical as possible. Figure 4 11. Cut the existing PVC hose as shown in Figure 2. 12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the formed purge hose (disconnected in Step 9) and the PVC hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed purge hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 2297 Figure 5 NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE IT OVER THE TOP OF THROTTLE LINKAGE. 13. Connect vacuum hose to MAP sensor. 14. Connect wiring harness connector to MAP sensor. 15. Install throttle body/air filter intake hose and tighten clamps. 16. Use the DRB II to erase any fault codes and perform the applicable verification tests. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-14-15-94 . . . . . . . . . . . . . . . . . 0.8 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set Absolute Pressure Sensor: All Technical Service Bulletins MAP Sensor - DTC's 13 or 14 Set Models 1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies Subject MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines Index DRIVEABILITY Date January 29, 1990 No. 18-03-90 (C18-20-9) P-164 BODY CODE LEGEND AA - ACCLAIM/,SPIRIT LEBARON LANDAU C/AC - DYNASTY/NEW YORKER LANDAU/SALON E - CARAVELLE/600 G/AG - DAYTONA H/AH - LANCER/LEBARON GTS J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE K/AK - ARIES/RELIANT P/AP - SHADOW/SUNDANCE S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle diagnostic memory. PARTS REQUIRED 1 MAP Sensor PN 5227351 1 Sensor Hose (3.0L Engine Only) PN 4557138 REPAIR PROCEDURE When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service Manual for replacement procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption Absolute Pressure Sensor: All Technical Service Bulletins Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Absolute Pressure Sensor: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 2306 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Barometric Pressure Sensor: Locations Engine Compartment Components. RH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2314 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Top RH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 2320 Engine Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2321 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 5 Coolant & charge temperature sensors The coolant temperature sensor, Fig. 5, is mounted in the thermostat housing and allows the SMEC to monitor engine operating temperature in order to provide proper air/fuel mixtures. The sensor provides a variable resistance which is proportional to coolant temperature. When the engine is cold and sensor resistance is low, the SMEC provides richer air/fuel mixtures and increases engine idle speed to provide acceptable cold engine performance and allow quick warm up. When coolant temperature and sensor resistance increase, the SMEC provides leaner air/fuel mixtures and lowers engine idle speed to provide proper exhaust emission control and increased fuel economy. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Senior 105 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2327 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2328 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect distributor lead wire at wiring harness connector. 2. Remove distributor cap retaining screws and remove distributor cap. 3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum. Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when reinstalling the distributor. 4. Remove the distributor hold down nut and remove the distributor from the engine. DISASSEMBLY 1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and remove lead wire. 2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or damaged slots. 3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing. 4. Remove 2 bearing retainer screws. 5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the distributor drive gear roll pin. 6. Remove distributor drive gear, remove distributor shaft and bearing assembly. REASSEMBLY 1. Install shaft and bearing assembly in distributor housing. 2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference marks made during disassembly, and install roll pin. 3. Install distributor shaft bearing retaining screws. 4. Install the photo optic sensing unit and bushing and tighten with 3 screws. 5. Install disk spacers and disk. Install disk assembly screw. 6. Install lead wire, and lead wire clamp screw. 7. Install protective cover on distributor housing. INSTALLATION 1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If engine has been cranked with distributor removed proceed to step 3 for installation. 2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the distributor is installed, the rotor will be in line with the previously scribed line on the air intake plenum. Proceed to step 4. 3. If the engine has been cranked with the distributor removed perform the following procedure: a. Rotate the crankshaft until the number one piston is at the top of its compression stroke. Distributor Cap Terminal Routing b. Rotate the distributor shaft until the rotor points to number one terminal. c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam shaft. With the distributor fully seated the rotor should be under the number one terminal. 4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers. Install hold down nut finger tight. 5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to ADJUSTMENT PROCEDURES for timing adjustment. . Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Engine Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2332 Intake Air Temperature Sensor: Description and Operation Fig. 5 Coolant & charge temperature sensors The charge temperature switch, Fig. 5, is mounted in the intake manifold and measures the temperature of the air/fuel mixture. This information is used by the SMEC to modify the air/fuel mixture. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Switch > Component Information > Locations Intake Air Temperature Switch: Locations RH Side Of Air Cleaner Assembly Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations Engine Compartment Components. RH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 2340 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2341 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 3 Manifold Absolute Pressure (MAP) sensor location The MAP sensor, Fig. 3, is mounted in the engine compartment on the dash panel and monitors intake manifold vacuum through a line connected to the intake plenum. The sensor converts manifold vacuum (negative pressure) and barometric pressure into electrical signals and transmits these signals to the SMEC. The SMEC uses these signals to monitor engine load and atmospheric conditions in order to determine the correct air/fuel mixture for vehicle operating conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2342 Manifold Pressure/Vacuum Sensor: Service and Repair 1. Remove vacuum hose from sensor. 2. Remove sensor attaching screws, then the sensor. 3. Reverse procedure to install. Ensure proper installation of vacuum hose to sensor and sensor to dash panel. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations On Exhaust Manifold Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2348 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2349 Oxygen Sensor: Description and Operation Fig. 4 Oxygen sensor The oxygen sensor, Fig. 4, produces voltage signals when exposed to oxygen in the exhaust gasses. The oxygen content in the exhaust gasses is directly proportional to the air/fuel mixture entering the engine, and the voltage signal produced by the sensor is inversely proportional to the amount of oxygen remaining in the exhaust gasses. The SMEC uses these signals to determine air/fuel mixtures entering the engine. The oxygen sensor is mounted in the rear exhaust manifold, and the sensing element must be heated by exhaust gasses before the sensor begins to produce voltage signals. When exhaust gas oxygen content is high (lean mixtures), the sensor produces a low voltage. When oxygen content is low (rich mixtures), the sensor produces a higher voltage. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2350 Oxygen Sensor: Service and Repair The oxygen sensor is to be removed using tool No. C-4907 or equivalent. After removal, clean threads in exhaust manifold using an 18mm x 1.5 x 6E tap. If reinstalling the same sensor, apply a suitable anti-seize to threads of sensor. New sensors are packaged with an anti-seize compound already applied to the threads and no further application is required. When installing sensor, torque to 20 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure Revision Models 1989 AS Subject Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI Index MISCELLANEOUS Date December 29, 1989 No. 26-34-89 P-13 (C26-34-9) BODY CODE LEGEND AS - 1989 RAM VAN, CARAVAN, VOYAGER Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 2355 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 2356 DIAGNOSTIC MANUAL REVISION Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH. 1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No. 81-699-9017. Pages 136 and 137. Please affix these revised pages in your manual. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2357 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2358 Throttle Position Sensor: Locations LH Rear Corner Of Cylinder Head Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2361 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2362 Throttle Position Sensor: Description and Operation The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The sensor produces a voltage signal which increases and decreases according to throttle position. The SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide open throttle, acceleration and deceleration. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2363 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle body mounting screws. 3. Lift TPS from throttle shaft, then remove O-ring. 4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw to 20 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2372 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2373 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2374 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2380 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2381 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2386 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2387 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2388 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2394 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2395 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 2398 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 2399 Transmission Position Switch/Sensor: Locations 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 2400 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 2403 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 2406 Transmission Position Switch/Sensor: Description and Operation PRNDL The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. It may have been replaced by a transmission range sensor (TRS). Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 2409 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 2410 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 2411 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations LH Side Of Engine Compartment. Upper LH Corner Of Transaxle Applicable to: 1989 w/Electronic Transaxle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2417 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2418 Vehicle Speed Sensor: Description and Operation The distance sensor is located in the transaxle extension housing and signals vehicle motion to the SMEC by generating eight pulses per axle shaft revolution. The SMEC uses this signal along with signals from the throttle position sensor to determine between a closed throttle deceleration and a normal idle condition, thereby allowing the SMEC to maintain desired control of the AIS motor. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure Revision Models 1989 AS Subject Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI Index MISCELLANEOUS Date December 29, 1989 No. 26-34-89 P-13 (C26-34-9) BODY CODE LEGEND AS - 1989 RAM VAN, CARAVAN, VOYAGER Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 2423 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 2424 DIAGNOSTIC MANUAL REVISION Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH. 1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No. 81-699-9017. Pages 136 and 137. Please affix these revised pages in your manual. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2425 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2426 Throttle Position Sensor: Locations LH Rear Corner Of Cylinder Head Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2429 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2430 Throttle Position Sensor: Description and Operation The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The sensor produces a voltage signal which increases and decreases according to throttle position. The SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide open throttle, acceleration and deceleration. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2431 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle body mounting screws. 3. Lift TPS from throttle shaft, then remove O-ring. 4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw to 20 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2440 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2441 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2442 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2448 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2449 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2454 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2455 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2456 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2462 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2463 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 2466 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 2467 Transmission Position Switch/Sensor: Locations 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 2468 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 2471 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 2474 Transmission Position Switch/Sensor: Description and Operation PRNDL The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. It may have been replaced by a transmission range sensor (TRS). Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 2477 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 2478 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 2479 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations LH Side Of Engine Compartment. Upper LH Corner Of Transaxle Applicable to: 1989 w/Electronic Transaxle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2485 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2486 Vehicle Speed Sensor: Description and Operation The distance sensor is located in the transaxle extension housing and signals vehicle motion to the SMEC by generating eight pulses per axle shaft revolution. The SMEC uses this signal along with signals from the throttle position sensor to determine between a closed throttle deceleration and a normal idle condition, thereby allowing the SMEC to maintain desired control of the AIS motor. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service Precautions > Customer Safety Information Catalytic Converter: Customer Safety Information 1. On vehicles equipped with catalytic converters the following conditions must be observed; a. Use only "UNLEADED FUEL." b. Avoid running out of fuel. c. In case of poor engine operation (misfiring), avoid driving the vehicle and correct the problem as soon as possible. d. Avoid push starting the vehicle. 2. Service vehicle on regular scheduled maintenance intervals to ensure proper engine performance and lower emission levels. 3. Always be conscious of fuel odors and excessive tailpipe emission (black smoke), these are problem indicators. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service Precautions > Customer Safety Information > Page 2492 Catalytic Converter: Technician Safety Information ELECTRICAL AND ELECTRONIC 1. Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. 2. Don't disconnect the battery when the engine is running. 3. Fully release locks prior to disconnecting connections, ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 4. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 5. In order to disable the ignition system, unplug the primary connections only. NEVER disconnect the secondary leads to disable the ignition system. 6. Do not use a self powered test lamp to check continuity. 7. Do not create any arcing to check the continuity of a circuit. 8. When charging battery, ensure battery cables are removed. 9. When replacing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, record stored trouble codes. ECM memory will be erased when ground cable is removed. 10. When measuring voltage at the control unit harness connector, disconnect harness connector first, then turn ignition "ON" as necessary. 11. To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. 12. Avoid getting water on any of the Fuel or Engine Control System Components. 13. Fuel and Engine Control System wiring should be at least 4 inches away from high tension cables. 14. Never pierce ignition leads or insulator boots to connect timing lights or analyzers. Use proper adapters. 15. When removing a spark plug wire twist the boot one quarter turn and pull on the boot only, never the lead itself. 16. Always use recommended power source in each testing procedure. 17. Never apply battery power to a component unless told to do so in a test procedure. 18. Do not try to disassemble the control unit. 19. Never use an auxiliary starting assist device which has a voltage rating above 12 volts to start engine. 20. In cases of electrical welding (for instance, spot welding), disconnect the climate control, injection, cruise control, ECU and radio. 21. In case of temperature above 176°F (80°C), (example: infra-red spray booth), remove all ECMs. 22. The battery produces a hazardous gas (hydrogen), avoid creating sparks near battery. FUEL SYSTEMS 1. Do not operate the fuel pump without fuel in the lines. 2. On fuel injected models do not depress the accelerator pedal while trying to start the car. 3. Handle all fuel injection related parts with care as they may easily be damaged. 4. Always use new gaskets or O-rings when installing fuel lines or injectors. 5. Lightly lubricate O-rings and flare connections with gasoline. Do not use engine oil, gear lubricant or brake fluid. 6. After servicing fuel system, check for leaks and correct as needed. ENGINE AND EXHAUST 1. On vehicles equipped with catalytic converters, the following conditions must be observed: a. Use only "UNLEADED FUEL". b. Avoid running out of fuel. c. In case of poor engine operation (misfiring), avoid driving the vehicle and correct the problem as soon as possible. d. Do not disconnect a spark plug wire with the engine running. e. Avoid push starting the vehicle. f. If running on a dynamometer, make sure the catalytic converter is well ventilated. g. Use caution when working near the catalytic converter to prevent the possibility of burns. 2. Do not use silicone based products on an oxygen sensor equipped vehicle to avoid damaging the sensor. 3. When performing a compression test, remove the fuel pump relay. (This will prevent fuel from being fed to the injectors). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service Precautions > Customer Safety Information > Page 2493 Catalytic Converter: Vehicle Damage Warnings ELECTRICAL AND ELECTRONIC 1. Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. 2. Don't disconnect the battery when the engine is running. 3. Fully release locks prior to disconnecting connections, ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 4. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 5. In order to disable the ignition system, unplug the primary connections only. NEVER disconnect the secondary leads to disable the ignition system. 6. Do not use a self powered test lamp to check continuity. 7. Do not create any arcing to check the continuity of a circuit. 8. When charging battery, ensure battery cables are removed. 9. When replacing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, record stored trouble codes. ECM memory will be erased when ground cable is removed. 10. When measuring voltage at the control unit harness connector, disconnect harness connector first, then turn ignition "ON" as necessary. 11. To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. 12. Avoid getting water on any of the Fuel or Engine Control System Components. 13. Fuel and Engine Control System wiring should be at least 4 inches away from high tension cables. 14. Never pierce ignition leads or insulator boots to connect timing lights or analyzers. Use proper adapters. 15. When removing a spark plug wire twist the boot one quarter turn and pull on the boot only, never the lead itself. 16. Always use recommended power source in each testing procedure. 17. Never apply battery power to a component unless told to do so in a test procedure. 18. Do not try to disassemble the control unit. 19. Never use an auxiliary starting assist device which has a voltage rating above 12 volts to start engine. 20. In cases of electrical welding (for instance, spot welding), disconnect the climate control, injection, cruise control, ECU and radio. 21. In case of temperature above 176°F (80°C), (example: infra-red spray booth), remove all ECMs. 22. The battery produces a hazardous gas (hydrogen), avoid creating sparks near battery. FUEL SYSTEMS 1. Do not operate the fuel pump without fuel in the lines. 2. On fuel injected models do not depress the accelerator pedal while trying to start the car. 3. Handle all fuel injection related parts with care as they may easily be damaged. 4. Always use new gaskets or O-rings when installing fuel lines or injectors. 5. Lightly lubricate O-rings and flare connections with gasoline. Do not use engine oil, gear lubricant or brake fluid. 6. After servicing fuel system, check for leaks and correct as needed. ENGINE AND EXHAUST 1. On vehicles equipped with catalytic converters, the following conditions must be observed: a. Use only "UNLEADED FUEL". b. Avoid running out of fuel. c. In case of poor engine operation (misfiring), avoid driving the vehicle and correct the problem as soon as possible. d. Do not disconnect a spark plug wire with the engine running. e. Avoid push starting the vehicle. f. If running on a dynamometer, make sure the catalytic converter is well ventilated. g. Use caution when working near the catalytic converter to prevent the possibility of burns. 2. Do not use silicone based products on an oxygen sensor equipped vehicle to avoid damaging the sensor. 3. When performing a compression test, remove the fuel pump relay. (This will prevent fuel from being fed to the injectors). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service Precautions > Page 2494 Catalytic Converter: Description and Operation Catalytic Converter THREE-WAY CATALYST This catalytic converter decreases HC, CO, and NOx emissions. The catalytic converter combines hydrocarbons (HC) and carbon monoxide (CO) with oxygen to form water (H2O) and carbon dioxide (CO2). The three-way catalytic converter contains rhodium which reduces or separates oxides of nitrogen (NOx) into nitrogen and oxygen. This action provides better exhaust emission control than is obtainable by using only exhaust gas recirculation, an oxidation catalyst or engine modifications. The three-way catalyst allows richer air/fuel mixtures, more spark advance and less exhaust gas recirculation. All these improve both driveability and fuel economy. Effective catalytic control of all three pollutants is possible when the correct level of CO is obtained, and excess oxygen is reduced. Therefore, it is necessary to maintain precise control of the air/fuel mixture entering the engine, keeping it very close to the stoichiometric point (chemically correct for theoretical complete combustion). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service Precautions > Page 2495 Catalytic Converter: Testing and Inspection The exhaust system should be checked for restriction before any components are replaced. Use the following procedures for diagnosis of the exhaust system: Check at Oxygen Sensor 1. Carefully remove O2 sensor with proper removal tool. 2. Install Exhaust Backpressure Tester in place of 02 sensor. 3. After completing test described below, be sure to coat threads of 02 sensor with antiseize compound prior to re-installation. Diagnosis: 1. With the engine at normal operating temperature and running at 2500 rpm, observe the exhaust system backpressure reading on the gauge. 2. If the backpressure exceeds 1 and 1/4 psi (8.62 kPa), a restricted exhaust system is indicated. 3. Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffler failure. 4. If there are no obvious reasons for the excessive backpressure, a restricted catalytic converter should be suspected, and replaced. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Emissions Maintenance Light > Component Information > Locations Emissions Maintenance Light: Locations Upper I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Emissions Maintenance Light > Component Information > Locations > Page 2499 Emissions Maintenance Light: Service and Repair Refer to Powertrain Management/Emission Control Systems/Service and Repair for reset procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations Canister Purge Solenoid This solenoid is located in the engine compartment, above the right headlight assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2504 Canister Purge Solenoid: Description and Operation Fig. 9 Canister purge solenoid location The purge solenoid, which controls both canister purge and fuel pressure regulator, Fig. 9, is operated by the SMEC. When energized, purge vacuum is prevented from being applied to the canister and fuel pressure is increased. Depending on data received from the charge and coolant temperature sensors at start up, the solenoid will be energized for a controlled amount of time. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2505 Canister Purge Solenoid: Service and Repair 1. Remove vacuum hose and electrical connector from solenoid. 2. Remove mounting fastener and remove solenoid. 3. Depress tab on top of solenoid to be replaced and slide the solenoid downward out of mounting bracket. 3. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations Charcoal Canister The canister is located behind the right-hand headlight assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Customer Interest: > 182188 > Dec > 88 > AIS Motor Erratic Idle Speed In Cold Ambients EGR Valve: Customer Interest AIS Motor - Erratic Idle Speed In Cold Ambients Models 1987-1989 C- & SBody Vehicles Equipped With 3.0L Engines Subject Erratic Idle Speed in Cold Ambients Index DRIVEABILITY Date December 12, 1988 No. 18-21-88 (C18-26) SYMPTOM/CONDITION Vehicles driven consistently in cold ambients may exhibit an erratic idle due to an A.I.S. motor failure. A revised A.I.S. motor is now available for those areas. NOTE: ERRATIC IDLE CONDITION MAY NOT SHOW UP WHEN USING THE DIAGNOSTIC TEST PROCEDURE, DUE TO THE WARM IN-SHOP AMBIENT TEMPERATURES. PARTS REQUIRED 1987-1988 3.0L VEHICLES 1 A.I.S. Motor PN 4458366 1989 3.0L VEHICLES 1 A.I.S. Motor PN 4458355 REPAIR PROCEDURE This repair involves replacing the A.I.S. motor with a revised A.I.S. motor. 1. Remove A.I.S. motor as outlined in the service manual. NOTE: FOR DIFFICULTY IN REMOVING A.I.S. MOTOR ATTACHING SCREWS, REFER TO TECHNICAL SERVICE BULLETIN 14-07-88. 2. Install new A.I.S. motor as outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-30-23-93 . . . . . . . . . 0.5 Hrs. FAILURE CODE: 61 - Intermittent Operation Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for EGR Valve: > 250189 > Sep > 89 > EGR Valve - Diagnostic Procedures Revision EGR Valve: All Technical Service Bulletins EGR Valve - Diagnostic Procedures Revision Models 1987-88 E, G, H, J, L, P, K & S Bodies And 1989 AA, AC, AG, AH, AJ, AK, AL, AP & AS Bodies Subject Revised EGR Valve Diagnostic Procedures Index DRIVEABILITY Date September 18, 1989 No. 25-01-89 (C25-01-9) P-3378 BODY CODE LEGEND E - CARAVELLE/600/NEW YORKER TURBO AA - SPIRIT/ACCLAIM AC - DYNASTY/NEW YORKER/LANDAU G/AG - DAYTONA H/AH - LANCER/LeBARON GTS (4-DOOR HATCHBACK) J/AJ - LeBARON L/AL - OMNI/HORIZON P/AP - SHADOW/SUNDANCE K/AK - ARIES/RELIANT S/AS CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION This Technical Service Bulletin contains a revised diagnostic procedure for testing EGR valves for a leaking poppet. The procedure applies only to vehicles equipped with a back pressure transducer. The procedure allows the EGR valve to be tested without removing the valve from the vehicle. PROCEDURE 1. Turn engine off. Remove the air cleaner exposing the inlet of the throttle body. On 2.5L Turbo I (California emissions equipped vehicles), remove the compressor outlet hose at the throttle body. 2. Disconnect the back pressure hose from the EGR valve. 3. Using a nozzle with a rubber grommet connection, direct compressed shop air (regulated to 50-60 Psi) through the steel back pressure tube on the EGR valve while opening and closing the throttle blade. 4. If the sound from the compressed air changes distinctly while opening and closing the throttle, the poppet is leaking and air is entering the intake manifold. Replace the EGR valve. POLICY: For information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for EGR Valve: > 182188 > Dec > 88 > AIS Motor - Erratic Idle Speed In Cold Ambients EGR Valve: All Technical Service Bulletins AIS Motor - Erratic Idle Speed In Cold Ambients Models 1987-1989 C- & SBody Vehicles Equipped With 3.0L Engines Subject Erratic Idle Speed in Cold Ambients Index DRIVEABILITY Date December 12, 1988 No. 18-21-88 (C18-26) SYMPTOM/CONDITION Vehicles driven consistently in cold ambients may exhibit an erratic idle due to an A.I.S. motor failure. A revised A.I.S. motor is now available for those areas. NOTE: ERRATIC IDLE CONDITION MAY NOT SHOW UP WHEN USING THE DIAGNOSTIC TEST PROCEDURE, DUE TO THE WARM IN-SHOP AMBIENT TEMPERATURES. PARTS REQUIRED 1987-1988 3.0L VEHICLES 1 A.I.S. Motor PN 4458366 1989 3.0L VEHICLES 1 A.I.S. Motor PN 4458355 REPAIR PROCEDURE This repair involves replacing the A.I.S. motor with a revised A.I.S. motor. 1. Remove A.I.S. motor as outlined in the service manual. NOTE: FOR DIFFICULTY IN REMOVING A.I.S. MOTOR ATTACHING SCREWS, REFER TO TECHNICAL SERVICE BULLETIN 14-07-88. 2. Install new A.I.S. motor as outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-30-23-93 . . . . . . . . . 0.5 Hrs. FAILURE CODE: 61 - Intermittent Operation Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Valve: > 250189 > Sep > 89 > EGR Valve - Diagnostic Procedures Revision EGR Valve: All Technical Service Bulletins EGR Valve - Diagnostic Procedures Revision Models 1987-88 E, G, H, J, L, P, K & S Bodies And 1989 AA, AC, AG, AH, AJ, AK, AL, AP & AS Bodies Subject Revised EGR Valve Diagnostic Procedures Index DRIVEABILITY Date September 18, 1989 No. 25-01-89 (C25-01-9) P-3378 BODY CODE LEGEND E - CARAVELLE/600/NEW YORKER TURBO AA - SPIRIT/ACCLAIM AC - DYNASTY/NEW YORKER/LANDAU G/AG - DAYTONA H/AH - LANCER/LeBARON GTS (4-DOOR HATCHBACK) J/AJ - LeBARON L/AL - OMNI/HORIZON P/AP - SHADOW/SUNDANCE K/AK - ARIES/RELIANT S/AS CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION This Technical Service Bulletin contains a revised diagnostic procedure for testing EGR valves for a leaking poppet. The procedure applies only to vehicles equipped with a back pressure transducer. The procedure allows the EGR valve to be tested without removing the valve from the vehicle. PROCEDURE 1. Turn engine off. Remove the air cleaner exposing the inlet of the throttle body. On 2.5L Turbo I (California emissions equipped vehicles), remove the compressor outlet hose at the throttle body. 2. Disconnect the back pressure hose from the EGR valve. 3. Using a nozzle with a rubber grommet connection, direct compressed shop air (regulated to 50-60 Psi) through the steel back pressure tube on the EGR valve while opening and closing the throttle blade. 4. If the sound from the compressed air changes distinctly while opening and closing the throttle, the poppet is leaking and air is entering the intake manifold. Replace the EGR valve. POLICY: For information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Page 2532 EGR Mounting Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component Information > Description and Operation Fillpipe Restrictor: Description and Operation FUEL HOSES AND CLAMPS The hoses used on fuel injected models are of a special type and only hoses marked EFI/EFM may be used as replacements. The clamps used are of a rolled edge construction to prevent cutting hoses, and all replacements must be of this type. NO-LEAD FILLER TUBE All catalyst equipped models have a special filler tube. The filler tube also contains a deflector to prevent the addition of fuel by other than an unleaded fuel nozzle. Labels are attached at the instrument panel and near the fuel door reading "unleaded fuel only" to remind the operator. PRESSURE/VACUUM FILLER CAP The loss of liquid fuel or vapor is prevented by using a filler cap which releases under 10.9 to 13.45 kPa (1.58 to 1.95 psi). Only caps with these specifications may be used as replacements to maintain the integrity of the fuel system. ROLL-OVER VALVE All fuel tanks of the closed type use a roll-over valve mounted on the top of the fuel tank. The roll-over valve prevents fuel flow to the evaporative loss canister. In addition to the roll-over valve there is a one way check valve mounted on the fuel return line, in the tank, which prevents fuel from backing up into the return line from the tank. Under loss of fuel pressure conditions, or conditions such as roll-over where tank pressure may exceed fuel return pressure, the check valve closes, preventing fuel loss from tank. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Customer Interest for Positive Crankcase Ventilation Valve: > 091689 > Oct > 89 > Engine - Oil Consumption Positive Crankcase Ventilation Valve: Customer Interest Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Customer Interest for Positive Crankcase Ventilation Valve: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 2545 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Positive Crankcase Ventilation Valve: > 091689 > Oct > 89 > Engine - Oil Consumption Positive Crankcase Ventilation Valve: All Technical Service Bulletins Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Positive Crankcase Ventilation Valve: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 2551 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations System not equipped with fuel pressure test port. (To test fuel pressure tee into system with adapter.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair 1. Loosen gas cap and allow tank pressure to release. 2. Remove wiring harness connector from any injector, then ground one injector terminal. 3. Connect a suitable jumper wire to a second terminal, then touch the positive post of the battery for approximately 10 seconds and release system pressure. 4. Remove jumper wires and service fuel system as required. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications IDLE SPEED Idle speed adjustment is electronically controlled by the Automatic Idle Speed (AIS) Motor and is not adjustable. For diagnosis of incorrect idle speed, refer to COMPUTERIZED ENGINE CONTROLS. IDLE SPEED Automatic ............................................................................................................................................. .................................................................. 800 RPM Manual .............................................................. ...................................................................................................................................................... 800 RPM Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 2563 Idle Speed: Testing and Inspection 1. Remove air cleaner assembly, then plug heated air door vacuum hose. 2. With vehicle in PARK for A/T, or NEUTRAL for M/T, START engine and warm until cooling fan cycles ON and OFF at least once. STOP engine. 3. Connect suitable timing light, then disconnect coolant temperature sensor. START engine, and ensure basic timing is set to 12° BTDC. 4. STOP engine and reconnect coolant temperature sensor wire. 5. Disconnect PCV valve hose from intake manifold nipple. 6. Attach tool No. C-5004 or equivalent (.125 inch orifice in attached hose) to intake manifold PCV nipple. 7. Connect DRB II or equivalent scanner, then START engine and allow to idle for at least 1 minute. 8. Using scanner, place read/hold switch in read position and depress ATM button until code 70 appears. 9. Place read/hold switch to hold position, then the following should occur: a. AIS motor will fully close. b. Idle spark advance will become fixed. c. Idle fuel will become enriched. d. Engine rpm will be displayed on diagnostic read-out tool in units of rpm x 10. For example, display 95 equals 95 x 10 which indicates 950 rpm. 10. Check idle rpm. If idle rpm is within 850-1250 rpm then throttle body minimum air flow is satisfactory. If idle rpm is not as specified, clean or replace throttle body, refer to MAINTENANCE PROCEDURES. Retest minimum air flow after throttle body cleaning. 11. STOP engine, then remove tool No. C-5004 (orifice) from intake manifold PCV nipple. Install PCV valve hose. 12 Erase fault codes. Remove scanner, then install air cleaner assembly and heated air door vacuum hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 2564 Idle Speed: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle speed using this screw, unless directed to do so in a service procedure. Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air Control (IAC) motor, and is not adjustable. If idle is outside of specified RPM, or is rough, or unstable, inspect and clean throttle body if deposits are visible. Perform Minimum Idle Air Flow Test if applicable. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle mixture using this screw! Idle mixture is electronically controlled by the Powertrain Control Module (PCM), and is not adjustable. If an idle mixture problem is suspected, check oxygen sensor and feedback system. SEE Computers and Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 182188 > Dec > 88 > AIS Motor - Erratic Idle Speed In Cold Ambients Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins AIS Motor - Erratic Idle Speed In Cold Ambients Models 1987-1989 C- & SBody Vehicles Equipped With 3.0L Engines Subject Erratic Idle Speed in Cold Ambients Index DRIVEABILITY Date December 12, 1988 No. 18-21-88 (C18-26) SYMPTOM/CONDITION Vehicles driven consistently in cold ambients may exhibit an erratic idle due to an A.I.S. motor failure. A revised A.I.S. motor is now available for those areas. NOTE: ERRATIC IDLE CONDITION MAY NOT SHOW UP WHEN USING THE DIAGNOSTIC TEST PROCEDURE, DUE TO THE WARM IN-SHOP AMBIENT TEMPERATURES. PARTS REQUIRED 1987-1988 3.0L VEHICLES 1 A.I.S. Motor PN 4458366 1989 3.0L VEHICLES 1 A.I.S. Motor PN 4458355 REPAIR PROCEDURE This repair involves replacing the A.I.S. motor with a revised A.I.S. motor. 1. Remove A.I.S. motor as outlined in the service manual. NOTE: FOR DIFFICULTY IN REMOVING A.I.S. MOTOR ATTACHING SCREWS, REFER TO TECHNICAL SERVICE BULLETIN 14-07-88. 2. Install new A.I.S. motor as outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-30-23-93 . . . . . . . . . 0.5 Hrs. FAILURE CODE: 61 - Intermittent Operation Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 182188 > Dec > 88 > AIS Motor - Erratic Idle Speed In Cold Ambients Auxiliary Air Valve (Idle Speed): Customer Interest AIS Motor - Erratic Idle Speed In Cold Ambients Models 1987-1989 C- & SBody Vehicles Equipped With 3.0L Engines Subject Erratic Idle Speed in Cold Ambients Index DRIVEABILITY Date December 12, 1988 No. 18-21-88 (C18-26) SYMPTOM/CONDITION Vehicles driven consistently in cold ambients may exhibit an erratic idle due to an A.I.S. motor failure. A revised A.I.S. motor is now available for those areas. NOTE: ERRATIC IDLE CONDITION MAY NOT SHOW UP WHEN USING THE DIAGNOSTIC TEST PROCEDURE, DUE TO THE WARM IN-SHOP AMBIENT TEMPERATURES. PARTS REQUIRED 1987-1988 3.0L VEHICLES 1 A.I.S. Motor PN 4458366 1989 3.0L VEHICLES 1 A.I.S. Motor PN 4458355 REPAIR PROCEDURE This repair involves replacing the A.I.S. motor with a revised A.I.S. motor. 1. Remove A.I.S. motor as outlined in the service manual. NOTE: FOR DIFFICULTY IN REMOVING A.I.S. MOTOR ATTACHING SCREWS, REFER TO TECHNICAL SERVICE BULLETIN 14-07-88. 2. Install new A.I.S. motor as outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-30-23-93 . . . . . . . . . 0.5 Hrs. FAILURE CODE: 61 - Intermittent Operation Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component Information > Description and Operation Fillpipe Restrictor: Description and Operation FUEL HOSES AND CLAMPS The hoses used on fuel injected models are of a special type and only hoses marked EFI/EFM may be used as replacements. The clamps used are of a rolled edge construction to prevent cutting hoses, and all replacements must be of this type. NO-LEAD FILLER TUBE All catalyst equipped models have a special filler tube. The filler tube also contains a deflector to prevent the addition of fuel by other than an unleaded fuel nozzle. Labels are attached at the instrument panel and near the fuel door reading "unleaded fuel only" to remind the operator. PRESSURE/VACUUM FILLER CAP The loss of liquid fuel or vapor is prevented by using a filler cap which releases under 10.9 to 13.45 kPa (1.58 to 1.95 psi). Only caps with these specifications may be used as replacements to maintain the integrity of the fuel system. ROLL-OVER VALVE All fuel tanks of the closed type use a roll-over valve mounted on the top of the fuel tank. The roll-over valve prevents fuel flow to the evaporative loss canister. In addition to the roll-over valve there is a one way check valve mounted on the fuel return line, in the tank, which prevents fuel from backing up into the return line from the tank. Under loss of fuel pressure conditions, or conditions such as roll-over where tank pressure may exceed fuel return pressure, the check valve closes, preventing fuel loss from tank. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 18-05-97 > Feb > 97 > Engine - Driveway Die Out/Rough Idle/Low Power Fuel: All Technical Service Bulletins Engine - Driveway Die Out/Rough Idle/Low Power NO: 18-05-97 GROUP: Vehicle Performance DATE: Feb. 14, 1997 SUBJECT: Intake Valve Deposits THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-16-93, DATED NOV. 12, 1993 AND 18-20-94, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1993 AND 1994 TECHNICAL SERVICE BULLETIN MANUALS (PUBLICATION NO's. 81-699-94000 AND 81-699-95054). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE MODEL AND APPLICATION CHANGES. MODELS: **1989 - 1995** (AA) Spirit/Acclaim/LeBaron Sedan **1988 - 1993** (AC) Dynasty/New Yorker Salon **1990 - 1994** (AG) Daytona **1990 - 1995** (AJ) LeBaron Coupe/LeBaron Convertible **1992 - 1994** (AP) Shadow/Shadow Convertible/Sundance **1987 - 1995** (AS) Town & Country/Caravan/Voyager **1996 - 1997** (NS) Town & Country/Caravan/Voyager **NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.0L ENGINE.** SYMPTOM/CONDITION: Driveway die out, rough idle, lack of power, sags, and hesitation. DISCUSSION: The above conditions may be the result of a build up of deposits on the back of the intake valves causing blockage of fuel delivery into the upper combustion chamber. This blockage results in fuel starvation. The deposits can be the result of fuel blending methods that have insufficient or ineffective fuel detergent additives. Fuel quality is a direct result of the crude oil used, the refinement process, the storage, delivery and distribution methods, and the blending of additive compounds. Using fuel with a higher posted octane number does not guarantee high quality, or that it is blended with adequate or effective detergent, corrosion inhibitors, or additives. Gasoline/Oxygenate blends which use unleaded gasoline and compounds that contain oxygen, such as alcohol, ethanol, MTBE, and ETBE may not indicate that adequate or effective detergent additives are available either. Gasoline Companies acknowledge that fuel quality is important. A number of them advertise, as well as warrant their fuel is blended to contain the necessary additives for efficient and clean operation of modern vehicles. Fuels available from these companies should be considered to assure full performance and clean operation. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, make sure the PCM is at the latest software version. If all systems are functioning as designed, ask the customer about the fuel that is being used in the vehicle. If there is a question about the quality of the fuel, suggest that only fuels be used that are warranted by the gasoline company against the build up of deposits. REPAIR PROCEDURE: Depending on the amount of deposit on the valves, there are several methods that can be used to remove them. 1. The use of Mopar Fuel Injector Cleaner has shown reasonable results on light deposits. Add one bottle of Mopar Fuel Injector Cleaner, p/n 4318007, to a full tank of gas. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 18-05-97 > Feb > 97 > Engine - Driveway Die Out/Rough Idle/Low Power > Page 2592 CAUTION: UNDER NO CIRCUMSTANCES SHOULD THIS FUEL INJECTOR CLEANER BE ADDED TO A PARTIALLY FILLED FUEL TANK. Mopar Fuel Injector Cleaner will remove light deposits that have built up over a period of time. However, it is not intended for continuous use. Owners should be advised of the cause of their driveability concern and a recommendation should be made to try other brands of fuel. 2. For moderate to heavy deposits, the intake valves should be cleaned. The suggested method for cleaning involves removal of the cylinder head from the engine. The head must be disassembled, and the carbon removed from the valves and surrounding components with a wire brush. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Customer Interest for Fuel: > 18-05-97 > Feb > 97 > Engine - Driveway Die Out/Rough Idle/Low Power Fuel: Customer Interest Engine - Driveway Die Out/Rough Idle/Low Power NO: 18-05-97 GROUP: Vehicle Performance DATE: Feb. 14, 1997 SUBJECT: Intake Valve Deposits THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-16-93, DATED NOV. 12, 1993 AND 18-20-94, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1993 AND 1994 TECHNICAL SERVICE BULLETIN MANUALS (PUBLICATION NO's. 81-699-94000 AND 81-699-95054). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE MODEL AND APPLICATION CHANGES. MODELS: **1989 - 1995** (AA) Spirit/Acclaim/LeBaron Sedan **1988 - 1993** (AC) Dynasty/New Yorker Salon **1990 - 1994** (AG) Daytona **1990 - 1995** (AJ) LeBaron Coupe/LeBaron Convertible **1992 - 1994** (AP) Shadow/Shadow Convertible/Sundance **1987 - 1995** (AS) Town & Country/Caravan/Voyager **1996 - 1997** (NS) Town & Country/Caravan/Voyager **NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.0L ENGINE.** SYMPTOM/CONDITION: Driveway die out, rough idle, lack of power, sags, and hesitation. DISCUSSION: The above conditions may be the result of a build up of deposits on the back of the intake valves causing blockage of fuel delivery into the upper combustion chamber. This blockage results in fuel starvation. The deposits can be the result of fuel blending methods that have insufficient or ineffective fuel detergent additives. Fuel quality is a direct result of the crude oil used, the refinement process, the storage, delivery and distribution methods, and the blending of additive compounds. Using fuel with a higher posted octane number does not guarantee high quality, or that it is blended with adequate or effective detergent, corrosion inhibitors, or additives. Gasoline/Oxygenate blends which use unleaded gasoline and compounds that contain oxygen, such as alcohol, ethanol, MTBE, and ETBE may not indicate that adequate or effective detergent additives are available either. Gasoline Companies acknowledge that fuel quality is important. A number of them advertise, as well as warrant their fuel is blended to contain the necessary additives for efficient and clean operation of modern vehicles. Fuels available from these companies should be considered to assure full performance and clean operation. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, make sure the PCM is at the latest software version. If all systems are functioning as designed, ask the customer about the fuel that is being used in the vehicle. If there is a question about the quality of the fuel, suggest that only fuels be used that are warranted by the gasoline company against the build up of deposits. REPAIR PROCEDURE: Depending on the amount of deposit on the valves, there are several methods that can be used to remove them. 1. The use of Mopar Fuel Injector Cleaner has shown reasonable results on light deposits. Add one bottle of Mopar Fuel Injector Cleaner, p/n 4318007, to a full tank of gas. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Customer Interest for Fuel: > 18-05-97 > Feb > 97 > Engine - Driveway Die Out/Rough Idle/Low Power > Page 2598 CAUTION: UNDER NO CIRCUMSTANCES SHOULD THIS FUEL INJECTOR CLEANER BE ADDED TO A PARTIALLY FILLED FUEL TANK. Mopar Fuel Injector Cleaner will remove light deposits that have built up over a period of time. However, it is not intended for continuous use. Owners should be advised of the cause of their driveability concern and a recommendation should be made to try other brands of fuel. 2. For moderate to heavy deposits, the intake valves should be cleaned. The suggested method for cleaning involves removal of the cylinder head from the engine. The head must be disassembled, and the carbon removed from the valves and surrounding components with a wire brush. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 2599 Fuel: Specifications GASOLINE: Unleaded gasoline must be used with all engines. Premium unleaded fuel 92 octane is not recommended. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair 1. Loosen gas cap and allow tank pressure to release. 2. Remove wiring harness connector from any injector, then ground one injector terminal. 3. Connect a suitable jumper wire to a second terminal, then touch the positive post of the battery for approximately 10 seconds and release system pressure. 4. Remove jumper wires and service fuel system as required. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 181189A > Dec > 89 > Fuel Injectors Long Crank Time to Start Fuel Injector: Customer Interest Fuel Injectors - Long Crank Time to Start Models 1983-1990 S/AS Body, 1988-1990 C/AC Body, 1989-90 AA-Body and 1990 AG and AJ Bodies With 3.0L Engine Subject Long Crank Time Before Starting Leaking Fuel Injectors Index DRIVEABILITY Date December 22, 1989 No. 18-11-89 REVISION A (C18-29-9) P-4406 BODY CODE LEGEND AA - SPIRIT/ACCLAIM/LEBARON LANDAU C/AC - DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AJ - LEBARON (COUPE/CONVERTIBLE) S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-11-89, Dated 8/21/89, WHICH SHOULD BE REMOVED FROM YOUR FILES. SYMPTOM/CONDITION As vehicle mileage accumulates, the owner may notice that the vehicle has longer crank time (3 seconds or longer) before starting. This could occur after either cold or hot soak periods. If the customer complaint is long crank time, use the following procedure. Do not use any other diagnostic tests. PARTS REQUIRED 2 Plenum Gaskets PN MD094128 1 EGR Gasket (for '87 & '88) PN MD103625 1 Vacuum Tee (1/4 x 1/4 x 1/4) PN 4306994* 1 Vacuum Connector (1/4 x 1/4) PN 4201275* *NOTE: THESE COMPONENTS ARE REUSABLE AND CAN BE USED FOR TESTING OF SUBSEQUENT VEHICLES. THE EXACT VACUUM TEE AND VACUUM CONNECTOR MUST BE USED FOR THIS TEST. THE USE OF OTHER SIZE TEES OR CONNECTORS WILL RESULT IN INVALID TEST RESULTS. ALL OTHER EQUIPMENT MUST BE USED AS SPECIFIED. REPAIR PROCEDURE This procedure outlines the diagnosis of leaking fuel injectors, which may cause long crank time before starting. 1. Start and run engine until it reaches operating temperature. Wait until radiator fan cycles twice, then turn off engine. This procedure must be performed while the engine is at normal operating temperature. 2. Remove shop exhaust hose from tailpipe, if it was connected during engine warm-up. 3. Remove air inlet duct to the throttle body. Remove throttle linkage. On 1987 and 1988 vehicles, remove the EGR tube attached to the intake plenum. Remove top of intake plenum. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 181189A > Dec > 89 > Fuel Injectors Long Crank Time to Start > Page 2612 4. Using compressed air, blow out the intake manifold runners for EXACTLY FIVE (5) SECONDS EACH. 5. Remove coil ignition cable from distributor cap and attach to a good ground. 6. Use the DRB II to actuate fuel pump to pressurize the fuel system (for 1987 and 1988 vehicles use ATM mode 01 "coil spark," and for 1989 and 1990 vehicles use ATM "ignition coil"). Keep ATM activated for one minute (MUST BE EXACTLY ONE MINUTE) then exit ATM. 7. Obtain a 5-foot long section of 1/4" I.D. rubber hose (MUST BE EXACTLY 5 FEET OF 1/4" I.D. HOSE) to be used as an air sample line connected to a hydrocarbon exhaust gas analyzer. Make sure that the exhaust gas analyzer has a clean filter and is calibrated before performing this test. FIGURE 1 8. Install vacuum connector (PN 4201275) in the sample line at the end to be inserted into the intake manifold runner. Install vacuum tee (PN 4306994) at EXACTLY the middle of the sample line so that fresh air will be drawn in (see Figure 1). FIGURE 2 9. Wait for EXACTLY FIVE (5) MINUTES after exiting ATM, and then, one by one, insert the sample line approximately 5-6" down into each intake manifold runner (MARK THE HOSE WITH A PIECE OF TAPE SO THAT THE HOSE IS INSERTED EXACTLY THE SAME DISTANCE INTO EACH RUNNER). Record the peak HC (hydrocarbon) reading for each intake runner, being sure to let the analyzer reset to zero (0) before taking the next reading. NOTE: THE INTAIKE MANIFOLD IS A CROSSOVER DESIGN. THEREFORE, TO TAKE READINGS FOR CYLINDERS 2, 4, AND 6 (WHICH ARE NEAREST THE FRONT OF THE VEHICLE), THE REAR MANIFOID RUNNERS MUST BE CHECKED (FIGURE 2). 10. After taking the readings from each intake runner, replace that cylinder's fuel injector only if HC readings are 100 ppm or greater. 11. Reinstall intake manifold plenum and torque bolts to 13 N-m (115 in.lbs.). On 1987 and 1988 vehicles, reinstall EGR tube to intake plenum and torque to 22 N-m (200 in.lbs.) 12. Reinstall the throttle cables and air inlet duct. 13. Reinstall coil ignition cable to distributor cap. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: EFFECTIVE JANUARY 1, 1990 Labor Operation No. 14-30-20-68 . . . . . . . . . . . 0.3 Hrs. (Injector Infra-Red Test) 14-30-20-23 . . . . . . . . . . . 0.9 Hrs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 181189A > Dec > 89 > Fuel Injectors Long Crank Time to Start > Page 2613 (Replace 1 to 3 Injectors) 14-30-20-24 . . . . . . . . . . . 1.1 Hrs. (Replace 4 to 6 Injectors) FAILURE CODE: 43 - Fuel Leaks Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 181189A > Dec > 89 > Fuel Injectors - Long Crank Time to Start Fuel Injector: All Technical Service Bulletins Fuel Injectors - Long Crank Time to Start Models 1983-1990 S/AS Body, 1988-1990 C/AC Body, 1989-90 AA-Body and 1990 AG and AJ Bodies With 3.0L Engine Subject Long Crank Time Before Starting Leaking Fuel Injectors Index DRIVEABILITY Date December 22, 1989 No. 18-11-89 REVISION A (C18-29-9) P-4406 BODY CODE LEGEND AA - SPIRIT/ACCLAIM/LEBARON LANDAU C/AC - DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AJ - LEBARON (COUPE/CONVERTIBLE) S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-11-89, Dated 8/21/89, WHICH SHOULD BE REMOVED FROM YOUR FILES. SYMPTOM/CONDITION As vehicle mileage accumulates, the owner may notice that the vehicle has longer crank time (3 seconds or longer) before starting. This could occur after either cold or hot soak periods. If the customer complaint is long crank time, use the following procedure. Do not use any other diagnostic tests. PARTS REQUIRED 2 Plenum Gaskets PN MD094128 1 EGR Gasket (for '87 & '88) PN MD103625 1 Vacuum Tee (1/4 x 1/4 x 1/4) PN 4306994* 1 Vacuum Connector (1/4 x 1/4) PN 4201275* *NOTE: THESE COMPONENTS ARE REUSABLE AND CAN BE USED FOR TESTING OF SUBSEQUENT VEHICLES. THE EXACT VACUUM TEE AND VACUUM CONNECTOR MUST BE USED FOR THIS TEST. THE USE OF OTHER SIZE TEES OR CONNECTORS WILL RESULT IN INVALID TEST RESULTS. ALL OTHER EQUIPMENT MUST BE USED AS SPECIFIED. REPAIR PROCEDURE This procedure outlines the diagnosis of leaking fuel injectors, which may cause long crank time before starting. 1. Start and run engine until it reaches operating temperature. Wait until radiator fan cycles twice, then turn off engine. This procedure must be performed while the engine is at normal operating temperature. 2. Remove shop exhaust hose from tailpipe, if it was connected during engine warm-up. 3. Remove air inlet duct to the throttle body. Remove throttle linkage. On 1987 and 1988 vehicles, remove the EGR tube attached to the intake plenum. Remove top of intake plenum. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 181189A > Dec > 89 > Fuel Injectors - Long Crank Time to Start > Page 2619 4. Using compressed air, blow out the intake manifold runners for EXACTLY FIVE (5) SECONDS EACH. 5. Remove coil ignition cable from distributor cap and attach to a good ground. 6. Use the DRB II to actuate fuel pump to pressurize the fuel system (for 1987 and 1988 vehicles use ATM mode 01 "coil spark," and for 1989 and 1990 vehicles use ATM "ignition coil"). Keep ATM activated for one minute (MUST BE EXACTLY ONE MINUTE) then exit ATM. 7. Obtain a 5-foot long section of 1/4" I.D. rubber hose (MUST BE EXACTLY 5 FEET OF 1/4" I.D. HOSE) to be used as an air sample line connected to a hydrocarbon exhaust gas analyzer. Make sure that the exhaust gas analyzer has a clean filter and is calibrated before performing this test. FIGURE 1 8. Install vacuum connector (PN 4201275) in the sample line at the end to be inserted into the intake manifold runner. Install vacuum tee (PN 4306994) at EXACTLY the middle of the sample line so that fresh air will be drawn in (see Figure 1). FIGURE 2 9. Wait for EXACTLY FIVE (5) MINUTES after exiting ATM, and then, one by one, insert the sample line approximately 5-6" down into each intake manifold runner (MARK THE HOSE WITH A PIECE OF TAPE SO THAT THE HOSE IS INSERTED EXACTLY THE SAME DISTANCE INTO EACH RUNNER). Record the peak HC (hydrocarbon) reading for each intake runner, being sure to let the analyzer reset to zero (0) before taking the next reading. NOTE: THE INTAIKE MANIFOLD IS A CROSSOVER DESIGN. THEREFORE, TO TAKE READINGS FOR CYLINDERS 2, 4, AND 6 (WHICH ARE NEAREST THE FRONT OF THE VEHICLE), THE REAR MANIFOID RUNNERS MUST BE CHECKED (FIGURE 2). 10. After taking the readings from each intake runner, replace that cylinder's fuel injector only if HC readings are 100 ppm or greater. 11. Reinstall intake manifold plenum and torque bolts to 13 N-m (115 in.lbs.). On 1987 and 1988 vehicles, reinstall EGR tube to intake plenum and torque to 22 N-m (200 in.lbs.) 12. Reinstall the throttle cables and air inlet duct. 13. Reinstall coil ignition cable to distributor cap. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: EFFECTIVE JANUARY 1, 1990 Labor Operation No. 14-30-20-68 . . . . . . . . . . . 0.3 Hrs. (Injector Infra-Red Test) 14-30-20-23 . . . . . . . . . . . 0.9 Hrs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 181189A > Dec > 89 > Fuel Injectors - Long Crank Time to Start > Page 2620 (Replace 1 to 3 Injectors) 14-30-20-24 . . . . . . . . . . . 1.1 Hrs. (Replace 4 to 6 Injectors) FAILURE CODE: 43 - Fuel Leaks Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 2621 Fuel Injector: Locations Fuel Injectors And Rail Assembly The 6 fuel injectors are found attached to the fuel rail, mounted under the intake plenum. The plenum must be removed to access the fuel injectors. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 2622 Fuel Injector: Description and Operation Fig. 7 Fuel injector The fuel injector, Fig. 7, is a solenoid operated valve which is energized and controlled by the SMEC. When voltage is applied to the injector solenoid, a spring loaded ball is lifted off its seat and fuel is sprayed into the combustion chamber through spray orifices. The spray orifices and injector tip design cause the fuel to be sprayed in an even conical pattern prior to entering the intake air stream. The amount of fuel delivered by the injector is determined by the amount of time that the injector solenoid is energized. The SMEC determines the amount of fuel necessary to maintain ideal air/fuel mixtures based upon various sensor inputs. The SMEC then energizes the fuel injector for a sufficient amount of time to deliver the necessary amount of fuel. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 2623 Fuel Injector: Testing and Inspection NOTE: Make sure injectors have been cleaned with an approved cleaner prior to testing. The injector balance test is done to verify a balanced distribution of fuel to all cylinders. 1. Start by hooking up a fuel pressure gauge at the schrader valve or inline before the fuel pressure regulator (refer to gauge manufacturer instructions). 2. Pressurize the fuel rail by turning ignition to ON position, and energizing the fuel pump by selecting ASD in the ATM test mode with the DRB II or equivalent scanner. Fuel pressure should rise to maximum working pressure. Refer to SPECIFICATIONS. 3. Remove injector harness connector and connect an injector pulse tester. 4. Pulse one injector at a time. Allow pressure to rise and stabilize in between each injector tested. NOTE: The time each injector is pulsed is very important. Each injector should be pulsed at the same time interval, (example..1 ms each). 5. The rate of drop should be even across all the injectors. All pressure drops should be within 3% of each other, if not replace injector. 6. If there is no pressure drop when injector is pulsed, verify there is a good connection between the injector and pulse tester. If connection is good, a check of the injector circuit is required. 7. First, check the resistance of the injector, if resistance is OK verify there is power to injector by reconnecting the injector harness connector and START engine. 8. Use a "NOID" light to check for pulses (light off and on). If it does not light this is an indication of a problem in the injector to SMEC circuit. Refer to COMPUTERIZED ENGINE CONTROLS for further testing. If light pulses, recheck pressure drop to verify malfunction. NOTE: It may not be possible to connect a noid light to the harness while connected to injector. If this is the case disconnect harness and connect noid light to harness and check pulses. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure Fuel Injector: Service and Repair Fuel Injector Cleaning Procedure PROCEDURE: 1. Fuel system pressure must be released prior to service, refer to FUEL SYSTEM PRESSURE RELEASE. 2. Disconnect the fuel supply line from the inlet side of the fuel rail. 3. Attach the fuel supply line to the return line. 4. Plug the fuel return fitting at the fuel rail, or connect to tester/cleaner depending on configuration. 5. Connect the fuel supply hose from the tester/cleaner to the fuel supply manifold. 6. Turn the tester/cleaner ON. (Tester/cleaner should run 10 minutes.) 7. START the engine and check the fuel lines for leakage. If there is any sign of leakage, turn the vehicle and the tester/cleaner OFF and repair the location where fuel is leaking. Then return to Step 6. 8. When the engine speed has stabilized, set the idle speed at 2000 rpm. Run the remainder of the 10 minute cycle to eliminate all the air in the fuel supply hose and fuel rail. 9. Turn power switch OFF and disconnect power lines. 10. Disconnect cleaner supply hose from the fuel supply manifold. 11. Connect vehicle fuel lines. START engine and check for leaks. Lubricate O-rings prior to installation and ensure fuel lines are securely connected. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 2626 Fuel Injector: Service and Repair Fuel Injector Replacement Fuel Injector REMOVAL 1. Fuel system pressure release must be performed prior to service. Refer to MAINTENANCE PROCEDURES. 2. Fuel rail must be removed prior to servicing fuel injectors. 3. Disconnect the wiring connector from the fuel rail to the injector. 4. Remove the fuel injector lock clip, and slide the injector straight out of the fuel rail cup. 5. Check each injector O-ring for damage and replace any damaged O-rings prior to reinstallation. If the injector is to be re-used, place a protective cap over the injector tip, while it is removed. INSTALLATION 1. Before installing injectors lubricate the O-ring with a drop of engine oil. 2. Install injector top into fuel rail cup. 3. Install injector lock clip by sliding open end into injector slot, and onto the fuel rail cup side slots. 4. Install injector electrical connector. 5. Perform fuel system pressure test to check for leaks, refer to DIAGNOSIS AND TESTING/FUEL SYSTEM DIAGNOSIS for procedure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Pressure Regulator: Locations Fuel Pressure Regulator The fuel pressure regulator is mounted to the fuel rail assembly at the opposite end from the fuel inlet line. The intake plenum must be removed to access the fuel pressure regulator. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2630 Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator The fuel pressure regulator is used to maintain a constant pressure differential at the fuel injector tip of 48 psi. The pressure regulator uses a vacuum assisted spring loaded diaphragm to control the fuel return port in order to maintain constant pressure. Pressurized fuel is delivered first to the fuel injector and then flows to the pressure regulator. When fuel pressure acting on the regulator diaphragm exceeds 48 psi, the regulator spring is compressed and the fuel return port is opened. When fuel pressure drops below 48 psi, spring tension causes the diaphragm to block the fuel return port. As manifold vacuum increases during deceleration, less pressure is needed to supply the same amount of fuel into the air flow. In order to fine tune the fuel pressure under all operating conditions, the vacuum assists in opening the fuel port during high vacuum conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Fuel Pressure Regulator Replacement Fuel Pressure Regulator: Service and Repair Fuel Pressure Regulator Replacement Fuel Pressure Regulator REMOVAL 1. Fuel system pressure must be released prior to service. Refer to MAINTENANCE PROCEDURES. 2. The fuel rail must be removed prior to fuel pressure regulator service, refer to FUEL RAIL for removal procedure. 3. Remove 2 attaching bolts and remove fuel pressure regulator from fuel rail. Inspect O-ring for damage or wear and replace if necessary. 4. Loosen and remove fuel return hose. INSTALLATION 1. Lube fuel pressure O-ring with clean engine oil prior to reinstallation. Press regulator into fuel rail and attach 2 mounting bolts. Torque to 8.7 Nm (77 lb-in). 2. Install fuel return hose and torque to 1 Nm (10 lb-in). 3. After reinstallation of fuel rail and all other components perform fuel pressure test to check for leaks. Refer to Powertrain Management/Fuel Delivery and Air Induction/Testing and Inspection/Procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Fuel Pressure Regulator Replacement > Page 2633 Fuel Pressure Regulator: Service and Repair Fuel Rail Assembly & Fuel Pressure Regulator Fig. 14 Removing fuel pressure regulator hose 1. Perform fuel system pressure release procedure. 2. Disconnect battery ground cable. 3. Disconnect air cleaner to throttle body hose. 4. Disconnect throttle cable and kick down linkage from throttle body. 5. Disconnect vacuum hoses and electrical connectors from throttle body. 6. Disconnect PCV and brake booster hoses from air intake plenum. 7. Remove EGR tube flange from air intake plenum. 8. Disconnect electrical connectors from charge and coolant temperature sensors. 9. Disconnect vacuum hose connections from air intake plenum. 10. Disconnect fuel hoses from fuel rail. 11. Remove eight bolts attaching air intake plenum to intake manifold, then remove air intake plenum. 12. Disconnect vacuum hoses from fuel rail and fuel pressure regulator, Fig. 14. 13. Disconnect fuel injector wiring harness from engine wiring harness. 14. Remove fuel pressure regulator attaching bolts, then loosen hose clamps and remove regulator. 15. Remove fuel rail attaching bolts, then carefully rail assembly from intake manifold. 16. Reverse procedure to install and note the following: a. Prior to installation lubricate O-rings with a drop clean engine oil. b. Ensure injectors are seated in receiver cup with lock ring. c. Ensure injectors are fully seated in ports. d. Torque fuel rail attaching bolts to 115 inch lbs. e. Torque fuel pressure regulator attaching bolts to 95 inch lbs. f. Prior to starting engine check all hoses and electrical connectors for proper connection. g. After completing installation, check system for leaks. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations System not equipped with fuel pressure test port. (To test fuel pressure tee into system with adapter.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations System not equipped with fuel pressure test port. (To test fuel pressure tee into system with adapter.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Engine Compartment Components This vehicle utilizes the Automatic Shutdown (ASD) Relay to control the Fuel Pump operation. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Locations Fuel Rail: Locations Fuel Injectors And Rail Assembly The fuel rail assembly is mounted beneath the intake plenum, on top of the engine. The intake plenum must be removed to access the fuel rail. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Locations > Page 2648 Fuel Rail: Description and Operation Fuel Injectors And Rail Assembly The fuel rail is a steel distribution pipe with mounting points for the fuel pressure regulator, 6 fuel injectors, and injector wire harness. The fuel rail performs the dual functions of fuel supply to the injection components, and providing the necessary brackets and fittings to mount the components to the engine. Fuel enters the fuel rail at the inlet tube, proceeds to the 6 fuel injectors, then to the fuel pressure regulator, and returns to the tank through the fuel pressure regulator. The fuel rail is under constant fuel pressure and fuel pressure release is required prior to servicing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Locations > Page 2649 Fuel Rail: Service and Repair REMOVAL 1. Fuel system pressure must be released prior to service. Refer to MAINTENANCE PROCEDURES. 2. Disconnect negative battery terminal, and remove air cleaner to throttle body hose. Throttle Cable Auto Transaxle 3. Remove throttle cable and transaxle kickdown linkage. Throttle Body Connections 4. Remove Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors from throttle body. Remove vacuum hose harness from throttle body, and remove PCV and brake booster hoses from air intake plenum. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Locations > Page 2650 Coolant Temperature Sensor Connections 5. Remove wiring connector from coolant temperature sensor. Remove vacuum connections from air intake plenum vacuum connector. Remove fuel hoses from fuel rail. Intake Plenum Removal 6. Remove all 8 fasteners from air intake plenum and remove plenum from intake manifold. Cover intake manifold ports before proceeding. 7. Disconnect fuel injector harness from engine harness. Remove fuel pressure regulator attaching bolts. Remove fuel pressure regulator from rail. Check fuel pressure regulator O-ring for damage or wear and replace as necessary. 8. Remove fuel rail mounting bolts and lift fuel rail assembly from intake manifold, using care to avoid damaging injectors or injector O-rings. INSTALLATION 1. Make sure injectors are seated into fuel rail receiver cups, and injector lock clips are in place. Check injector holes to make sure they are clean and any plugs have been removed. Lube injector O-rings with clean engine oil prior to installation. 2. Place the tip of each injector in its respective port and push the rail assembly into place until all injectors are seated in the ports. Install the fuel rail attaching bolts and torque to 13 Nm (115 lb-in). 3. Lube fuel pressure regulator O-ring with clean engine oil, and install fuel pressure regulator onto fuel rail. Install mounting bolts and torque to 8.7 Nm (77 lb-in). Install fuel pressure regulator hoses and clamps and torque to 1 Nm (10 lb-in). 4. Connect fuel injector wiring harness to engine wiring harness, and connect vacuum harness to fuel rail assembly. Remove covering from intake manifold, and clean surface. 5. Place intake manifold gaskets on lower manifold, with beaded sealer up. Install intake plenum and torque fasteners to 13 Nm (115 lb-in). 6. Connect fuel inlet line to fuel rail and torque clamp to 1 Nm (10 lb-in). Connect vacuum harness to air intake plenum and fuel pressure regulator. Connect coolant temperature sensor electrical connector to sensor. 7. Connect brake booster supply hose to intake plenum and connect PCV hose to plenum. Connect AIS motor and TPS, and connect vacuum vapor harness to throttle body. 8. Install throttle cable, and air inlet hose assembly. Connect negative battery terminal. 9. Pressurize fuel system and check for leaks. Refer to DIAGNOSIS AND TESTING/FUEL SYSTEM DIAGNOSIS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Description and Operation Fuel Reservoir: Description and Operation An electric fuel pump is located in a specially designed reservoir within the fuel tank. The reservoir ensures that fuel is available at the pump inlet during all operating conditions, particularly when little fuel remains in the tank. The fuel pump is energized by the ASD relay and operates whenever the relay is activated. Fuel is drawn into the pump through a `sock type' filter screen, and the pump contains an integral fuel inlet check valve to prevent drain back. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Locations Fuel Return Line: Locations Fuel Tank Filter And Hose Location The fuel tank is found in the rear of the vehicle, lines and hoses are typically routed along the right (passenger) frame rail. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Locations > Page 2657 Fuel Return Line: Description and Operation FUEL HOSES AND CLAMPS The hoses used on fuel injected models are of a special type and only hoses marked EFI/EFM may be used as replacements. The clamps used are of a rolled edge construction to prevent cutting hoses, and all replacements must be of this type. NO-LEAD FILLER TUBE All catalyst equipped models have a special filler tube. The filler tube also contains a deflector to prevent the addition of fuel by other than an unleaded fuel nozzle. Labels are attached at the instrument panel and near the fuel door reading "unleaded fuel only" to remind the operator. PRESSURE/VACUUM FILLER CAP The loss of liquid fuel or vapor is prevented by using a filler cap which releases under 10.9 to 13.45 kPa (1.58 to 1.95 psi). Only caps with these specifications may be used as replacements to maintain the integrity of the fuel system. ROLL-OVER VALVE All fuel tanks of the closed type use a roll-over valve mounted on the top of the fuel tank. The roll-over valve prevents fuel flow to the evaporative loss canister. In addition to the roll-over valve there is a one way check valve mounted on the fuel return line, in the tank, which prevents fuel from backing up into the return line from the tank. Under loss of fuel pressure conditions, or conditions such as roll-over where tank pressure may exceed fuel return pressure, the check valve closes, preventing fuel loss from tank. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Locations Fuel Supply Line: Locations Fuel Tank Filter And Hose Location The fuel tank is found in the rear of the vehicle, lines and hoses are typically routed along the right (passenger) frame rail. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Locations > Page 2661 Fuel Supply Line: Description and Operation FUEL HOSES AND CLAMPS The hoses used on fuel injected models are of a special type and only hoses marked EFI/EFM may be used as replacements. The clamps used are of a rolled edge construction to prevent cutting hoses, and all replacements must be of this type. NO-LEAD FILLER TUBE All catalyst equipped models have a special filler tube. The filler tube also contains a deflector to prevent the addition of fuel by other than an unleaded fuel nozzle. Labels are attached at the instrument panel and near the fuel door reading "unleaded fuel only" to remind the operator. PRESSURE/VACUUM FILLER CAP The loss of liquid fuel or vapor is prevented by using a filler cap which releases under 10.9 to 13.45 kPa (1.58 to 1.95 psi). Only caps with these specifications may be used as replacements to maintain the integrity of the fuel system. ROLL-OVER VALVE All fuel tanks of the closed type use a roll-over valve mounted on the top of the fuel tank. The roll-over valve prevents fuel flow to the evaporative loss canister. In addition to the roll-over valve there is a one way check valve mounted on the fuel return line, in the tank, which prevents fuel from backing up into the return line from the tank. Under loss of fuel pressure conditions, or conditions such as roll-over where tank pressure may exceed fuel return pressure, the check valve closes, preventing fuel loss from tank. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Locations Fuel Filler Hose: Locations Fuel Tank Filter And Hose Location The fuel tank is found in the rear of the vehicle, lines and hoses are typically routed along the right (passenger) frame rail. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Top Of Fuel Tank Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2669 Fuel Gauge Sender: Testing and Inspection Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by clamps, check to see whether the insulation has been severed thereby grounding the wire. In the case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of the tank unit. 1. Disconnect wiring from fuel tank sending unit. 2. Connect wiring to a known good sending unit. 3. Connect a jumper wire between sending unit pick up tube and ground. Fuel Tank Sending Unit (Typical) 4. Check fuel gauge as follows: Allow at least two minutes for gauge to settle at each test point. a. Move and clip float arm to its empty stop and turn ignition to the On position, gauge should read Empty or below. b. Move and clip float arm to the Full position, gauge should read Full or above. 5. If gauge does not meet specifications, check the following items for possible malfunction: a. Wiring and connections between gauge sending unit and multiple connector behind left kick panel. b. Wiring and connections between multiple connector and printed circuit board terminals. c. Circuit continuity between printed circuit board terminals and gauge terminals. If the above items are satisfactory, the gauge is defective and must be replaced. 6. If fuel gauge meets specifications check original fuel tank sending unit as follows: a. Remove fuel tank sending unit from fuel tank and connect a jumper wire between sending unit pick up tube and ground. 7. Repeat step 4. 8. If fuel gauge is now within specifications, check the following as possible cause: a. Ground wire from sending unit to left side cowl for continuity. b. Sending unit deformed. Ensure float arm moves freely and pick up tube is not bent. c. Inspect float. d. Sending unit improperly installed. Install correctly. e. Mounting flange on fuel tank for sending unit deformed. f. Fuel tank bottom deformed causing improper positioning of pick-up tube. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure Release Valve > Component Information > Locations Fuel Tank Pressure Release Valve: Locations Pressure Relief/Roll Over Valve The Pressure Relief/Roll Over Valve is located on top of the fuel tank and may only be accessed when the fuel tank has been lowered. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure Release Valve > Component Information > Locations > Page 2673 Fuel Tank Pressure Release Valve: Service and Repair Pressure Relief/Roll Over Valve REMOVAL 1. Fuel system pressure must be released prior to service. 2. Fuel tank must be removed from vehicle prior to service. Refer to FUEL TANK REPLACEMENT AND REPAIR PROCEDURES. 3. Slide the blade of a screwdriver between the rubber mounting grommet and the fuel tank, making sure not to slide the screwdriver between the roll-over valve and grommet. Use a second screwdriver to brace the first and pry the roll-over valve out of the tank. 4. Remove the grommet from the valve, and make sure there is no damage or wear evident on the grommet. If grommet is worn it must be replaced. Pressure Relief/Rollover Valve INSTALLATION 1. Install the rubber grommet into the fuel tank, and seat it around the curled lip of the tank. 2. Lubricate the grommet with power steering fluid, and push roll-over valve into grommet until properly seated. Twist grommet if necessary to align to correct position. Reinstall fuel tank. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations Idle Speed/Throttle Actuator - Electronic: Component Locations LH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations > Page 2678 Engine Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2679 Idle Speed/Throttle Actuator - Electronic: Description and Operation The AIS motor is operated by the SMEC and controls engine idle speed by controlling air flow through the throttle body by-pass channel. The SMEC computes proper idle speed based in signals from vehicle and engine sensors and the switch inputs, and transmits voltage signals to the AIS motor to open or close the by-pass channel in order to maintain the proper engine speed. Basic, no-load idle speed is determined by the amount of air flowing through the throttle body past the closed throttle plate. The AIS motor alters idle speed by allowing increased air flow through the by-pass channel; increasing idle speed when the channel is opened and decreasing idle speed when the channel is closed. In addition, the AIS motor is signaled to open the by-pass channel during deceleration to prevent stalling and mixture enrichment caused by sudden closing of the throttle plate. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2680 Idle Speed/Throttle Actuator - Electronic: Service and Repair 1. Disconnect battery ground cable, then remove air cleaner assembly. 2. Disconnect four pin connector from AIS, then remove temperature sending unit from throttle body housing. 3. Remove two AIS to throttle body torx head retaining screws. 4. Remove AIS from throttle body housing with O-ring. 5. Reverse procedure to install. Install new O-ring and torque retaining screws to 20 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Relay Locations--next To Battery The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the inner fender. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 2685 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions Main Relay (Computer/Fuel System): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions > Page 2688 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Page 2689 Main Relay (Computer/Fuel System): Description and Operation Relay Locations--next To Battery The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel injectors, and electric fuel pump at all times when the ignition switch is in the START position. When the ignition switch is in the RUN position and the engine control module is receiving reference signals from the distributor, power will also be supplied. If there is no reference signal after two seconds the engine control module will de-energize the ASD and no power will be supplied to the ignition coil, fuel injectors, or electric fuel pump. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay Relay Terminal Identification ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with circuit codes, and color codes, and their function: Circuit No. Terminal No. Color Code Description J1 30 Red Has battery input voltage supplied through fusible link. Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output voltage to fuel pump, O2 sensor, fuel injectors, and coil. K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine Controller (SMEC). The SMEC provides input voltage to relay. K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when distributor signal is present. N/A 87A N/A Not used in these applications. ASD RELAY TEST NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent. Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no scanner is available proceed with the following test. 1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage. If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present proceed to step 2. 2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to the START position and crank the engine. If Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2692 output voltage is present during cranking, the ASD relay is functioning normally and no further testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3. 3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86) wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD relay, and test operation. 4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning, and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14 (terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists replace and ASD relay and test operation. 5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58 of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Engine Compartment Components This vehicle utilizes the Automatic Shutdown (ASD) Relay to control the Fuel Pump operation. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Relay Locations--next To Battery The Auto Shutdown (ASD) Relay is located on the left-hand side of the engine compartment on the inner fender. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 2701 Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions Main Relay (Computer/Fuel System): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Diagram Information and Instructions > Page 2704 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Page 2705 Main Relay (Computer/Fuel System): Description and Operation Relay Locations--next To Battery The Auto Shut Down (ASD) Relay controls power to the ignition coil, fuel injectors, and electric fuel pump. Controlled by the Engine Controller the ASD supplies power to the ignition coil, fuel injectors, and electric fuel pump at all times when the ignition switch is in the START position. When the ignition switch is in the RUN position and the engine control module is receiving reference signals from the distributor, power will also be supplied. If there is no reference signal after two seconds the engine control module will de-energize the ASD and no power will be supplied to the ignition coil, fuel injectors, or electric fuel pump. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Main Relay (Computer/Fuel System): Testing and Inspection Auto Shutdown (ASD) Relay Relay Terminal Identification ASD RELAY TERMINAL IDENTIFICATION The following is a list of the terminal numbers, with circuit codes, and color codes, and their function: Circuit No. Terminal No. Color Code Description J1 30 Red Has battery input voltage supplied through fusible link. Z1 87 Green/blk. Connected to J1 circuit (terminal 30) in the energized position, supplies output voltage to fuel pump, O2 sensor, fuel injectors, and coil. K14 86 Blue/wht. Connected to the electromagnet, (diode) and the Single Module Engine Controller (SMEC). The SMEC provides input voltage to relay. K19 85 Blue/yel. Connected to the electromagnet (diode) and grounded by the SMEC when distributor signal is present. N/A 87A N/A Not used in these applications. ASD RELAY TEST NOTE: The ASD relay operation may be tested with the use of the DRB II scanner or equivalent. Refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for procedure. If no scanner is available proceed with the following test. 1. Connect a voltmeter to the J1 (terminal 30) wire at the ASD connector. Check for battery voltage. If no voltage is present, check fusible links and supply voltage from the battery. If voltage is present proceed to step 2. 2. Connect the voltmeter to the Z1 (terminal 87) wire at the ASD connector. Turn the ignition key to the START position and crank the engine. If Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2708 output voltage is present during cranking, the ASD relay is functioning normally and no further testing of the ASD relay is necessary. If no voltage is present at the Z1 wire, proceed to step 3. 3. Connect the voltmeter to the K14 (terminal 86) wire at the ASD connector. Turn the ignition key to the RUN position. Input voltage from the SMEC to the ASD relay should be present. If voltage is present proceed to step 4. If no voltage is present, disconnect the 60 way and 14 way SMEC connectors, and the ASD relay connector. Connect an ohmmeter between the K14 (terminal 86) wire and the blue/white wire at pin connector no.12 of the SMEC, and check for continuity. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING for SMEC testing procedures. If no continuity exists, repair open in wire, reconnect SMEC and ASD relay, and test operation. 4. Connect voltmeter to K19 (terminal 85) wire at ASD connector. Turn ignition key to START position, and crank engine, while observing voltage at K19. Voltage should be present at K19 and drop to less than 1 volt within 2 seconds during cranking. If voltage drops ASD relay is functioning, and no further testing of the ASD relay is necessary. If voltage does not drop, proceed to step 5. If no voltage is present, disconnect the ASD relay, and connect an ohmmeter between the K14 (terminal 86) and K19 (terminal 85) of the ASD relay and check for continuity. If no continuity exists replace and ASD relay and test operation. 5. Disconnect the 60 way and 14 way SMEC connectors and ASD relay. Connect an ohmmeter between the K19 wire at the ASD relay connector and the Blue/Yellow wire at pin connector no. 58 of the SMEC. Check for continuity. If no continuity exists repair open in wire, reconnect SMEC and ASD relay, and test operation. If continuity exists, refer to COMPUTERIZED ENGINE CONTROLS/DIAGNOSIS AND TESTING, for SMEC testing procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations Rollover Valve: Locations Pressure Relief/Roll Over Valve The Pressure Relief/Roll Over Valve is located on top of the fuel tank and may only be accessed when the fuel tank has been lowered. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 2712 Rollover Valve: Service and Repair Pressure Relief/Roll Over Valve REMOVAL 1. Fuel system pressure must be released prior to service. 2. Fuel tank must be removed from vehicle prior to service. Refer to FUEL TANK REPLACEMENT AND REPAIR PROCEDURES. 3. Slide the blade of a screwdriver between the rubber mounting grommet and the fuel tank, making sure not to slide the screwdriver between the roll-over valve and grommet. Use a second screwdriver to brace the first and pry the roll-over valve out of the tank. 4. Remove the grommet from the valve, and make sure there is no damage or wear evident on the grommet. If grommet is worn it must be replaced. Pressure Relief/Rollover Valve INSTALLATION 1. Install the rubber grommet into the fuel tank, and seat it around the curled lip of the tank. 2. Lubricate the grommet with power steering fluid, and push roll-over valve into grommet until properly seated. Twist grommet if necessary to align to correct position. Reinstall fuel tank. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure Revision Models 1989 AS Subject Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI Index MISCELLANEOUS Date December 29, 1989 No. 26-34-89 P-13 (C26-34-9) BODY CODE LEGEND AS - 1989 RAM VAN, CARAVAN, VOYAGER Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 2718 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 2719 DIAGNOSTIC MANUAL REVISION Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH. 1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No. 81-699-9017. Pages 136 and 137. Please affix these revised pages in your manual. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2720 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2721 Throttle Position Sensor: Locations LH Rear Corner Of Cylinder Head Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2724 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 2725 Throttle Position Sensor: Description and Operation The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The sensor produces a voltage signal which increases and decreases according to throttle position. The SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide open throttle, acceleration and deceleration. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 2726 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle body mounting screws. 3. Lift TPS from throttle shaft, then remove O-ring. 4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw to 20 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 180889 > May > 89 > Throttle Body Intermittent Loss of Engine Power Throttle Body: Customer Interest Throttle Body - Intermittent Loss of Engine Power Models 1987-89 S/AS & C/AC Bodies 1989 AA Body All With 3.0L Engine Subject Intermittent Loss Of Engine Power During Slow Speed Deceleration Index DRIVEABILITY Date May 30, 1989 No. 18-08-89 (C18-09-9) P-2096 BODY CODE LEGEND C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V AA SPIRIT/ACCLAIM SYMPTOM/CONDITION Intermittent loss of power (3.0L engine) during slow speed deceleration. PARTS REQUIRED 1 Mopar Parts Cleaner PN 4318037 1 Throttle Body Base Gasket PN 4300071 (1987-88) 1 Throttle Body Base Gasket PN 4324426 (1989) Scotch Brite Pad (Green) REPAIR PROCEDURE If the engine idles slow or rough after deceleration, or requires long crank times when cold, it may be caused by residue which has accumulated between the throttle blade and the throttle body bore. This residue will restrict airflow at closed throttle. Removing this residue from the throttle body bore and throttle blade should return the minimum air flow speed to proper specifications. 1. Perform the minimum airflow test as outlined in the Powertrain Diagnostics Procedures Manual. Be sure to use Miller Tool C-5004 when checking minimum air flow RPM. 2. If the minimum airflow RPM is below 800 RPM as indicated on the DRB II, remove the throttle body from the engine. 3. While holding the throttle open, spray the throttle body bore with Mopar Parts Cleaner PN 4318037. Spray the entire throttle body bore and the manifold side of the throttle blade. It is important to use only Mopar Parts Cleaner PN 4318037. Do not submerse the throttle body in solvents, gasoline or any other cleaning fluids. CAUTION: USE THIS CLEANER ONLY IN A WELL VENTILATED AREA. DO NOT LET THIS CLEANER COME IN CONTACT WITH SKIN. RUBBER OR BUTYL GLOVES ARE RECOMMENDED. WASH THOROUGHLY AFTER USE. AVOID EYE CONTACT. AVOID INGESTING. 4. Use a small (1" x 1") piece of green Scotch Brite scuff pad to clean the throttle body bore and the throttle blade. While holding the throttle open, clean both the top and bottom of the throttle body bore. Also clean the manifold side and edges of the throttle blade-. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 180889 > May > 89 > Throttle Body Intermittent Loss of Engine Power > Page 2735 NOTE: IT IS IMPORTANT THIS CLEANING OPERATION BE PERFORMED THOROUGHLY AND COMPLETELY. THE EDGE OF THE THROTTLE BLADE AND THE PORTION OP THE THROTTLE BODY BORE THAT IS IN THE CLOSEST PROXIMITY OF THE CLOSED THROTTLE BLADE ARE THE MOST CRITICAL AREAS THE CLEANING SHOULD BE CONCENTRARED. THESE AREAS MUST BE FREE OF ALL DEPOSITS WHEN THE CLEANING IS COMPLETED. 5. Spray the throttle body with Mopar Parts Cleaner PN 4318037 and then blow dry with compressed shop air. Inspect for any foreign material which may have been left behind from the cleaning process. CAUTION: DO NOT APPLY SHOP AIR PRESSURE DIRECTLY INTO THROTTLE SHAFT AND THROTTLE BODY HOUSING HOLES. 6. Reinstall the throttle body and check to see if the minimum air flow RPM is within specification. If the air flow is still not within specification, repeat the cleaning procedure in step 4 above. If the minimum air flow RPM is still not within specification, the problem is not caused by throttle body contamination. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 14-30-01-99 . . . . . . . . . . . . . . . . 1.2 Hrs. FAILURE CODE: 08 - Blocked Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 180889 > May > 89 > Throttle Body - Intermittent Loss of Engine Power Throttle Body: All Technical Service Bulletins Throttle Body - Intermittent Loss of Engine Power Models 1987-89 S/AS & C/AC Bodies 1989 AA Body All With 3.0L Engine Subject Intermittent Loss Of Engine Power During Slow Speed Deceleration Index DRIVEABILITY Date May 30, 1989 No. 18-08-89 (C18-09-9) P-2096 BODY CODE LEGEND C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V AA SPIRIT/ACCLAIM SYMPTOM/CONDITION Intermittent loss of power (3.0L engine) during slow speed deceleration. PARTS REQUIRED 1 Mopar Parts Cleaner PN 4318037 1 Throttle Body Base Gasket PN 4300071 (1987-88) 1 Throttle Body Base Gasket PN 4324426 (1989) Scotch Brite Pad (Green) REPAIR PROCEDURE If the engine idles slow or rough after deceleration, or requires long crank times when cold, it may be caused by residue which has accumulated between the throttle blade and the throttle body bore. This residue will restrict airflow at closed throttle. Removing this residue from the throttle body bore and throttle blade should return the minimum air flow speed to proper specifications. 1. Perform the minimum airflow test as outlined in the Powertrain Diagnostics Procedures Manual. Be sure to use Miller Tool C-5004 when checking minimum air flow RPM. 2. If the minimum airflow RPM is below 800 RPM as indicated on the DRB II, remove the throttle body from the engine. 3. While holding the throttle open, spray the throttle body bore with Mopar Parts Cleaner PN 4318037. Spray the entire throttle body bore and the manifold side of the throttle blade. It is important to use only Mopar Parts Cleaner PN 4318037. Do not submerse the throttle body in solvents, gasoline or any other cleaning fluids. CAUTION: USE THIS CLEANER ONLY IN A WELL VENTILATED AREA. DO NOT LET THIS CLEANER COME IN CONTACT WITH SKIN. RUBBER OR BUTYL GLOVES ARE RECOMMENDED. WASH THOROUGHLY AFTER USE. AVOID EYE CONTACT. AVOID INGESTING. 4. Use a small (1" x 1") piece of green Scotch Brite scuff pad to clean the throttle body bore and the throttle blade. While holding the throttle open, clean both the top and bottom of the throttle body bore. Also clean the manifold side and edges of the throttle blade-. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 180889 > May > 89 > Throttle Body - Intermittent Loss of Engine Power > Page 2741 NOTE: IT IS IMPORTANT THIS CLEANING OPERATION BE PERFORMED THOROUGHLY AND COMPLETELY. THE EDGE OF THE THROTTLE BLADE AND THE PORTION OP THE THROTTLE BODY BORE THAT IS IN THE CLOSEST PROXIMITY OF THE CLOSED THROTTLE BLADE ARE THE MOST CRITICAL AREAS THE CLEANING SHOULD BE CONCENTRARED. THESE AREAS MUST BE FREE OF ALL DEPOSITS WHEN THE CLEANING IS COMPLETED. 5. Spray the throttle body with Mopar Parts Cleaner PN 4318037 and then blow dry with compressed shop air. Inspect for any foreign material which may have been left behind from the cleaning process. CAUTION: DO NOT APPLY SHOP AIR PRESSURE DIRECTLY INTO THROTTLE SHAFT AND THROTTLE BODY HOUSING HOLES. 6. Reinstall the throttle body and check to see if the minimum air flow RPM is within specification. If the air flow is still not within specification, repeat the cleaning procedure in step 4 above. If the minimum air flow RPM is still not within specification, the problem is not caused by throttle body contamination. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 14-30-01-99 . . . . . . . . . . . . . . . . 1.2 Hrs. FAILURE CODE: 08 - Blocked Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 2742 Throttle Body: Locations Throttle Body The Throttle Body Assembly is mounted to the end of the intake plenum, on the left (drivers) side. It has a hose mounted to it connecting the air cleaner to the throttle body. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 2743 Throttle Body: Description and Operation Fig. 6 Throttle body assembly The throttle body, Fig. 6, assembly is located on the left end of the air intake plenum and houses the throttle plate, throttle position sensor and the AIS motor. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 2744 Throttle Body: Testing and Inspection 1. Remove air cleaner assembly, then plug heated air door vacuum hose. 2. With vehicle in PARK for A/T, or NEUTRAL for M/T, START engine and warm until cooling fan cycles ON and OFF at least once. STOP engine. 3. Connect suitable timing light, then disconnect coolant temperature sensor. START engine, and ensure basic timing is set to 12° BTDC. 4. STOP engine and reconnect coolant temperature sensor wire. 5. Disconnect PCV valve hose from intake manifold nipple. 6. Attach tool No. C-5004 or equivalent (.125 inch orifice in attached hose) to intake manifold PCV nipple. 7. Connect DRB II or equivalent scanner, then START engine and allow to idle for at least 1 minute. 8. Using scanner, place read/hold switch in read position and depress ATM button until code 70 appears. 9. Place read/hold switch to hold position, then the following should occur: a. AIS motor will fully close. b. Idle spark advance will become fixed. c. Idle fuel will become enriched. d. Engine rpm will be displayed on diagnostic read-out tool in units of rpm x 10. For example, display 95 equals 95 x 10 which indicates 950 rpm. 10. Check idle rpm. If idle rpm is within 850-1250 rpm then throttle body minimum air flow is satisfactory. If idle rpm is not as specified, clean or replace throttle body, refer to MAINTENANCE PROCEDURES. Retest minimum air flow after throttle body cleaning. 11. STOP engine, then remove tool No. C-5004 (orifice) from intake manifold PCV nipple. Install PCV valve hose. 12 Erase fault codes. Remove scanner, then install air cleaner assembly and heated air door vacuum hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Cleaning Throttle Body: Service and Repair Throttle Body Cleaning 1. Under normal or severe operating conditions, it is possible for the throttle body to build deposits in the air flow area near the PCV inlet, and/or near the Automatic Idle Speed (AIS) inlet. These deposits can cause driveability problems that may or may not appear as a fault code in diagnosis. 2. Visually inspect the throttle body air flow area and if deposits are present refer to Powertrain Management/Fuel Delivery and Air Induction /Throttle Body/Service and Repair and remove the throttle body. Carefully clean any deposits from the throttle body air flow area, and insure that the intake plenum is also clean. NOTE: Do not use harsh abrasives or tank solvent washing to clean the throttle body. 3. Reinstall the throttle body and intake plenum if it was removed, refer to Powertrain Management/Fuel Delivery and Air Induction/Testing and Inspection/Procedures, and perform the test. If the throttle body fails the minimum air flow test no further service is possible and the throttle body must be replaced. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Cleaning > Page 2747 Throttle Body: Service and Repair Throttle Body Replacement Throttle Body REMOVAL 1. Disconnect negative battery terminal, and remove air cleaner hose and clamp. Disconnect and remove throttle cable, and transaxle linkage. 2. Disconnect Automatic Idle Speed (AIS) motor, and Throttle Position Sensor (TPS). Disconnect vacuum hoses from throttle body. 3. Remove throttle body to intake manifold mounting nuts. Remove throttle body and gasket. INSTALLATION 1. Install throttle body with new gasket and torque mounting nuts to 20 Nm (175 lb-in). 2. Install throttle body vacuum hoses, TPS connector, and AIS motor connector. Install throttle cable. 3. Install air cleaner hose and clamp and torque clamp to 3 Nm (30 lb-in). Connect negative battery terminal and check operation. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair Accelerator Pedal Assembly REMOVAL 1. Inside vehicle hold up the gas pedal and remove the throttle cable retainer and throttle cable from the upper end of the pedal shaft. The throttle lever must be rotated towards wide open throttle to allow enough cable slack to permit removal. 2. From the engine compartment pull the throttle cable out through the dash, leaving the dash grommet in place. Throttle Cable 3. Remove the throttle cable from the throttle lever, then remove cable from throttle bracket. INSTALLATION 1. Install the cable housing into the cable mounting bracket on the engine. Install cable end into second groove of the throttle cam. Push cable through dash grommet and reconnect to accelerator pedal. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision Throttle Position Sensor: Technical Service Bulletins Fuel Injection - TPS Diagnostic Procedure Revision Models 1989 AS Subject Fuel Injection Diagnostic Test Procedure Manual-Revision 1989 3.0L EFI Index MISCELLANEOUS Date December 29, 1989 No. 26-34-89 P-13 (C26-34-9) BODY CODE LEGEND AS - 1989 RAM VAN, CARAVAN, VOYAGER Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 2755 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel Injection - TPS Diagnostic Procedure Revision > Page 2756 DIAGNOSTIC MANUAL REVISION Attached you will find revision pages for the following Diagnostic Test Procedure Manual. This revision covers the subject CHECKING FOR FAULT MESSAGE-TPS VOLTAGE HIGH. 1989 3.0 Liter Electronic Fuel Injection Ram Van, Caravan, and Voyager Publication No. 81-699-9017. Pages 136 and 137. Please affix these revised pages in your manual. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2757 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2758 Throttle Position Sensor: Locations LH Rear Corner Of Cylinder Head Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2761 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 2762 Throttle Position Sensor: Description and Operation The TPS is mounted on the throttle body and senses the angle of the throttle plate opening. The sensor produces a voltage signal which increases and decreases according to throttle position. The SMEC uses these voltage signals to tailor air/fuel mixtures for varying conditions such as idle, wide open throttle, acceleration and deceleration. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 2763 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect three way connector at throttle position sensor (TPS), then remove TPS to throttle body mounting screws. 3. Lift TPS from throttle shaft, then remove O-ring. 4. Reverse procedure to install. Install new O-ring and torque TPS to throttle body mounting screw to 20 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Cylinder Location 1988-1996 3.0L (182) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Cylinder Location > Page 2769 Distributor Cap From The Top - Includes Connections Inside The Cap. (Round Terminals Are Plug Wire Connections On The Top Of The Cap.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations 1988-1996 3.0L (182) 3.0L Except Stealth Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Marks and Indicators: Diagrams TIMING MARK 3.0L Timing Scale Above Crank Pulley--Viewed From Front Of Car Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2781 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Senior 105 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2787 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2788 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect distributor lead wire at wiring harness connector. 2. Remove distributor cap retaining screws and remove distributor cap. 3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum. Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when reinstalling the distributor. 4. Remove the distributor hold down nut and remove the distributor from the engine. DISASSEMBLY 1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and remove lead wire. 2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or damaged slots. 3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing. 4. Remove 2 bearing retainer screws. 5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the distributor drive gear roll pin. 6. Remove distributor drive gear, remove distributor shaft and bearing assembly. REASSEMBLY 1. Install shaft and bearing assembly in distributor housing. 2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference marks made during disassembly, and install roll pin. 3. Install distributor shaft bearing retaining screws. 4. Install the photo optic sensing unit and bushing and tighten with 3 screws. 5. Install disk spacers and disk. Install disk assembly screw. 6. Install lead wire, and lead wire clamp screw. 7. Install protective cover on distributor housing. INSTALLATION 1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If engine has been cranked with distributor removed proceed to step 3 for installation. 2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the distributor is installed, the rotor will be in line with the previously scribed line on the air intake plenum. Proceed to step 4. 3. If the engine has been cranked with the distributor removed perform the following procedure: a. Rotate the crankshaft until the number one piston is at the top of its compression stroke. Distributor Cap Terminal Routing b. Rotate the distributor shaft until the rotor points to number one terminal. c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam shaft. With the distributor fully seated the rotor should be under the number one terminal. 4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers. Install hold down nut finger tight. 5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to ADJUSTMENT PROCEDURES for timing adjustment. . Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Specifications Distributor: Specifications Distributer Adapter ............................................................................................................................... .......................................... 14 Nm (120 in lbs) Distributer Housing Bolt ............................................. .................................................................................................................... 15 Nm (130 in lbs) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Specifications > Page 2792 Distributor: Locations Distributor Hold-Down The Optical Distributor is located at the back of the engine, behind the right-hand cylinder head. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Specifications > Page 2793 Distributor: Service and Repair REMOVAL 1. Disconnect distributor lead wire at wiring harness connector. 2. Remove distributor cap retaining screws and remove distributor cap. 3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum. Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when reinstalling the distributor. 4. Remove the distributor hold down nut and remove the distributor from the engine. DISASSEMBLY 1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and remove lead wire. 2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or damaged slots. 3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing. 4. Remove 2 bearing retainer screws. 5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the distributor drive gear roll pin. 6. Remove distributor drive gear, remove distributor shaft and bearing assembly. REASSEMBLY 1. Install shaft and bearing assembly in distributor housing. 2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference marks made during disassembly, and install roll pin. 3. Install distributor shaft bearing retaining screws. 4. Install the photo optic sensing unit and bushing and tighten with 3 screws. 5. Install disk spacers and disk. Install disk assembly screw. 6. Install lead wire, and lead wire clamp screw. 7. Install protective cover on distributor housing. INSTALLATION 1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If engine has been cranked with distributor removed proceed to step 3 for installation. 2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the distributor is installed, the rotor will be in line with the previously scribed line on the air intake plenum. Proceed to step 4. 3. If the engine has been cranked with the distributor removed perform the following procedure: a. Rotate the crankshaft until the number one piston is at the top of its compression stroke. Distributor Cap Terminal Routing b. Rotate the distributor shaft until the rotor points to number one terminal. c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam shaft. With the distributor fully seated the rotor should be under the number one terminal. 4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers. Install hold down nut finger tight. 5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to ADJUSTMENT PROCEDURES for timing adjustment. . Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2800 Ignition Coil: Description and Operation The Ignition Coil is designed to step up primary voltage of 12V to 25,000-35,000V. It is composed of a primary winding, secondary winding and a core of soft iron. The primary winding is made up of approximately 200 turns of heavy wire (approximately No. 18 gauge). The secondary winding is wound around the soft iron core, and the primary wiring surrounds the secondary. The purpose of the core is to concentrate the magnetic field. It transforms the battery voltage to the high secondary voltage (about 28kv) every time it receives a signal. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2805 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2811 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2817 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Senior 105 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2823 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2824 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect distributor lead wire at wiring harness connector. 2. Remove distributor cap retaining screws and remove distributor cap. 3. Rotate the engine crankshaft until the distributor rotor is pointing toward the intake plenum. Scribe a mark on the plenum at this point to indicate the position of the rotor for reference when reinstalling the distributor. 4. Remove the distributor hold down nut and remove the distributor from the engine. DISASSEMBLY 1. Remove protective cover from the distributor housing. Remove lead wire clamp screw and remove lead wire. 2. Remove disc assembly screw. Remove disk spacers and disk. Check disk for warpage cracks or damaged slots. 3. Remove bushing and 3 photo optic sensing unit fasteners. Remove unit from distributor housing. 4. Remove 2 bearing retainer screws. 5. Make reassembly alignment marks on gear and shaft, then with a pin punch drive out the distributor drive gear roll pin. 6. Remove distributor drive gear, remove distributor shaft and bearing assembly. REASSEMBLY 1. Install shaft and bearing assembly in distributor housing. 2. Install distributor drive gear on shaft, taking care to ensure proper alignment with reference marks made during disassembly, and install roll pin. 3. Install distributor shaft bearing retaining screws. 4. Install the photo optic sensing unit and bushing and tighten with 3 screws. 5. Install disk spacers and disk. Install disk assembly screw. 6. Install lead wire, and lead wire clamp screw. 7. Install protective cover on distributor housing. INSTALLATION 1. If engine has not been cranked with distributor removed proceed to step 2 for installation. If engine has been cranked with distributor removed proceed to step 3 for installation. 2. Position the distributor in the engine, making sure O-ring is properly seated on distributor, and is not cut or worn. Carefully engage the distributor drive with the cam shaft drive, so that when the distributor is installed, the rotor will be in line with the previously scribed line on the air intake plenum. Proceed to step 4. 3. If the engine has been cranked with the distributor removed perform the following procedure: a. Rotate the crankshaft until the number one piston is at the top of its compression stroke. Distributor Cap Terminal Routing b. Rotate the distributor shaft until the rotor points to number one terminal. c. Lower the distributor into the opening, engaging the distributor drive with the drive on the cam shaft. With the distributor fully seated the rotor should be under the number one terminal. 4. Install the distributor cap, making sure all plug wires are seated securely in the cap towers. Install hold down nut finger tight. 5. Connect distributor lead wire and negative battery cable lead. Set ignition timing, refer to ADJUSTMENT PROCEDURES for timing adjustment. . Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations Ignition Switch: Locations I/P, Cowl & Steering Column Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations > Page 2828 Steering Column Components Top Of Steering Column Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations > Page 2829 Ignition Switch: Service and Repair Fig. 10 Ignition switch replacement 1. If equipped, disarm airbag system, refer to MAINTENANCE PROCEDURES. 2. Remove left lower instrument panel cover. 3. Position gear selector to D and disconnect indicator cable, if equipped with automatic transaxle. 4. Remove lower panel reinforcement, then five steering column to support bracket attaching nuts. 5. Lower column and disconnect ignition switch electrical connector. 6. Position ignition lock cylinder in Lock position. 7. Tape ignition switch rod to steering column to prevent rod from falling out of lock cylinder assembly. 8. Remove two ignition switch attaching screws, then the switch. 9. Reverse procedure to install. Rearm airbag system, refer to MAINTENANCE PROCEDURES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. .................... 0.9 to 1.1 mm (0.039 to 0.044 in) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Specifications > Page 2834 Spark Plug: Specifications Tightening Specifications Spark Plug Torque ............................................................................................................................... ...................................................... 28 Nm (20 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 2846 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 2852 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 2853 Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 2854 Transmission Solenoid Connector Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging Torque Converter Clutch Solenoid: Customer Interest Converter Lock Up Solenoid Bucking/Surging Models 1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies Subject Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines. Index DRIVEABILITY Date February 12, 1990 No. 18-02-90 P-205 (C18-27-9) BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ - LEBARON COUPE/LEBARON CONVERTIBLE AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4 speed automatic transmission. SYMPTOM/CONDITION A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur under light deceleration conditions, especially when cresting a hill. DIAGNOSIS The above conditions can be diagnosed by disconnecting the transmission lock-up torque converter solenoid, and driving the vehicle under the above conditions. If the problem goes away, follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test Procedure for correction. PARTS REQUIRED Driveability Kit PN 4419447 Consists of: 1 Wiring Jumper Assembly PN 4400768 1 Lock-Up Solenoid Cap PN 4419446 2 Tie Wrap PN 6015756 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE The following procedure involves disconnecting the lock-up torque convertor solenoid. The customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2 miles per gallon may be noticed, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 2863 FIGURE A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 2864 FIGURE B 1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located directly behind the transmission dipstick (Figures A and B). 2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in Step 1. 3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A). 3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places using tie wrap, PN 6015756 (Figure B). 4. Install supplied cap, PN 4419446, onto lock-up solenoid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 2865 FIGURE C 5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and attach near VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 21-96-01-90 0.2 Hrs. FAILURE CODE: AM - Authorized modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging Torque Converter Clutch Solenoid: All Technical Service Bulletins Converter Lock Up Solenoid Bucking/Surging Models 1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies Subject Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines. Index DRIVEABILITY Date February 12, 1990 No. 18-02-90 P-205 (C18-27-9) BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ - LEBARON COUPE/LEBARON CONVERTIBLE AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4 speed automatic transmission. SYMPTOM/CONDITION A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur under light deceleration conditions, especially when cresting a hill. DIAGNOSIS The above conditions can be diagnosed by disconnecting the transmission lock-up torque converter solenoid, and driving the vehicle under the above conditions. If the problem goes away, follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test Procedure for correction. PARTS REQUIRED Driveability Kit PN 4419447 Consists of: 1 Wiring Jumper Assembly PN 4400768 1 Lock-Up Solenoid Cap PN 4419446 2 Tie Wrap PN 6015756 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE The following procedure involves disconnecting the lock-up torque convertor solenoid. The customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2 miles per gallon may be noticed, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 2871 FIGURE A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 2872 FIGURE B 1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located directly behind the transmission dipstick (Figures A and B). 2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in Step 1. 3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A). 3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places using tie wrap, PN 6015756 (Figure B). 4. Install supplied cap, PN 4419446, onto lock-up solenoid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 2873 FIGURE C 5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and attach near VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 21-96-01-90 0.2 Hrs. FAILURE CODE: AM - Authorized modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations Part Throttle Unlock Solenoid (3speed) LH Side Of Engine Compartment 3 Speed Automatic RH Side Of Transaxle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 2876 Applicable to: 3 Speed A-413 Automatic Transaxle 4 Speed Automatic Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 2877 Electrical Connections, 3 Speed Automatic Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 2878 Torque Converter Clutch Solenoid: Description and Operation Part Throttle Unlock Solenoid (3 Speed Automatic) This solenoid is controlled by the engine controller. The engine controller applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. The lock-up torque converter is only locked up when the transmission is in direct drive and when the throttle position is not fluctuating. If the engine controller receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the engine controller will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2889 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2890 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2891 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2892 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2893 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2894 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift Control Module: Customer Interest A/T - 41TE Harsh 2nd - 1st Gear Downshift NO.: 21-16-93 Rev. A GROUP: Transmission DATE: Oct 8, 1993 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED. CHANGES ARE HIGHLIGHTED BY **ASTERISKS**. MODELS: 1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue 1992 (AP) Shadow/Sundance SYMPTOM/CONDITION: Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service Manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 2899 TIME ALLOWANCE: Labor Operation No. **08-19-05-99** 0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift Control Module: Customer Interest A/T - 41TE Harsh 2-1 Gear Downshift NO.: 21-16-92 GROUP: Transmission DATE: Nov. 2, 1992 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle MODELS: 1989-1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990-1992 (AY) Imperial/New Yorker Fifth Avenue SYMPTOM/CONDITION: Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 2904 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting Control Module: Customer Interest A/T - A604 Excessive Upshifting/Downshifting Models 1989-90 AA, AC, AG, AJ, AS, & AY Bodies Subject A-604 Transmission Excessive Upshifting/ Downshifting Index TRANSMISSION Date April 9, 1990 No. 21-12-90 (C21-06-0) P-1042 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY AY - IMPERIAL/NEW YORKER FIFTH AVENUE SYMPTOM/CONDITION Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition when the vehicle is fully loaded, driving up a grade or into a head wind. This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior (1989) model year A-604 controllers. A new A-604 controller, PN 4557585, entered production late March 1990. The new controller allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle torque load changes. DIAGNOSIS Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does not apply. Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain Diagnostic Procedure Manual. If no fault codes are present, perform the following repair procedure. If fault codes are present, they must be corrected and the corrections verified before performing the following repair procedure. PARTS REQUIRED 1. 1 - Controller PN 4557585 REPAIR PROCEDURE This repair involves the replacement of the transaxle controller. 1. Disconnect the negative battery cable. 2. Disconnect the 60-way connector from the controller. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 2909 3. Remove the controller. 4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds. 5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds. 6. Reconnect the negative battery cable. 7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-05-96 0.6 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2915 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2916 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2917 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2918 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2919 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 2920 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2nd - 1st Gear Downshift NO.: 21-16-93 Rev. A GROUP: Transmission DATE: Oct 8, 1993 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED. CHANGES ARE HIGHLIGHTED BY **ASTERISKS**. MODELS: 1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue 1992 (AP) Shadow/Sundance SYMPTOM/CONDITION: Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service Manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 2925 TIME ALLOWANCE: Labor Operation No. **08-19-05-99** 0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2-1 Gear Downshift NO.: 21-16-92 GROUP: Transmission DATE: Nov. 2, 1992 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle MODELS: 1989-1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990-1992 (AY) Imperial/New Yorker Fifth Avenue SYMPTOM/CONDITION: Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 2930 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting Control Module: All Technical Service Bulletins A/T - A604 Excessive Upshifting/Downshifting Models 1989-90 AA, AC, AG, AJ, AS, & AY Bodies Subject A-604 Transmission Excessive Upshifting/ Downshifting Index TRANSMISSION Date April 9, 1990 No. 21-12-90 (C21-06-0) P-1042 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY AY - IMPERIAL/NEW YORKER FIFTH AVENUE SYMPTOM/CONDITION Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition when the vehicle is fully loaded, driving up a grade or into a head wind. This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior (1989) model year A-604 controllers. A new A-604 controller, PN 4557585, entered production late March 1990. The new controller allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle torque load changes. DIAGNOSIS Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does not apply. Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain Diagnostic Procedure Manual. If no fault codes are present, perform the following repair procedure. If fault codes are present, they must be corrected and the corrections verified before performing the following repair procedure. PARTS REQUIRED 1. 1 - Controller PN 4557585 REPAIR PROCEDURE This repair involves the replacement of the transaxle controller. 1. Disconnect the negative battery cable. 2. Disconnect the 60-way connector from the controller. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 2935 3. Remove the controller. 4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds. 5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds. 6. Reconnect the negative battery cable. 7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-05-96 0.6 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision Technical Service Bulletin # 210889 Date: 890403 A/T Reaction Shaft Support - Revision Models 1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle Subject Revised Reaction Shaft Support Index TRANSMISSION Date April 3, 1989 No. 21-08-89 P-1408 (C21-16-9) Description BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER SYMPTOM/CONDITION NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE AUTOMATIC TRANSAXLE, PART NUMBER 4446659. The procedure outlined in this bulletin should be followed if removal and disassembly of the transaxle is required. DIAGNOSIS 1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual (#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A) to determine if disassembly is required. Use the following procedure when the transaxle is disassembled for repair. PARTS REQUIRED 1 Repair package P/N 4549248 1 Gasket Package P/N 4504558 1 Controller (AS REQUIRED) P/N 5234678 NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT CLUTCH HUB IS REQUIRED. Input Clutch Retainer P/N 4431609 REPAIR PROCEDURE 1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the following guidelines. 2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or subsequent) controller. Always check input shaft end play before disassembling the transaxle. Step A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 2940 FIGURE 1 - FRONT PUMP REACTION SHAFT 1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves, replace it with the four ring reaction support supplied in the repair package (Figure 1). If the reaction support that is removed from the transaxle has four ring grooves, the repair package is not needed. Step B FIGURE 2 - INPUT CLUTCH RETAINER 1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer as shown. If the bump is present, replace the retainer with a new one (P/N 4431609). 2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package. When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the compression of the Orings. 3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is no difference in any of the O-rings. The color was added to facilitate assembly. 4. Inspect and replace any distressed (burned) clutch components as required. Step C 1. Remove and discard the steel separator plate from the valve body. 2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow to the overdrive clutch circuit. Step D Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 2941 1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play to the service preferred setting of .005" to .015". The actual total end play specification is .005" to .025" and is acceptable if the service preferred setting cannot be obtained. Other Recommendations 1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not use other kinds of petroleum based greases such as chassis grease that could plug critical orifices or might be incompatible with transmission fluid. 2. Replace the torque convertor if a clutch failure has occurred. 3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY. Replace it if necessary. 4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has occurred. 5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be used if ATF Plus is not available. POLICY: Reimbursable within the limits of the warranty. TIME ALLOWANCE: Labor Operation No. 21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs. FAILURE CODE: 7H - Reaction shaft/supt. assy. failed Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 2942 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision Technical Service Bulletin # 210889 Date: 890403 A/T Reaction Shaft Support - Revision Models 1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle Subject Revised Reaction Shaft Support Index TRANSMISSION Date April 3, 1989 No. 21-08-89 P-1408 (C21-16-9) Description BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER SYMPTOM/CONDITION NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE AUTOMATIC TRANSAXLE, PART NUMBER 4446659. The procedure outlined in this bulletin should be followed if removal and disassembly of the transaxle is required. DIAGNOSIS 1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual (#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A) to determine if disassembly is required. Use the following procedure when the transaxle is disassembled for repair. PARTS REQUIRED 1 Repair package P/N 4549248 1 Gasket Package P/N 4504558 1 Controller (AS REQUIRED) P/N 5234678 NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT CLUTCH HUB IS REQUIRED. Input Clutch Retainer P/N 4431609 REPAIR PROCEDURE 1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the following guidelines. 2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or subsequent) controller. Always check input shaft end play before disassembling the transaxle. Step A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 2948 FIGURE 1 - FRONT PUMP REACTION SHAFT 1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves, replace it with the four ring reaction support supplied in the repair package (Figure 1). If the reaction support that is removed from the transaxle has four ring grooves, the repair package is not needed. Step B FIGURE 2 - INPUT CLUTCH RETAINER 1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer as shown. If the bump is present, replace the retainer with a new one (P/N 4431609). 2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package. When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the compression of the Orings. 3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is no difference in any of the O-rings. The color was added to facilitate assembly. 4. Inspect and replace any distressed (burned) clutch components as required. Step C 1. Remove and discard the steel separator plate from the valve body. 2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow to the overdrive clutch circuit. Step D Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 2949 1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play to the service preferred setting of .005" to .015". The actual total end play specification is .005" to .025" and is acceptable if the service preferred setting cannot be obtained. Other Recommendations 1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not use other kinds of petroleum based greases such as chassis grease that could plug critical orifices or might be incompatible with transmission fluid. 2. Replace the torque convertor if a clutch failure has occurred. 3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY. Replace it if necessary. 4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has occurred. 5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be used if ATF Plus is not available. POLICY: Reimbursable within the limits of the warranty. TIME ALLOWANCE: Labor Operation No. 21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs. FAILURE CODE: 7H - Reaction shaft/supt. assy. failed Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 2950 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 2953 Control Module: Locations Power Distribution Center Power Distribution Center Fuse Block Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 2954 Control Module: Diagrams Part 1 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 2955 Part 2 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 2956 Part 3 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 2957 Part 4 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 2958 Part 5 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 2959 Part 6 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 2960 Part 7 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 2961 Part 8 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 2962 Part 9 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 2963 Part 10 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 2964 Part 11 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 Control Module: Description and Operation A604 DESCRIPTION This computer is dedicated to the control of the A-604 Transaxle. It has a connector shaped similarly to the one on the Engine Controller. It contains on-board diagnostics and fault code memory which is accessed by the DRBII Diagnostic Tool through Chrysler's C2D Bus. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 > Page 2967 Control Module: Description and Operation 41TE Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 > Page 2968 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 2971 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 2975 Back Up Lamp Relay / Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 2976 Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 2977 Transmission Control System Relay: Description and Operation DESCRIPTION This relay is operated by the A-604 controller. Its purpose is to make operating voltage available to the solenoids and switches located in the Solenoid Pack. When the Controller opens the relay, voltage is taken away from the solenoids and the transmission goes into a limp-in mode. While in this mode, only second gear, reverse and neutral are available. This relay may also be referred to as the Safety Shutdown Relay. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations Transmission Position Relay: Component Locations Back Up Lamp Relay / Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page 2982 Back Up Lamp Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation A604 (41TE) 4 Speed Transaxle DESCRIPTION The PRNDL switch is similar in appearance to the Neutral Safety Switch. Its purpose is to help the transaxle controller sense the shifter position (manual valve), and help operate the reverse lamps. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2996 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2997 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2998 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3004 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3005 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3010 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3011 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3012 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3018 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3019 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3022 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3023 Transmission Position Switch/Sensor: Locations 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3024 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 3027 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 3030 Transmission Position Switch/Sensor: Description and Operation PRNDL The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. It may have been replaced by a transmission range sensor (TRS). Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3033 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3034 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3035 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 3044 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3049 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3050 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3051 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3057 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 3062 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 3063 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 3064 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3065 Input / Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Transmission Speed Sensor: Description and Operation Output Speed Sensor DESCRIPTION This is a two wire, magnetic pick-up device used to sense the output speed of the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor > Page 3068 Transmission Speed Sensor: Description and Operation Turbine Speed Sensor A604 (41TE) 4 Speed Transaxle DESCRIPTION This is a two wire, magnetic pick-up device used to sense the input speed of the transaxle (torque convertor turbine). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 3069 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 3084 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 3090 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3091 Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3092 Transmission Solenoid Connector Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging Torque Converter Clutch Solenoid: Customer Interest Converter Lock Up Solenoid Bucking/Surging Models 1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies Subject Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines. Index DRIVEABILITY Date February 12, 1990 No. 18-02-90 P-205 (C18-27-9) BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ - LEBARON COUPE/LEBARON CONVERTIBLE AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4 speed automatic transmission. SYMPTOM/CONDITION A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur under light deceleration conditions, especially when cresting a hill. DIAGNOSIS The above conditions can be diagnosed by disconnecting the transmission lock-up torque converter solenoid, and driving the vehicle under the above conditions. If the problem goes away, follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test Procedure for correction. PARTS REQUIRED Driveability Kit PN 4419447 Consists of: 1 Wiring Jumper Assembly PN 4400768 1 Lock-Up Solenoid Cap PN 4419446 2 Tie Wrap PN 6015756 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE The following procedure involves disconnecting the lock-up torque convertor solenoid. The customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2 miles per gallon may be noticed, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging > Page 3101 FIGURE A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging > Page 3102 FIGURE B 1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located directly behind the transmission dipstick (Figures A and B). 2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in Step 1. 3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A). 3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places using tie wrap, PN 6015756 (Figure B). 4. Install supplied cap, PN 4419446, onto lock-up solenoid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging > Page 3103 FIGURE C 5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and attach near VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 21-96-01-90 0.2 Hrs. FAILURE CODE: AM - Authorized modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging Torque Converter Clutch Solenoid: All Technical Service Bulletins Converter Lock Up Solenoid Bucking/Surging Models 1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies Subject Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines. Index DRIVEABILITY Date February 12, 1990 No. 18-02-90 P-205 (C18-27-9) BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ - LEBARON COUPE/LEBARON CONVERTIBLE AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4 speed automatic transmission. SYMPTOM/CONDITION A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur under light deceleration conditions, especially when cresting a hill. DIAGNOSIS The above conditions can be diagnosed by disconnecting the transmission lock-up torque converter solenoid, and driving the vehicle under the above conditions. If the problem goes away, follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test Procedure for correction. PARTS REQUIRED Driveability Kit PN 4419447 Consists of: 1 Wiring Jumper Assembly PN 4400768 1 Lock-Up Solenoid Cap PN 4419446 2 Tie Wrap PN 6015756 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE The following procedure involves disconnecting the lock-up torque convertor solenoid. The customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2 miles per gallon may be noticed, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3109 FIGURE A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3110 FIGURE B 1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located directly behind the transmission dipstick (Figures A and B). 2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in Step 1. 3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A). 3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places using tie wrap, PN 6015756 (Figure B). 4. Install supplied cap, PN 4419446, onto lock-up solenoid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3111 FIGURE C 5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and attach near VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 21-96-01-90 0.2 Hrs. FAILURE CODE: AM - Authorized modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations Part Throttle Unlock Solenoid (3speed) LH Side Of Engine Compartment 3 Speed Automatic RH Side Of Transaxle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3114 Applicable to: 3 Speed A-413 Automatic Transaxle 4 Speed Automatic Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3115 Electrical Connections, 3 Speed Automatic Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3116 Torque Converter Clutch Solenoid: Description and Operation Part Throttle Unlock Solenoid (3 Speed Automatic) This solenoid is controlled by the engine controller. The engine controller applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. The lock-up torque converter is only locked up when the transmission is in direct drive and when the throttle position is not fluctuating. If the engine controller receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the engine controller will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 3127 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 3133 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3134 Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3135 Transmission Solenoid Connector Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging Torque Converter Clutch Solenoid: Customer Interest Converter Lock Up Solenoid Bucking/Surging Models 1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies Subject Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines. Index DRIVEABILITY Date February 12, 1990 No. 18-02-90 P-205 (C18-27-9) BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ - LEBARON COUPE/LEBARON CONVERTIBLE AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4 speed automatic transmission. SYMPTOM/CONDITION A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur under light deceleration conditions, especially when cresting a hill. DIAGNOSIS The above conditions can be diagnosed by disconnecting the transmission lock-up torque converter solenoid, and driving the vehicle under the above conditions. If the problem goes away, follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test Procedure for correction. PARTS REQUIRED Driveability Kit PN 4419447 Consists of: 1 Wiring Jumper Assembly PN 4400768 1 Lock-Up Solenoid Cap PN 4419446 2 Tie Wrap PN 6015756 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE The following procedure involves disconnecting the lock-up torque convertor solenoid. The customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2 miles per gallon may be noticed, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3144 FIGURE A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3145 FIGURE B 1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located directly behind the transmission dipstick (Figures A and B). 2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in Step 1. 3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A). 3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places using tie wrap, PN 6015756 (Figure B). 4. Install supplied cap, PN 4419446, onto lock-up solenoid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3146 FIGURE C 5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and attach near VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 21-96-01-90 0.2 Hrs. FAILURE CODE: AM - Authorized modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging Torque Converter Clutch Solenoid: All Technical Service Bulletins Converter Lock Up Solenoid Bucking/Surging Models 1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies Subject Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines. Index DRIVEABILITY Date February 12, 1990 No. 18-02-90 P-205 (C18-27-9) BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ - LEBARON COUPE/LEBARON CONVERTIBLE AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4 speed automatic transmission. SYMPTOM/CONDITION A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur under light deceleration conditions, especially when cresting a hill. DIAGNOSIS The above conditions can be diagnosed by disconnecting the transmission lock-up torque converter solenoid, and driving the vehicle under the above conditions. If the problem goes away, follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test Procedure for correction. PARTS REQUIRED Driveability Kit PN 4419447 Consists of: 1 Wiring Jumper Assembly PN 4400768 1 Lock-Up Solenoid Cap PN 4419446 2 Tie Wrap PN 6015756 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE The following procedure involves disconnecting the lock-up torque convertor solenoid. The customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2 miles per gallon may be noticed, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging > Page 3152 FIGURE A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging > Page 3153 FIGURE B 1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located directly behind the transmission dipstick (Figures A and B). 2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in Step 1. 3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A). 3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places using tie wrap, PN 6015756 (Figure B). 4. Install supplied cap, PN 4419446, onto lock-up solenoid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid Bucking/Surging > Page 3154 FIGURE C 5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and attach near VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 21-96-01-90 0.2 Hrs. FAILURE CODE: AM - Authorized modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations Part Throttle Unlock Solenoid (3speed) LH Side Of Engine Compartment 3 Speed Automatic RH Side Of Transaxle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3157 Applicable to: 3 Speed A-413 Automatic Transaxle 4 Speed Automatic Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3158 Electrical Connections, 3 Speed Automatic Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3159 Torque Converter Clutch Solenoid: Description and Operation Part Throttle Unlock Solenoid (3 Speed Automatic) This solenoid is controlled by the engine controller. The engine controller applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. The lock-up torque converter is only locked up when the transmission is in direct drive and when the throttle position is not fluctuating. If the engine controller receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the engine controller will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Kickdown Band: Specifications Kickdown Band Adjustment Locknut 35 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Kickdown > Page 3164 Band: Specifications Raverse Band Adjusting Locknut 120 in.lb Reverse Band Shaft Plug 60 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > Front Band Adjustment Band: Adjustments Front Band Adjustment Fig. 4 Kickdown band adjusting screw location 1. Loosen locknut and back off nut approximately 5 turns, Fig. 4. Ensure adjusting screw turns freely in transaxle case. 2. Using adjusting screw tightener tool No. C-3380-A and C-3705, torque band adjusting screw to 47-50 inch lbs. If tightener tool No. C-3705 is not used, torque adjusting screw to 72 inch lbs. 3. Back off adjusting screw 2-1/2 turns. 4. Hold adjusting screw in this position and torque locknut to 35 ft-lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > Front Band Adjustment > Page 3167 Band: Adjustments Rear Band Adjustment 1. Loosen, then back off locknut approximately 5 turns. 2. Torque adjusting screw to 41 inch lbs. 3. Back off adjusting screw 3-1/2 turns and torque locknut to 10 ft-lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Band Apply Servo: Customer Interest A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3176 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3177 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3178 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Band Apply Servo: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3184 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3185 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3186 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 212290 > Nov > 90 > A/T - A604 1-2 Gear Upshift Shudder Clutch: Customer Interest A/T - A604 1-2 Gear Upshift Shudder SUBJECT: 1-2 Upshift Shudder 1989-91 Vehicles Equipped With A-604 Transmission NO.: 21-22-90 GROUP: TRANSMISSION DATE: Nov. 19, 1990 MODELS: 1989-91 (AA) SPIRIT/ACCLAIM/LEBARON (AC) DYNASTY/NEW YORKER/LANDAU/SALON (AG) DAYTONA (AJ) LEBARON COUPE/LEBARON CONVERTIBLE (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY (AY) IMPERIAL/NEW YORKER FIFTH AVENUE SYMPTOM/CONDITION: Some vehicles equipped with the A-604 transmission may exhibit an occasional shudder during the 1-2 upshift. This condition is most noticeable when the vehicle is being operated on a smooth blacktop road after the transmission has reached normal operating temperature. DIAGNOSIS: Check transmission fluid level and condition. Connect the DRB II. Record fault codes. Perform the diagnostic test as outlined in the appropriate Powertrain Diagnostic Manual. Be sure to complete the shift lever test, clutch test and record clutch volumes (CVI). Select the RPM display on the DRB II. Road test the vehicle a sufficient distance to ensure the transmission has warmed up. NOTE: THE FOLLOWING STEP SHOUID BE PERFORMED ON A SMOOTH BLACKTOP ROAD. Initiate a 1-2 upshift from a throttle angle (TSP) of 10" through wide open throttle in steps of 50. If shudder was experienced during the 1-2 upshift, perform the repair procedure. If no shudder was experienced, but fluid condition, fault codes, shift lever test or clutch test indicate a problem, correct as required. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves removing the transaxle, and reconditioning the 2-4 clutch. Use the appropriate Service Manual as a guide in performing the following steps. 1. Remove the transaxle assembly. 2. Remove the oil pan and valve body. 3. Measure and record the input shaft end play. 4. Remove input speed sensor. 5. Remove the oil pump and gasket. NOTE: ON 1991 VEHICLES BE SURE TO REMOVE THE INTERNAL OIL COOLER BYPASS VALVE. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 212290 > Nov > 90 > A/T - A604 1-2 Gear Upshift Shudder > Page 3195 6. Remove the No. 1 caged needle bearing. 7. Remove the input clutch assembly. 8. Remove the front sun gear and No. 4 thrust washer. 9. Remove the front carrier and rear annulus assembly and the No. 6 needle bearing. 10. Remove the rear sun gear and No. 7 needle bearing. 11. Remove the 2-4 clutch retainer snap ring using tool 5058. 12. Remove the 2-4 clutch retainer and return spring. 13. Disassemble and clean the 2-4 clutch retainer and piston. 14. Install the 4 new clutch discs PN 4567212, and 4 new clutch plates PN 4412247. 15. Assemble the 2-4 retainer, using new clutch seal package PN 4504050. 16. Install the 2-4 retainer, spring, and snap ring. 17. Check the 2-4 clutch clearance. The clearance should be 0.76 to 2.64 mm (.030 to .140). If clearance is not within specification, the clutch is not assembled properly. 18. Install the rear sun gear and No. 7 needle bearing. 19. Install the front carrier and rear annulus assembly and the No. 6 needle bearing. 20. Install the front sun gear and No. 4 thrust washer. NOTE: IF INPUT SHAFT END PLAY WAS FOUND OUT OF SPECIFICATION .13 TO .64 mm (.005 To .025) DURING DISASSEMBLY REPIACE THE NO. 4 THRUST WASHER WITH THE CORRECT WASHER AT THIS TIME. 21. Install the input clutch assembly. 22. Install the No. 1 caged needle bearing. 23. Install oil pump using new gasket package PN 4504555. NOTE: ON 1991 VEHICLES BE SURE TO INSTALL THE INTERNAL OIL COOLER BYPASS VALVE. 24. Install input speed sensor. 25. Check input shaft end play. 26. Install the valve body, using new valve body gasket package PN 4504553. 27. Install oil pan. 28. Install the transaxle assembly. 29. Refill the transaxle with MOPAR ATF PLUS (ATF Type 7176), or DEXTRON II. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 1-2 Upshift Shudder 21-34-02-92 ........ 4.8 Hrs. FAILURE CODE: 58 - Internal defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210996 > Jun > 96 > A/T - Clutch Volume Index QuIck Learn Clutch: All Technical Service Bulletins A/T - Clutch Volume Index QuIck Learn NO: 21-09-96 GROUP: Transmission DATE: June 28, 1996 SUBJECT: Clutch Volume Index Quick Learn Procedure Requirement After Transaxle Overhaul Or Replacement-41TE Transaxle MODELS: 1989 - 1992 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1992 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1992 (AG) Daytona 1989 - 1992 (AJ) LeBaron Coupe/LeBaron Convertible 1992 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1992 (AS) Town & Country/Caravan/Voyager 1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue DISCUSSION: NOTE: FAILURE TO PERFORM THE QUICK LEARN PROCEDURE OR BATTERY DISCONNECT, AS DESCRIBED BELOW, AFTER A TRANSAXLE IS REPLACED OR OVERHAULED CAN RESULT IN A LOW MILEAGE TRANSAXLE FAILURE OR POOR INITIAL SHIFT QUALITY. The DRB III will now support the quick learn procedure for the 1989 thru 1992 Model Year Vehicles equipped with a service replacement EATX II (with cooling fins) Transmission Control Module (TCM) having the following part numbers: 4796121, 4796122, 4696123, 4696124. For EATX II TCM part numbers that precede the above list, refer to Repair Procedure No. 1 of Technical Service Bulletin 18-24-95, dated June 23, 1995. NOTE: 1993 AND LATER 41TE/42LE TCM'S HAVE ALWAYS BEEN QUICK LEARN CAPABLE. For EATX I (without cooling fins) TCM's, disconnecting the battery for one minute or performing the battery disconnect function with the DRB will reset the clutch volume index (CVI) to an acceptable range and the quick learn procedure is not required. You must use DRB III code version 19.2 (released on Mar. 1, 1996 with TIL disc 1102) or later in order to be able to quick learn 1989 thru 1992 model year vehicles. Quick learn must be done on any 41TE or 42LE equipped vehicle when the transmission has been replaced or where transmission work has been performed which affects CVI. For example, clutch pack replacements. NOTE: THE READING OF EATX DIAGNOSTIC TROUBLE CODES (DTC'S) AND PROPER DIAGNOSTICS FOR 1989 THRU 1992 MODEL YEAR VEHICLES MUST BE PERFORMED USING THE MDS AND A DRB II WITH THE APPROPRIATE CARTRIDGE OR DRB III, OR USING A STAND ALONE DRB III WITH THE SUPER CARD INSTALLED. AFTER PERFORMING DIAGNOSTICS YOU MUST ERASE ANY DTC'S USING ONE OF THE TOOL CONFIGURATIONS LISTED ABOVE BEFORE PROCEEDING WITH THE QUICK LEARN PROCEDURE. PROCEDURE: The EATX II quick learn procedure is required whenever a transaxle is repaired or replaced. 1. Ensure the transmission fluid level is correct. 2. Start vehicle, place the shift lever in Overdrive (OD), move the vehicle at least five feet with the engine running and then place shifter in Neutral (N). Apply the parking brake and let the engine idle. This purges the air in the clutch circuits to prevent erroneous clutch volume values which could cause poor initial shift quality or a low mileage transaxle failure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210996 > Jun > 96 > A/T - Clutch Volume Index QuIck Learn > Page 3201 3. Using the DRB III select the 1994 - 1997 Diagnostics option (1) and choose Transmissions. 4. Choose the Trans Overhauled/Replaced option and follow the instructions on the DRB III screen. NOTE: AFTER PERFORMING QUICK LEARN USE A PROPER DIAGNOSTIC CONFIGURATION TO READ THE DTC'S. IF ONLY DTC 12 EXISTS, ERASE THE DTC. IF THERE ARE OTHER DTC'S, PERFORM THE PROPER DIAGNOSTICS FOR THOSE DTC'S. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 212290 > Nov > 90 > A/T - A604 1-2 Gear Upshift Shudder Clutch: All Technical Service Bulletins A/T - A604 1-2 Gear Upshift Shudder SUBJECT: 1-2 Upshift Shudder 1989-91 Vehicles Equipped With A-604 Transmission NO.: 21-22-90 GROUP: TRANSMISSION DATE: Nov. 19, 1990 MODELS: 1989-91 (AA) SPIRIT/ACCLAIM/LEBARON (AC) DYNASTY/NEW YORKER/LANDAU/SALON (AG) DAYTONA (AJ) LEBARON COUPE/LEBARON CONVERTIBLE (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY (AY) IMPERIAL/NEW YORKER FIFTH AVENUE SYMPTOM/CONDITION: Some vehicles equipped with the A-604 transmission may exhibit an occasional shudder during the 1-2 upshift. This condition is most noticeable when the vehicle is being operated on a smooth blacktop road after the transmission has reached normal operating temperature. DIAGNOSIS: Check transmission fluid level and condition. Connect the DRB II. Record fault codes. Perform the diagnostic test as outlined in the appropriate Powertrain Diagnostic Manual. Be sure to complete the shift lever test, clutch test and record clutch volumes (CVI). Select the RPM display on the DRB II. Road test the vehicle a sufficient distance to ensure the transmission has warmed up. NOTE: THE FOLLOWING STEP SHOUID BE PERFORMED ON A SMOOTH BLACKTOP ROAD. Initiate a 1-2 upshift from a throttle angle (TSP) of 10" through wide open throttle in steps of 50. If shudder was experienced during the 1-2 upshift, perform the repair procedure. If no shudder was experienced, but fluid condition, fault codes, shift lever test or clutch test indicate a problem, correct as required. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves removing the transaxle, and reconditioning the 2-4 clutch. Use the appropriate Service Manual as a guide in performing the following steps. 1. Remove the transaxle assembly. 2. Remove the oil pan and valve body. 3. Measure and record the input shaft end play. 4. Remove input speed sensor. 5. Remove the oil pump and gasket. NOTE: ON 1991 VEHICLES BE SURE TO REMOVE THE INTERNAL OIL COOLER BYPASS VALVE. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 212290 > Nov > 90 > A/T - A604 1-2 Gear Upshift Shudder > Page 3206 6. Remove the No. 1 caged needle bearing. 7. Remove the input clutch assembly. 8. Remove the front sun gear and No. 4 thrust washer. 9. Remove the front carrier and rear annulus assembly and the No. 6 needle bearing. 10. Remove the rear sun gear and No. 7 needle bearing. 11. Remove the 2-4 clutch retainer snap ring using tool 5058. 12. Remove the 2-4 clutch retainer and return spring. 13. Disassemble and clean the 2-4 clutch retainer and piston. 14. Install the 4 new clutch discs PN 4567212, and 4 new clutch plates PN 4412247. 15. Assemble the 2-4 retainer, using new clutch seal package PN 4504050. 16. Install the 2-4 retainer, spring, and snap ring. 17. Check the 2-4 clutch clearance. The clearance should be 0.76 to 2.64 mm (.030 to .140). If clearance is not within specification, the clutch is not assembled properly. 18. Install the rear sun gear and No. 7 needle bearing. 19. Install the front carrier and rear annulus assembly and the No. 6 needle bearing. 20. Install the front sun gear and No. 4 thrust washer. NOTE: IF INPUT SHAFT END PLAY WAS FOUND OUT OF SPECIFICATION .13 TO .64 mm (.005 To .025) DURING DISASSEMBLY REPIACE THE NO. 4 THRUST WASHER WITH THE CORRECT WASHER AT THIS TIME. 21. Install the input clutch assembly. 22. Install the No. 1 caged needle bearing. 23. Install oil pump using new gasket package PN 4504555. NOTE: ON 1991 VEHICLES BE SURE TO INSTALL THE INTERNAL OIL COOLER BYPASS VALVE. 24. Install input speed sensor. 25. Check input shaft end play. 26. Install the valve body, using new valve body gasket package PN 4504553. 27. Install oil pan. 28. Install the transaxle assembly. 29. Refill the transaxle with MOPAR ATF PLUS (ATF Type 7176), or DEXTRON II. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 1-2 Upshift Shudder 21-34-02-92 ........ 4.8 Hrs. FAILURE CODE: 58 - Internal defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604 Momentary Decleration/Clutch Slippage Technical Service Bulletin # 210189A Date: 890522 A/T - A604 Momentary Decleration/Clutch Slippage Models 1989 AC & AS Bodies Equipped With A604 Transaxle Subject Momentary Deceleration, Default To Second Gear (Limp-In) Mode Or Excessive Clutch Slippage During 3-4 Upshift Index TRANSMISSION Date May 22, 1989 No. 21-01-89 REVISION A (21-19-9) P-1962 BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - CARAVAN/VOYAGER THIS BULLETIN SERVICE TECHNICAL SERVICE BULLETIN # 21-01-89 (DATED 1/30/89) WHICH SHOULD BE REMOVED FROM YOUR FILE. NOTE: THIS TECHNICAL SERVICE BULLETIN IS ONLY TO BE USED IF CODES 39, 46 OR NO CODES AT ALL ARE FOUND IN THE MEMORY. SYMPTOM/CONDITION - Momentary deceleration/loss of power during 3-4 shift. - Default to 2nd gear after a 3-4 shift fault code 39: Gear Ratio. - Chronic inability in achieving 4th. gear. - Excessive clutch slippage during a 3-4 shift. These symptoms may result from an improperly functioning seal ring between the underdrive and overdrive clutch circuits. During a 3-4 shift, fluid may leak into the underdrive circuit causing the underdrive clutch to drag. DIAGNOSIS Use procedure on following pages for diagnosis. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor operation No. 08-19-05-90 . . . . . . . . . . . . . . . . . . . . . . . 0.5 Hrs. A-604 Transaxle Test 49/Code 46 Test Procedure 98-19-05-91 . . . . . . . . . . . . . . . . . . . . . . . 0.6 Hrs. A-604 Transaxle Test 50/Testing, Clutch Volumes 09-19-05-92 . . . . . . . . . . . .. . . . .. . . . . . . . 0.3 Hrs. Transaxle Electronic Controller-Replace FAILURE CODE: 58 - Internal defect Diagnosis Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604 Momentary Decleration/Clutch Slippage > Page 3211 CAUTION: Do not perform this procedure unless the vehicle has 3-4 shift as described In TSB 21-01-89 Revision A. Fault codes other than 46 and 39 must be diagnosed using regular diagnostic tests, starting with Test # 1. Test 49CODE 46 Test ProcedureCode 46 can only be generated by an upgraded transaxle controller P/N. If you find code 46 in memory, the vehicle already has the upgrade - DO NOT REPLACE THE CONTROLLER. Code 46 is primarily set in memory after the controller has made 3 unsuccessful attempts at a proper 304 upshift. Controller logic then prevents the transaxle from any further upshift attempts and causes it to remain in third gear until downshifts into first gears have been obtained. Code 46 will not cause a limp-in (default to second) condition. Faulty connections at the Turbine or Output speed sensors can result in aborted 3-4 upshifts and set code 46 in memory. Carefully inspect the Turbine and Output speed sensor connectors for anything that could cause an intermittent connection to the sensor (i.e., spread, bent or misaligned terminals). If the connectors are OK, proceed with the road test below. Road Test Road test to confirm that code 46 can be repeated by using the following guidelines: A. Use the DRBII to clear any fault codes before load testing. B. Leaving the DRBII connected, road test the vehicle using the guidelines found in step # 3 of Test 50, then continue to road test with an emphasis on the 3-4 shift. Use a variety of throttle settings for doing the 3-4 shift. C. If transaxle performance is judged to be acceptable, return the vehicle to the owner. D. If code 46 continues to repeat, go to Test 50 Step 7. Test 50TESTING the A-604 Clutch Volumes Transaxles that have 3-4 shift problems could have normal or slightly discolored fluid but no serious clutch distress. The DRBII diagnostic tool can be Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604 Momentary Decleration/Clutch Slippage > Page 3212 used to help determine the amount of clutch wear in all A-604 clutches with the exception of reverse. NOTE: A transmission which has experienced a sudden clutch failure may be incapable of learning the correct clutch volume index values. A road test of a transmission with this condition may exhibit an upshift runaway condition, but have acceptable clutch volumes. In this case, a clutch is obviously failing. 1. Finding A-604 clutch volumes Connect the DRBII to the vehicle's bus diagnostic connector as shown in Transaxle Test # 1. (Entering A-604 Diagnostics and Bus Tests) After selecting the Transmission Section, drop down to the "SELECT TEST" level using the "YES" key. The first select test is the "DISPLAY FAULT CODES" display. Using the "F1" key, move to the left past the "CLEAR FAULT CODES" display until you see . . . SELECT TEST CONTINUE PRESS F1/F2 A604 TRANSAXLE PRESS F1, F2 FOR MORE . . . displayed on the DRBII. (NOTE: This display is not shown on the DRBII functional flow diagram found at the beginning of this book.) Use the "YES" key to drop down to the display shown below. CONDITIONS SHOWN OCCUR IN REAL TIME AND MAY BE NORMAL Press "YES" again . . . SELECT TEST ENGINEERING DATA 1 A604 TRANSAXLE PRESS F1, F2 FOR MORE Press the "F2" key . . . SELECT TEST ENGINEERING DATA 2 A604 TRANSAXLE PRESS F1, F2 FOR MORE Press the "YES" key again. 2. Understanding clutch volume values The display on the DRBII shows the four A-604 clutches that can be examined for clutch wear. Next to each clutch is a number that represents the volume required to fill and pressurize that clutch circuit. The initial values that will be displayed following a battery disconnect are shown on the next page. LR - 64 OD-89 2-4 - 48 UD - 45 NOTE: Thses are start up values and are not to be used in the actual diagnosis of the transaxle. These numbers will change as the A-604 controller "learns" or updates clutch fill volumes due to the normal usage and wear that occurs during the life of the transaxle. New clutch discs will have maximum friction material present and tend to take less fluid to fill and apply - hence the value for these clutch circuits is smaller. As the clutch ages, the clutch clearance increases, increasing the amount of off required to fill and apply the clutch - hence the value for these clutch circuits will be larger. NOTE: To obtain useful clutch information on a vehicle which may have recently had its battery disconnected, the transaxle controller must be allowed to "re-learn" each clutch circuit. 3. "Teaching" clutch volume values to the A-604 controller A. The transaxle fluid level must be properly set. B. The transaxle must be at normal operaing temperatures. C. At least three constant throttle upshifts at approximately half throttle from a standing start through the 2-3 upshift must be made. (These learn the overdrive and 2-4 clutch.) D. At least three heavy throttle downshifts to 1st at 15 mph must be made. (These learn the low/reverse clutch.) E. At least three part throttle 4-3 downshifts between 40 and 50 mph must be made. (These learn the underdrive clutch.) 4. Acceptable transaxle clutch volume value guidelines The range of clutch volume values which have been found to be within normal wear limits are shown below: LR - 35 TO 85 OD - 75 TO 135 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604 Momentary Decleration/Clutch Slippage > Page 3213 2-4 - 20 TO 77 UD - 24 TO 70 5. Other factors effecting clutch volume values 1. Incorrect fluid level 2. High transaxle temperature level 3. Restricted clutch feed circuit 4. Restricted solenoid food circuit 5. Valve body leakage 6. Leaky lip seals 7. Leaky seal rings 8. Case porosity 9. Circuit leak in pump housing 10. Circuit leak in reaction shaft support 11. Damaged accumulator seal ring 12. Clogged oil filter 13. Aerated fluid 14. Faulty oil pump 15. Insufficient clutch pack clearance 16. Sticky regulator valve 17. Failed clutch return spring NOTE: The above factors will normally be accompanied by transaxle symptoms not always related to this procedure. 6. Interpreting clutch volume values If all clutch volume values are still within the acceptable guidelines found in step 4, the vehicle may be serviced by only replacing the A-604 controller with the current released. Road test the vehicle using the instructions found in step # 8. If any clutch volume value exceeds the upper range limit, a worn clutch pack is likely. Refer to Technical Service Bulletin 21-08-89 7. Proper road test procedure A. Use the DRBII to clear any fault codes before road testing. B. Leaving the DRBII connected, road test the vehicle using the guidelines found in step # 3, then continue to road test with an emphasis on the 3-4 shift. C. If code 48 occurs early during the road test, erase the code and continue the road test. (A false code 48 can sometimes set during the shift learning process.) D. If transaxle performance is judged to be acceptable, return the vehicle to the owner E. If Code 46 continues to repeat, verify proper turbine and output sensor connection. Repair or replace transmission per current policy if problem persists. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision Technical Service Bulletin # 210889 Date: 890403 A/T Reaction Shaft Support - Revision Models 1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle Subject Revised Reaction Shaft Support Index TRANSMISSION Date April 3, 1989 No. 21-08-89 P-1408 (C21-16-9) Description BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER SYMPTOM/CONDITION NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE AUTOMATIC TRANSAXLE, PART NUMBER 4446659. The procedure outlined in this bulletin should be followed if removal and disassembly of the transaxle is required. DIAGNOSIS 1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual (#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A) to determine if disassembly is required. Use the following procedure when the transaxle is disassembled for repair. PARTS REQUIRED 1 Repair package P/N 4549248 1 Gasket Package P/N 4504558 1 Controller (AS REQUIRED) P/N 5234678 NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT CLUTCH HUB IS REQUIRED. Input Clutch Retainer P/N 4431609 REPAIR PROCEDURE 1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the following guidelines. 2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or subsequent) controller. Always check input shaft end play before disassembling the transaxle. Step A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3218 FIGURE 1 - FRONT PUMP REACTION SHAFT 1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves, replace it with the four ring reaction support supplied in the repair package (Figure 1). If the reaction support that is removed from the transaxle has four ring grooves, the repair package is not needed. Step B FIGURE 2 - INPUT CLUTCH RETAINER 1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer as shown. If the bump is present, replace the retainer with a new one (P/N 4431609). 2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package. When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the compression of the Orings. 3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is no difference in any of the O-rings. The color was added to facilitate assembly. 4. Inspect and replace any distressed (burned) clutch components as required. Step C 1. Remove and discard the steel separator plate from the valve body. 2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow to the overdrive clutch circuit. Step D Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3219 1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play to the service preferred setting of .005" to .015". The actual total end play specification is .005" to .025" and is acceptable if the service preferred setting cannot be obtained. Other Recommendations 1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not use other kinds of petroleum based greases such as chassis grease that could plug critical orifices or might be incompatible with transmission fluid. 2. Replace the torque convertor if a clutch failure has occurred. 3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY. Replace it if necessary. 4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has occurred. 5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be used if ATF Plus is not available. POLICY: Reimbursable within the limits of the warranty. TIME ALLOWANCE: Labor Operation No. 21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs. FAILURE CODE: 7H - Reaction shaft/supt. assy. failed Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3220 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210996 > Jun > 96 > A/T - Clutch Volume Index QuIck Learn Clutch: All Technical Service Bulletins A/T - Clutch Volume Index QuIck Learn NO: 21-09-96 GROUP: Transmission DATE: June 28, 1996 SUBJECT: Clutch Volume Index Quick Learn Procedure Requirement After Transaxle Overhaul Or Replacement-41TE Transaxle MODELS: 1989 - 1992 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1992 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1992 (AG) Daytona 1989 - 1992 (AJ) LeBaron Coupe/LeBaron Convertible 1992 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1992 (AS) Town & Country/Caravan/Voyager 1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue DISCUSSION: NOTE: FAILURE TO PERFORM THE QUICK LEARN PROCEDURE OR BATTERY DISCONNECT, AS DESCRIBED BELOW, AFTER A TRANSAXLE IS REPLACED OR OVERHAULED CAN RESULT IN A LOW MILEAGE TRANSAXLE FAILURE OR POOR INITIAL SHIFT QUALITY. The DRB III will now support the quick learn procedure for the 1989 thru 1992 Model Year Vehicles equipped with a service replacement EATX II (with cooling fins) Transmission Control Module (TCM) having the following part numbers: 4796121, 4796122, 4696123, 4696124. For EATX II TCM part numbers that precede the above list, refer to Repair Procedure No. 1 of Technical Service Bulletin 18-24-95, dated June 23, 1995. NOTE: 1993 AND LATER 41TE/42LE TCM'S HAVE ALWAYS BEEN QUICK LEARN CAPABLE. For EATX I (without cooling fins) TCM's, disconnecting the battery for one minute or performing the battery disconnect function with the DRB will reset the clutch volume index (CVI) to an acceptable range and the quick learn procedure is not required. You must use DRB III code version 19.2 (released on Mar. 1, 1996 with TIL disc 1102) or later in order to be able to quick learn 1989 thru 1992 model year vehicles. Quick learn must be done on any 41TE or 42LE equipped vehicle when the transmission has been replaced or where transmission work has been performed which affects CVI. For example, clutch pack replacements. NOTE: THE READING OF EATX DIAGNOSTIC TROUBLE CODES (DTC'S) AND PROPER DIAGNOSTICS FOR 1989 THRU 1992 MODEL YEAR VEHICLES MUST BE PERFORMED USING THE MDS AND A DRB II WITH THE APPROPRIATE CARTRIDGE OR DRB III, OR USING A STAND ALONE DRB III WITH THE SUPER CARD INSTALLED. AFTER PERFORMING DIAGNOSTICS YOU MUST ERASE ANY DTC'S USING ONE OF THE TOOL CONFIGURATIONS LISTED ABOVE BEFORE PROCEEDING WITH THE QUICK LEARN PROCEDURE. PROCEDURE: The EATX II quick learn procedure is required whenever a transaxle is repaired or replaced. 1. Ensure the transmission fluid level is correct. 2. Start vehicle, place the shift lever in Overdrive (OD), move the vehicle at least five feet with the engine running and then place shifter in Neutral (N). Apply the parking brake and let the engine idle. This purges the air in the clutch circuits to prevent erroneous clutch volume values which could cause poor initial shift quality or a low mileage transaxle failure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210996 > Jun > 96 > A/T - Clutch Volume Index QuIck Learn > Page 3226 3. Using the DRB III select the 1994 - 1997 Diagnostics option (1) and choose Transmissions. 4. Choose the Trans Overhauled/Replaced option and follow the instructions on the DRB III screen. NOTE: AFTER PERFORMING QUICK LEARN USE A PROPER DIAGNOSTIC CONFIGURATION TO READ THE DTC'S. IF ONLY DTC 12 EXISTS, ERASE THE DTC. IF THERE ARE OTHER DTC'S, PERFORM THE PROPER DIAGNOSTICS FOR THOSE DTC'S. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604 Momentary Decleration/Clutch Slippage Technical Service Bulletin # 210189A Date: 890522 A/T - A604 Momentary Decleration/Clutch Slippage Models 1989 AC & AS Bodies Equipped With A604 Transaxle Subject Momentary Deceleration, Default To Second Gear (Limp-In) Mode Or Excessive Clutch Slippage During 3-4 Upshift Index TRANSMISSION Date May 22, 1989 No. 21-01-89 REVISION A (21-19-9) P-1962 BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - CARAVAN/VOYAGER THIS BULLETIN SERVICE TECHNICAL SERVICE BULLETIN # 21-01-89 (DATED 1/30/89) WHICH SHOULD BE REMOVED FROM YOUR FILE. NOTE: THIS TECHNICAL SERVICE BULLETIN IS ONLY TO BE USED IF CODES 39, 46 OR NO CODES AT ALL ARE FOUND IN THE MEMORY. SYMPTOM/CONDITION - Momentary deceleration/loss of power during 3-4 shift. - Default to 2nd gear after a 3-4 shift fault code 39: Gear Ratio. - Chronic inability in achieving 4th. gear. - Excessive clutch slippage during a 3-4 shift. These symptoms may result from an improperly functioning seal ring between the underdrive and overdrive clutch circuits. During a 3-4 shift, fluid may leak into the underdrive circuit causing the underdrive clutch to drag. DIAGNOSIS Use procedure on following pages for diagnosis. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor operation No. 08-19-05-90 . . . . . . . . . . . . . . . . . . . . . . . 0.5 Hrs. A-604 Transaxle Test 49/Code 46 Test Procedure 98-19-05-91 . . . . . . . . . . . . . . . . . . . . . . . 0.6 Hrs. A-604 Transaxle Test 50/Testing, Clutch Volumes 09-19-05-92 . . . . . . . . . . . .. . . . .. . . . . . . . 0.3 Hrs. Transaxle Electronic Controller-Replace FAILURE CODE: 58 - Internal defect Diagnosis Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604 Momentary Decleration/Clutch Slippage > Page 3231 CAUTION: Do not perform this procedure unless the vehicle has 3-4 shift as described In TSB 21-01-89 Revision A. Fault codes other than 46 and 39 must be diagnosed using regular diagnostic tests, starting with Test # 1. Test 49CODE 46 Test ProcedureCode 46 can only be generated by an upgraded transaxle controller P/N. If you find code 46 in memory, the vehicle already has the upgrade - DO NOT REPLACE THE CONTROLLER. Code 46 is primarily set in memory after the controller has made 3 unsuccessful attempts at a proper 304 upshift. Controller logic then prevents the transaxle from any further upshift attempts and causes it to remain in third gear until downshifts into first gears have been obtained. Code 46 will not cause a limp-in (default to second) condition. Faulty connections at the Turbine or Output speed sensors can result in aborted 3-4 upshifts and set code 46 in memory. Carefully inspect the Turbine and Output speed sensor connectors for anything that could cause an intermittent connection to the sensor (i.e., spread, bent or misaligned terminals). If the connectors are OK, proceed with the road test below. Road Test Road test to confirm that code 46 can be repeated by using the following guidelines: A. Use the DRBII to clear any fault codes before load testing. B. Leaving the DRBII connected, road test the vehicle using the guidelines found in step # 3 of Test 50, then continue to road test with an emphasis on the 3-4 shift. Use a variety of throttle settings for doing the 3-4 shift. C. If transaxle performance is judged to be acceptable, return the vehicle to the owner. D. If code 46 continues to repeat, go to Test 50 Step 7. Test 50TESTING the A-604 Clutch Volumes Transaxles that have 3-4 shift problems could have normal or slightly discolored fluid but no serious clutch distress. The DRBII diagnostic tool can be Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604 Momentary Decleration/Clutch Slippage > Page 3232 used to help determine the amount of clutch wear in all A-604 clutches with the exception of reverse. NOTE: A transmission which has experienced a sudden clutch failure may be incapable of learning the correct clutch volume index values. A road test of a transmission with this condition may exhibit an upshift runaway condition, but have acceptable clutch volumes. In this case, a clutch is obviously failing. 1. Finding A-604 clutch volumes Connect the DRBII to the vehicle's bus diagnostic connector as shown in Transaxle Test # 1. (Entering A-604 Diagnostics and Bus Tests) After selecting the Transmission Section, drop down to the "SELECT TEST" level using the "YES" key. The first select test is the "DISPLAY FAULT CODES" display. Using the "F1" key, move to the left past the "CLEAR FAULT CODES" display until you see . . . SELECT TEST CONTINUE PRESS F1/F2 A604 TRANSAXLE PRESS F1, F2 FOR MORE . . . displayed on the DRBII. (NOTE: This display is not shown on the DRBII functional flow diagram found at the beginning of this book.) Use the "YES" key to drop down to the display shown below. CONDITIONS SHOWN OCCUR IN REAL TIME AND MAY BE NORMAL Press "YES" again . . . SELECT TEST ENGINEERING DATA 1 A604 TRANSAXLE PRESS F1, F2 FOR MORE Press the "F2" key . . . SELECT TEST ENGINEERING DATA 2 A604 TRANSAXLE PRESS F1, F2 FOR MORE Press the "YES" key again. 2. Understanding clutch volume values The display on the DRBII shows the four A-604 clutches that can be examined for clutch wear. Next to each clutch is a number that represents the volume required to fill and pressurize that clutch circuit. The initial values that will be displayed following a battery disconnect are shown on the next page. LR - 64 OD-89 2-4 - 48 UD - 45 NOTE: Thses are start up values and are not to be used in the actual diagnosis of the transaxle. These numbers will change as the A-604 controller "learns" or updates clutch fill volumes due to the normal usage and wear that occurs during the life of the transaxle. New clutch discs will have maximum friction material present and tend to take less fluid to fill and apply - hence the value for these clutch circuits is smaller. As the clutch ages, the clutch clearance increases, increasing the amount of off required to fill and apply the clutch - hence the value for these clutch circuits will be larger. NOTE: To obtain useful clutch information on a vehicle which may have recently had its battery disconnected, the transaxle controller must be allowed to "re-learn" each clutch circuit. 3. "Teaching" clutch volume values to the A-604 controller A. The transaxle fluid level must be properly set. B. The transaxle must be at normal operaing temperatures. C. At least three constant throttle upshifts at approximately half throttle from a standing start through the 2-3 upshift must be made. (These learn the overdrive and 2-4 clutch.) D. At least three heavy throttle downshifts to 1st at 15 mph must be made. (These learn the low/reverse clutch.) E. At least three part throttle 4-3 downshifts between 40 and 50 mph must be made. (These learn the underdrive clutch.) 4. Acceptable transaxle clutch volume value guidelines The range of clutch volume values which have been found to be within normal wear limits are shown below: LR - 35 TO 85 OD - 75 TO 135 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210189A > May > 89 > A/T - A604 Momentary Decleration/Clutch Slippage > Page 3233 2-4 - 20 TO 77 UD - 24 TO 70 5. Other factors effecting clutch volume values 1. Incorrect fluid level 2. High transaxle temperature level 3. Restricted clutch feed circuit 4. Restricted solenoid food circuit 5. Valve body leakage 6. Leaky lip seals 7. Leaky seal rings 8. Case porosity 9. Circuit leak in pump housing 10. Circuit leak in reaction shaft support 11. Damaged accumulator seal ring 12. Clogged oil filter 13. Aerated fluid 14. Faulty oil pump 15. Insufficient clutch pack clearance 16. Sticky regulator valve 17. Failed clutch return spring NOTE: The above factors will normally be accompanied by transaxle symptoms not always related to this procedure. 6. Interpreting clutch volume values If all clutch volume values are still within the acceptable guidelines found in step 4, the vehicle may be serviced by only replacing the A-604 controller with the current released. Road test the vehicle using the instructions found in step # 8. If any clutch volume value exceeds the upper range limit, a worn clutch pack is likely. Refer to Technical Service Bulletin 21-08-89 7. Proper road test procedure A. Use the DRBII to clear any fault codes before road testing. B. Leaving the DRBII connected, road test the vehicle using the guidelines found in step # 3, then continue to road test with an emphasis on the 3-4 shift. C. If code 48 occurs early during the road test, erase the code and continue the road test. (A false code 48 can sometimes set during the shift learning process.) D. If transaxle performance is judged to be acceptable, return the vehicle to the owner E. If Code 46 continues to repeat, verify proper turbine and output sensor connection. Repair or replace transmission per current policy if problem persists. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision Technical Service Bulletin # 210889 Date: 890403 A/T Reaction Shaft Support - Revision Models 1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle Subject Revised Reaction Shaft Support Index TRANSMISSION Date April 3, 1989 No. 21-08-89 P-1408 (C21-16-9) Description BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER SYMPTOM/CONDITION NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE AUTOMATIC TRANSAXLE, PART NUMBER 4446659. The procedure outlined in this bulletin should be followed if removal and disassembly of the transaxle is required. DIAGNOSIS 1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual (#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A) to determine if disassembly is required. Use the following procedure when the transaxle is disassembled for repair. PARTS REQUIRED 1 Repair package P/N 4549248 1 Gasket Package P/N 4504558 1 Controller (AS REQUIRED) P/N 5234678 NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT CLUTCH HUB IS REQUIRED. Input Clutch Retainer P/N 4431609 REPAIR PROCEDURE 1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the following guidelines. 2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or subsequent) controller. Always check input shaft end play before disassembling the transaxle. Step A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3238 FIGURE 1 - FRONT PUMP REACTION SHAFT 1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves, replace it with the four ring reaction support supplied in the repair package (Figure 1). If the reaction support that is removed from the transaxle has four ring grooves, the repair package is not needed. Step B FIGURE 2 - INPUT CLUTCH RETAINER 1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer as shown. If the bump is present, replace the retainer with a new one (P/N 4431609). 2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package. When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the compression of the Orings. 3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is no difference in any of the O-rings. The color was added to facilitate assembly. 4. Inspect and replace any distressed (burned) clutch components as required. Step C 1. Remove and discard the steel separator plate from the valve body. 2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow to the overdrive clutch circuit. Step D Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3239 1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play to the service preferred setting of .005" to .015". The actual total end play specification is .005" to .025" and is acceptable if the service preferred setting cannot be obtained. Other Recommendations 1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not use other kinds of petroleum based greases such as chassis grease that could plug critical orifices or might be incompatible with transmission fluid. 2. Replace the torque convertor if a clutch failure has occurred. 3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY. Replace it if necessary. 4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has occurred. 5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be used if ATF Plus is not available. POLICY: Reimbursable within the limits of the warranty. TIME ALLOWANCE: Labor Operation No. 21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs. FAILURE CODE: 7H - Reaction shaft/supt. assy. failed Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3240 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch Clutch: Description and Operation Input Clutch The input clutch assembly is located directly behind the oil pump housing, and rides on the reaction shaft support journal. The assembly consists of the following: - Input shaft - Input hub - Clutch retainer - Clutch pistons Overdrive hub Underdrive hub Three input clutches (underdrive clutch, overdrive clutch and reverse clutch). When the torque converter turbine turns, the input shaft, hub and clutch retainer also turn Each of the three clutches in the input clutch assembly supply input power to a particular component in the planetary gear train when they are hydraulically applied. They are connected to the planetary gear-train through the overdrive hub assembly, underdrive hub assembly and the front sun gear assembly. When any of these clutches are applied, they turn or drive a component which is an input to the planetary gear-train. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 3243 Clutch: Description and Operation Low Reverse Clutch The Low/Reverse (L/R) clutch is used in both low and reverse gears. The L/R clutch is located in the back of the case, directly behind the 2-4 clutch. The L/R clutch actually shares the reaction plate of the 2-4 clutch. It consists of steel plates, clutch discs, belleville return spring, piston and a stamped steel piston retainer which is secured to the back of the case with screws. The L/R clutch surrounds the outside of the front carrier assembly, and locks or grounds the front planetary carrier/rear annulus gear assembly to the case when applied. Similar to the 2-4 clutch, the L/R clutch is a holding element and eliminates the need for bands. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 3244 Clutch: Description and Operation Overdrive and Reverse Clutch The Overdrive/Reverse (OD/REV) piston is between the input hub and the clutch retainer. This piston is unique in design for the following reasons: - It operates two separate clutches - It is located on the outside of the clutch retainer that houses the two clutches it operates The overdrive clutch is splined to the overdrive hub assembly, and the overdrive hub is splined to the front carrier assembly. When the overdrive clutch is applied hydraulically, the front carrier assembly is an input to the planetary gear-set in third (direct) and fourth (overdrive) gear ranges. The reverse clutch is splined to the front sun gear assembly. When the reverse clutch is applied hydraulically, it drives the front sun gear which is the input to the planetary gear-set in reverse gear range. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 3245 Clutch: Description and Operation Underdrive Clutch The underdrive piston, piston return spring and spring retainer are inside and to the front of the clutch retainer. These parts control the application of the Underdrive (UD) clutch. The underdrive clutch is named for its use in the three forward underdrive gear ranges: first, second and third. The underdrive clutch is splined to the underdrive hub assembly. The underdrive shaft, which is secured to the underdrive hub, is splined to the rear sun gear. When the underdrive clutch is applied hydraulically, the rear sun gear is the input to the planetary gear-set in first, second and third gears. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 3246 Clutch: Description and Operation 2-4 Clutch The 2-4 clutch is used in both second and fourth gears, and is located directly behind the input clutch assembly. The clutch consists of the following: - Stamped steel clutch piston retainer - Aluminum piston - Belleville return spring - Clutch plates - Steel separator plates - Reaction Plate The above parts are held in the case with snap rings. The 2-4 clutch surrounds the outside of the front sun gear assembly and when applied hydraulically, locks or grounds the front sun gear assembly to the case. The 2-4 clutch is a holding element. It is a multidisc clutch that provides more room within the transaxle, and eliminates the need for using a band and servo as are used in other transaxle applications. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3255 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3256 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3257 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3258 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3259 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3260 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd 1st Gear Downshift Control Module: Customer Interest A/T - 41TE Harsh 2nd - 1st Gear Downshift NO.: 21-16-93 Rev. A GROUP: Transmission DATE: Oct 8, 1993 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED. CHANGES ARE HIGHLIGHTED BY **ASTERISKS**. MODELS: 1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue 1992 (AP) Shadow/Sundance SYMPTOM/CONDITION: Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service Manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd 1st Gear Downshift > Page 3265 TIME ALLOWANCE: Labor Operation No. **08-19-05-99** 0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift Control Module: Customer Interest A/T - 41TE Harsh 2-1 Gear Downshift NO.: 21-16-92 GROUP: Transmission DATE: Nov. 2, 1992 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle MODELS: 1989-1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990-1992 (AY) Imperial/New Yorker Fifth Avenue SYMPTOM/CONDITION: Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 3270 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting Control Module: Customer Interest A/T - A604 Excessive Upshifting/Downshifting Models 1989-90 AA, AC, AG, AJ, AS, & AY Bodies Subject A-604 Transmission Excessive Upshifting/ Downshifting Index TRANSMISSION Date April 9, 1990 No. 21-12-90 (C21-06-0) P-1042 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY AY - IMPERIAL/NEW YORKER FIFTH AVENUE SYMPTOM/CONDITION Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition when the vehicle is fully loaded, driving up a grade or into a head wind. This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior (1989) model year A-604 controllers. A new A-604 controller, PN 4557585, entered production late March 1990. The new controller allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle torque load changes. DIAGNOSIS Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does not apply. Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain Diagnostic Procedure Manual. If no fault codes are present, perform the following repair procedure. If fault codes are present, they must be corrected and the corrections verified before performing the following repair procedure. PARTS REQUIRED 1. 1 - Controller PN 4557585 REPAIR PROCEDURE This repair involves the replacement of the transaxle controller. 1. Disconnect the negative battery cable. 2. Disconnect the 60-way connector from the controller. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 3275 3. Remove the controller. 4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds. 5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds. 6. Reconnect the negative battery cable. 7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-05-96 0.6 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3281 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3282 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3283 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3284 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3285 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3286 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2nd - 1st Gear Downshift NO.: 21-16-93 Rev. A GROUP: Transmission DATE: Oct 8, 1993 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED. CHANGES ARE HIGHLIGHTED BY **ASTERISKS**. MODELS: 1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue 1992 (AP) Shadow/Sundance SYMPTOM/CONDITION: Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service Manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 3291 TIME ALLOWANCE: Labor Operation No. **08-19-05-99** 0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2-1 Gear Downshift NO.: 21-16-92 GROUP: Transmission DATE: Nov. 2, 1992 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle MODELS: 1989-1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990-1992 (AY) Imperial/New Yorker Fifth Avenue SYMPTOM/CONDITION: Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 3296 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting Control Module: All Technical Service Bulletins A/T - A604 Excessive Upshifting/Downshifting Models 1989-90 AA, AC, AG, AJ, AS, & AY Bodies Subject A-604 Transmission Excessive Upshifting/ Downshifting Index TRANSMISSION Date April 9, 1990 No. 21-12-90 (C21-06-0) P-1042 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY AY - IMPERIAL/NEW YORKER FIFTH AVENUE SYMPTOM/CONDITION Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition when the vehicle is fully loaded, driving up a grade or into a head wind. This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior (1989) model year A-604 controllers. A new A-604 controller, PN 4557585, entered production late March 1990. The new controller allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle torque load changes. DIAGNOSIS Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does not apply. Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain Diagnostic Procedure Manual. If no fault codes are present, perform the following repair procedure. If fault codes are present, they must be corrected and the corrections verified before performing the following repair procedure. PARTS REQUIRED 1. 1 - Controller PN 4557585 REPAIR PROCEDURE This repair involves the replacement of the transaxle controller. 1. Disconnect the negative battery cable. 2. Disconnect the 60-way connector from the controller. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 3301 3. Remove the controller. 4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds. 5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds. 6. Reconnect the negative battery cable. 7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-05-96 0.6 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision Technical Service Bulletin # 210889 Date: 890403 A/T Reaction Shaft Support - Revision Models 1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle Subject Revised Reaction Shaft Support Index TRANSMISSION Date April 3, 1989 No. 21-08-89 P-1408 (C21-16-9) Description BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER SYMPTOM/CONDITION NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE AUTOMATIC TRANSAXLE, PART NUMBER 4446659. The procedure outlined in this bulletin should be followed if removal and disassembly of the transaxle is required. DIAGNOSIS 1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual (#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A) to determine if disassembly is required. Use the following procedure when the transaxle is disassembled for repair. PARTS REQUIRED 1 Repair package P/N 4549248 1 Gasket Package P/N 4504558 1 Controller (AS REQUIRED) P/N 5234678 NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT CLUTCH HUB IS REQUIRED. Input Clutch Retainer P/N 4431609 REPAIR PROCEDURE 1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the following guidelines. 2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or subsequent) controller. Always check input shaft end play before disassembling the transaxle. Step A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3306 FIGURE 1 - FRONT PUMP REACTION SHAFT 1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves, replace it with the four ring reaction support supplied in the repair package (Figure 1). If the reaction support that is removed from the transaxle has four ring grooves, the repair package is not needed. Step B FIGURE 2 - INPUT CLUTCH RETAINER 1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer as shown. If the bump is present, replace the retainer with a new one (P/N 4431609). 2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package. When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the compression of the Orings. 3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is no difference in any of the O-rings. The color was added to facilitate assembly. 4. Inspect and replace any distressed (burned) clutch components as required. Step C 1. Remove and discard the steel separator plate from the valve body. 2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow to the overdrive clutch circuit. Step D Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3307 1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play to the service preferred setting of .005" to .015". The actual total end play specification is .005" to .025" and is acceptable if the service preferred setting cannot be obtained. Other Recommendations 1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not use other kinds of petroleum based greases such as chassis grease that could plug critical orifices or might be incompatible with transmission fluid. 2. Replace the torque convertor if a clutch failure has occurred. 3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY. Replace it if necessary. 4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has occurred. 5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be used if ATF Plus is not available. POLICY: Reimbursable within the limits of the warranty. TIME ALLOWANCE: Labor Operation No. 21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs. FAILURE CODE: 7H - Reaction shaft/supt. assy. failed Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3308 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 182188 > Dec > 88 > AIS Motor - Erratic Idle Speed In Cold Ambients Technical Service Bulletin # 210889 Date: 890403 A/T Reaction Shaft Support - Revision Models 1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle Subject Revised Reaction Shaft Support Index TRANSMISSION Date April 3, 1989 No. 21-08-89 P-1408 (C21-16-9) Description BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER SYMPTOM/CONDITION NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE AUTOMATIC TRANSAXLE, PART NUMBER 4446659. The procedure outlined in this bulletin should be followed if removal and disassembly of the transaxle is required. DIAGNOSIS 1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual (#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A) to determine if disassembly is required. Use the following procedure when the transaxle is disassembled for repair. PARTS REQUIRED 1 Repair package P/N 4549248 1 Gasket Package P/N 4504558 1 Controller (AS REQUIRED) P/N 5234678 NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT CLUTCH HUB IS REQUIRED. Input Clutch Retainer P/N 4431609 REPAIR PROCEDURE 1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the following guidelines. 2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or subsequent) controller. Always check input shaft end play before disassembling the transaxle. Step A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 182188 > Dec > 88 > AIS Motor - Erratic Idle Speed In Cold Ambients > Page 3314 FIGURE 1 - FRONT PUMP REACTION SHAFT 1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves, replace it with the four ring reaction support supplied in the repair package (Figure 1). If the reaction support that is removed from the transaxle has four ring grooves, the repair package is not needed. Step B FIGURE 2 - INPUT CLUTCH RETAINER 1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer as shown. If the bump is present, replace the retainer with a new one (P/N 4431609). 2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package. When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the compression of the Orings. 3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is no difference in any of the O-rings. The color was added to facilitate assembly. 4. Inspect and replace any distressed (burned) clutch components as required. Step C 1. Remove and discard the steel separator plate from the valve body. 2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow to the overdrive clutch circuit. Step D Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 182188 > Dec > 88 > AIS Motor - Erratic Idle Speed In Cold Ambients > Page 3315 1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play to the service preferred setting of .005" to .015". The actual total end play specification is .005" to .025" and is acceptable if the service preferred setting cannot be obtained. Other Recommendations 1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not use other kinds of petroleum based greases such as chassis grease that could plug critical orifices or might be incompatible with transmission fluid. 2. Replace the torque convertor if a clutch failure has occurred. 3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY. Replace it if necessary. 4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has occurred. 5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be used if ATF Plus is not available. POLICY: Reimbursable within the limits of the warranty. TIME ALLOWANCE: Labor Operation No. 21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs. FAILURE CODE: 7H - Reaction shaft/supt. assy. failed Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 182188 > Dec > 88 > AIS Motor - Erratic Idle Speed In Cold Ambients > Page 3316 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 3319 Control Module: Locations Power Distribution Center Power Distribution Center Fuse Block Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 3320 Control Module: Diagrams Part 1 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 3321 Part 2 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 3322 Part 3 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 3323 Part 4 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 3324 Part 5 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 3325 Part 6 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 3326 Part 7 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 3327 Part 8 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 3328 Part 9 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 3329 Part 10 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 3330 Part 11 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > A604 Control Module: Description and Operation A604 DESCRIPTION This computer is dedicated to the control of the A-604 Transaxle. It has a connector shaped similarly to the one on the Engine Controller. It contains on-board diagnostics and fault code memory which is accessed by the DRBII Diagnostic Tool through Chrysler's C2D Bus. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > A604 > Page 3333 Control Module: Description and Operation 41TE Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > A604 > Page 3334 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 - Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > General Information > Page 3337 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T > Component Information > Locations Data Link Connector Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T > Component Information > Locations > Page 3341 Data Link Connector (6 - Way) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T > Component Information > Locations > Page 3342 Data Link Connector, A/T: Description and Operation DESCRIPTION A light blue six-way connector with four male pins. This connector allows the DRBII access to the CCD (Chrysler Collision Detection) Bus. With the DRBII connected here, the technician can perform diagnostic tests on the following: The Body Computer The Security Alarm System (SAM) The A-604 Transaxle The Electronic Instrument Cluster The Air Suspension System Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Description and Operation Differential: Description and Operation The 41TE uses a helical-type ring and pinion gear set. The ring gear is bolted to the differential case, and drives the differential case in all gear ranges. The differential case assembly consists of the differential case and within it, two pinion gears, two side gears and a pinion mate shaft retained with a roll pin. The differential case provides input power from the ring gear to the axle shafts through the case, pinion shaft, pinion gears and side gears. The pinion and side gears allow the right and left axles to rotate at different speeds while the vehicle is cornering. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note Differential: Service and Repair Service Note NOTE: The differential is serviced as an assembly. The only parts that are serviceable within the differential are the differential bearing cups and cones. If any other part fails within the differential, you must replace the differential assembly along with the transfer shaft. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 3348 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 3349 Differential: Service and Repair Disassembly The transfer shaft should be removed for differential repair and bearing turning torque checking. Differential Cover Bolts Remove Differential Cover 1. Remove the differential cover and bolts. Differential Retainer Bolts Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 3350 Remove Bearing Retainer 2. Remove the differential bearing retainer and bolts. 3. Using a plastic hammer, remove extension housing/adapter plate on the right side of the transaxle. WARNING: Hold onto differential assembly to prevent it from rolling out of housing. 4. Use Miller Special Tool 5048, 5048-3 Collets, and L-4539-2 Button to remove the differential bearing cone on the extension housing side. Position Button And Collets Onto Differential And Bearing (Ring Gear Side) Position Tool 5048 Over Button And Collets At Differential Bearing (Ring Gear Side) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 3351 Remove Differential Bearing Cone (Ring Gear Side) 5. Use Miller Special Tool 5048, 5048-4 Collets, and L-4539-2 Button to remove the differential bearing cone on the bearing retainer side. 6. Using Miller Special Tool L-4518 remove the differential bearing race from the extension housing. Position Bearing Cup Remover Tool In Retainer Remove Bearing Cup 7. Using Miller Special Tool 6062A remove the differential bearing race from the bearing retainer. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 3352 Differential: Service and Repair Assembly NOTE: Use MOPAR Silicone Rubber Adhesive Sealant, or equivalent, on retainer and extension housing/adapter plate to seal to case. Position Bearing Cone Onto Differential 1. Using Miller Special Tool L-4410, and C-4171, or equivalents, install differential bearing to differential (extension housing side). 2. Using Miller Special Tool 5052 and C-4171, or equivalents, install differential bearing to differential (bearing retainer side). Differential Bearing Retainer 3. Using Miller Special Tool 6061 and C-4171, or equivalents, install differential bearing race to bearing retainer. 4. Using Miller Special Tool L-4520 and C-4171, or equivalents, install differential bearing to extension housing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 3353 Differential: Service and Repair Service Note NOTE: The differential is serviced as an assembly. The only parts that are serviceable within the differential are the differential bearing cups and cones. If any other part fails within the differential, you must replace the differential assembly along with the transfer shaft. Disassembly The transfer shaft should be removed for differential repair and bearing turning torque checking. Differential Cover Bolts Remove Differential Cover 1. Remove the differential cover and bolts. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 3354 Differential Retainer Bolts Remove Bearing Retainer 2. Remove the differential bearing retainer and bolts. 3. Using a plastic hammer, remove extension housing/adapter plate on the right side of the transaxle. WARNING: Hold onto differential assembly to prevent it from rolling out of housing. 4. Use Miller Special Tool 5048, 5048-3 Collets, and L-4539-2 Button to remove the differential bearing cone on the extension housing side. Position Button And Collets Onto Differential And Bearing (Ring Gear Side) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 3355 Position Tool 5048 Over Button And Collets At Differential Bearing (Ring Gear Side) Remove Differential Bearing Cone (Ring Gear Side) 5. Use Miller Special Tool 5048, 5048-4 Collets, and L-4539-2 Button to remove the differential bearing cone on the bearing retainer side. 6. Using Miller Special Tool L-4518 remove the differential bearing race from the extension housing. Position Bearing Cup Remover Tool In Retainer Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 3356 Remove Bearing Cup 7. Using Miller Special Tool 6062A remove the differential bearing race from the bearing retainer. Assembly NOTE: Use MOPAR Silicone Rubber Adhesive Sealant, or equivalent, on retainer and extension housing/adapter plate to seal to case. Position Bearing Cone Onto Differential 1. Using Miller Special Tool L-4410, and C-4171, or equivalents, install differential bearing to differential (extension housing side). 2. Using Miller Special Tool 5052 and C-4171, or equivalents, install differential bearing to differential (bearing retainer side). Differential Bearing Retainer 3. Using Miller Special Tool 6061 and C-4171, or equivalents, install differential bearing race to bearing retainer. 4. Using Miller Special Tool L-4520 and C-4171, or equivalents, install differential bearing to extension housing. Checking Side Gear End Play Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 3357 Checking Side Gear End Play (Extension Housing Side) Checking Side Gear End Play (Bearing Retainer Side) Check side gear end play whenever the differential is removed for service. NOTE: Side gear end play must be BETWEEN 0.001 to 0.013 inch. Differential Bearing Preload Adjustment NOTE: Perform all differential bearing preload measurements with the transfer shaft and gear removed. ADJUSTMENT USING EXISTING SHIM 1. Position the transaxle assembly vertically on the support stand, differential bearing retainer side up. Tool L-4436 And Torque Wrench Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 3358 2. Install Tool L-4436A, or equivalent into the differential and onto the pinion mate shaft. 3. Rotate the differential at least one full revolution to ensure the tapered roller bearings are fully seated. Checking Differential Bearings Turning Torque 4. Using Tool L-4436A, or equivalent and an inch-pound torque wrench, check the turning torque of the differential. The turning torque should be between 5. If the turning torque is within specifications, remove tools. Setup is complete. 6. If turning torque is not within specifications proceed with the following steps. a. Remove differential bearing retainer from the transaxle case. b. Remove the bearing cup from the differential bearing retainer using Tool 6062A, or equivalent. c. Remove the existing shim from under the cup. d. Measure the existing shim. NOTE: If the turning torque was too high when measured, install a 0.05 mm (0.002 inch) thinner shim. If the turning torque is was too low, install a 0.05 mm (0.002 inch) thicker shim. Repeat until 5 to 18 inch pounds turning torque is obtained. Oil Baffle is not required to be installed when making shim selection. e. Install the proper shim under the bearing cup. Make sure the oil baffle is installed properly in the bearing retainer, below the bearing shim and cup. f. Install the differential bearing retainer using Tool 5052 and C-4171, or equivalents. Seal the retainer to the housing with MOPAR Adhesive Sealant and torque bolts to 28 Nm (250 inch lbs.). Checking Differential Bearings Turning Torque 7. Using Tool L-4436A, or equivalent and an inch-pound torque wrench, recheck the turning torque of the differential. The turning torque should be between 5 and 18 inch-pounds. Shim thickness need be determined only if any of the following parts are replaced: Transaxle case - Differential carrier - Differential bearing retainer - Extension housing 8. Attach a dial indicator to the case and zero the dial. Place the tip on the end of Special Tool L-4436-A, or equivalent. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 3359 9. Place a large screwdriver to each side of the ring gear and lift. Check the dial indicator for the amount of end play. CAUTION: Do not damage the transaxle case and/or differential retainer sealing surface. Differential Bearing Shim Chart 10. Using the end play measurement that was determined, add 0.18 mm (0.007 inch). This should give you between 5 and 18 inch pounds of bearing preload. Refer to the Differential Bearing Shim Chart above to determine which shim to use. 11. Remove the differential bearing retainer. Remove the bearing cup. 12. Install the oil baffle. Install the proper shim combination under the bearing cup. 13. Install the differential bearing retainer. Seal the retainer to the housing with MOPAR Silicone Rubber Adhesive Sealant. Torque bolts to 28 Nm (250 inch lbs.). 14. Using Miller Special Tool L-4436-A and an inch-pound torque wrench, check the turning torque of the differential. The turning torque should be between 5 - 18 inch-pounds. NOTE: If turning torque is too high install a 0.05 mm (0.002 inch) thicker shim. If the turning torque is too low, install a 0.05 mm (0.002 inch) thinner shim. Repeat until 5 - 18 inch-pounds of turning torque is obtained. PRELOAD ADJUSTMENT USING GAUGING SHIM (89 - 95 ALL) 1. Remove the bearing cup from the differential bearing retainer using Tool L-4518, and remove the existing shim from under the cup. 2. Install a .50 mm (020 inch) gauging shim into the retainer. Use an arbor press to install the cup. NOTE: Oil Baffle is not required when making shim selection. 3. Install the bearing retainer into the case and torque bolts to 28 Nm (250 in. lbs.). 4. Position the transaxle assembly vertically on the support stand and install Tool C-4995 into side gear. 5. Rotate the differential at least one full revolution to ensure tapered roller bearings are fully seated. 6. Attach a dial indicator to the case and zero the dial indicator. Place the indicator tip on the end of Tool L-4436. 7. Place a large screwdriver to each side of the ring gear and lift. Check the dial indicator for the amount of end play. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 3360 CAUTION: Do not damage the transaxle case and/or differential cover sealing surface. Differential Bearing Shim Chart 8. When the end play has been determined, refer to the Differential Bearing Shim Chart above for the correct shim combination. 9. remove the differential bearing retainer. Remove the bearing cup and the .50 mm (020 inch) gauging shim. 10 Install the proper shim combination under the bearing cup. make sure the oil baffle is installed properly in the bearing retainer, below the bearing shim and cup. 11. Install the differential bearing retainer. Seal the retainer to the housing with MOPAR RTV sealant. Torque bolts to 28 Nm (250 in. lbs.). 12. Using Tool C-4995 and an inch-pound torque wrench, check the turning torque of the differential. The turning torque should be between 5 and 18 inch pounds. NOTE: If the turning torque is too high, install a .05 mm (.002 inch) thinner shim. If the turning torque is too low, install a .05 mm (.002 inch) thicker shim. Repeat until 5-18 inch pounds turning torque is obtained. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > Customer Interest for Automatic Transmission Dipstick - Dipstick Tube: > 210988 > Nov > 88 > A/T Dipstick - Does Not Seat Fully Automatic Transmission Dipstick - Dipstick Tube: Customer Interest A/T Dipstick - Does Not Seat Fully Models 1989 AC- & ASBodies With The A- 604 Transaxle Subject Transaxle Fluid Level Dipstick Not Fully Seated Index TRANSMISSION Date November 21, 1988 No. 21-09-88 P-4913 (C21-17) BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - CARAVAN/VOYAGER SYMPTOM/CONDITION The transaxle dipstick may hang up and not fully seat on the transaxle fill tube on a small number of 1989 ACand AS-body vehicles equipped with the A-604 transaxle. This condition may be caused by the dipstick blade hanging up on the wall of the valve body transfer plate on transaxles built before transaxle date code 97150000 or by an oversized lip at the bottom of the fill tube. DIAGNOSIS Insert and remove the dipstick from the fill tube five (5) times, be sure to note the fluid level each time. The dipstick must insert freely and seat on the fill tube. The level reading must also repeat all five (5) times. If the dipstick does not insert freely and/or the fluid level reading is not repeatable, proceed with the repair procedure. REPAIR PROCEDURE This repair involves bending the end of the dipstick blade approximately 10 degrees. 1. Remove the dipstick from the fill tube. Grasp the dipstick with a pair of pliers just above the twist at the bottom of the dipstick blade. NOTE: THE WORDING "TRANS FLUID" ON THE DIPSTICK HANDLE MUST BE FACING UPRIGHT. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > Customer Interest for Automatic Transmission Dipstick - Dipstick Tube: > 210988 > Nov > 88 > A/T Dipstick - Does Not Seat Fully > Page 3369 FIGURE 1 FIGURE 2 2. Bend the bottom end of the dipstick blade up 10 degrees as shown in the Figure 1. Use the line drawing in Figure 2 as a guide to ensure the 10 degree angle is achieved. 3. Insert the dipstick in the fill tube, start engine, check and adjust the transaxle fluid level as required. NOTE: THE WORDING "TRANS FLUID" ON THE DIPSTICK HANDLE MUST BE FACING UPRIGHT WHEN INSERTING THE DIPSTICK. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 21-75-17-90 . . . . . . . . . . . 0.2 Hrs. FAILURE CODE: 06 - Bent Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Automatic Transmission Dipstick - Dipstick Tube: > 210988 > Nov > 88 > A/T Dipstick - Does Not Seat Fully Automatic Transmission Dipstick - Dipstick Tube: All Technical Service Bulletins A/T Dipstick Does Not Seat Fully Models 1989 AC- & ASBodies With The A- 604 Transaxle Subject Transaxle Fluid Level Dipstick Not Fully Seated Index TRANSMISSION Date November 21, 1988 No. 21-09-88 P-4913 (C21-17) BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - CARAVAN/VOYAGER SYMPTOM/CONDITION The transaxle dipstick may hang up and not fully seat on the transaxle fill tube on a small number of 1989 ACand AS-body vehicles equipped with the A-604 transaxle. This condition may be caused by the dipstick blade hanging up on the wall of the valve body transfer plate on transaxles built before transaxle date code 97150000 or by an oversized lip at the bottom of the fill tube. DIAGNOSIS Insert and remove the dipstick from the fill tube five (5) times, be sure to note the fluid level each time. The dipstick must insert freely and seat on the fill tube. The level reading must also repeat all five (5) times. If the dipstick does not insert freely and/or the fluid level reading is not repeatable, proceed with the repair procedure. REPAIR PROCEDURE This repair involves bending the end of the dipstick blade approximately 10 degrees. 1. Remove the dipstick from the fill tube. Grasp the dipstick with a pair of pliers just above the twist at the bottom of the dipstick blade. NOTE: THE WORDING "TRANS FLUID" ON THE DIPSTICK HANDLE MUST BE FACING UPRIGHT. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Automatic Transmission Dipstick - Dipstick Tube: > 210988 > Nov > 88 > A/T Dipstick - Does Not Seat Fully > Page 3375 FIGURE 1 FIGURE 2 2. Bend the bottom end of the dipstick blade up 10 degrees as shown in the Figure 1. Use the line drawing in Figure 2 as a guide to ensure the 10 degree angle is achieved. 3. Insert the dipstick in the fill tube, start engine, check and adjust the transaxle fluid level as required. NOTE: THE WORDING "TRANS FLUID" ON THE DIPSTICK HANDLE MUST BE FACING UPRIGHT WHEN INSERTING THE DIPSTICK. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 21-75-17-90 . . . . . . . . . . . 0.2 Hrs. FAILURE CODE: 06 - Bent Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid - A/T: Customer Interest A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3384 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3385 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3386 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid - A/T: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3392 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3393 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3394 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 211096 > Jul > 96 > A/T Ratcheting Sound When Coming To Stop Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 211096 > Jul > 96 > A/T Ratcheting Sound When Coming To Stop > Page 3400 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 211096 > Jul > 96 > A/T Ratcheting Sound When Coming To Stop > Page 3406 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Page 3407 Fluid - A/T: Specifications CAPACITY, Initial Refill*: ..................................................................................................................... ....................................................................AP** All ......................................................................................................................................................... .............................................3.8 Liters 4.0 Quarts *With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed **May use AF or MA when AP is not available only for "Topping off". Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check Fluid - A/T: Service and Repair Fluid Level & Condition Check Fluid Level The transmission and differential sump have a common oil sump with a opening between the two. The torque converter fills in both the "P" Park and "N" Neutral positions. Place the selector lever in "P" Park to check fluid level. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. This will assure complete oil level stabilization between differential and transmission. The fluid should be at normal operating temperature (approximately 82 C. or 180 F). The fluid level is correct if it is in the "HOT" region (cross-hatched area) on the oil level indicator. Fluid Condition Along with fluid level, it is important to check the condition of the fluid. - When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle overhaul is needed. Be sure to examine the fluid on the dipstick closely. - If there is any doubt about its condition, drain out a sample for a double check. Note: After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Low Fluid Level Symptoms Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. in any hydraulic system, air bubbles will make the fluid spongy, therefore pressures will be low and build up slowly. Improper Filling Level Symptoms Improper filling can also raise the fluid level too high. - When the transaxle has too much fluid, the gears churn up foam and cause the same conditions which occur with a low fluid level. In either case the air bubbles can cause over heating, fluid oxidation, and varnishing, which can interfere with normal valve, clutch and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent, where it may be mistaken for a leak. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 3410 Fluid - A/T: Service and Repair Fluid and Filter Change Fluid and Filter Change When the factory fill fluid is changed, only fluids labeled Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a clean dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 3411 Fluid - A/T: Service and Repair Fluid Drain and Refill Procedure 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body. 4. Clean the oil pan and magnet. Reinstall pan using Mopar RTV Sealant. Tighten oil pan bolts to 19 Nm (165 in-lbs). 5. Pour four quarts of Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill tube. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark on the dipstick. CAUTION: Do not over fill transaxle. Do not add oil if level is between: Lower holes for warm oil (100F). Upper holes for hot oil (180F). 8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill tube. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T Slips In Reverse At Low Temperature Fluid Filter - A/T: Customer Interest A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T Slips In Reverse At Low Temperature > Page 3420 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T Slips In Reverse At Low Temperature > Page 3421 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T Slips In Reverse At Low Temperature > Page 3422 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid Filter - A/T: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3428 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3429 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 3430 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill Fluid Filter - A/T: Service and Repair Fluid Drain and Refill 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body. 4. Clean the oil pan and magnet. Reinstall pan using new MOPAR RTV sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill tube. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark. CAUTION: Do not overfill transaxle. Do not acid oil if level is between: Lower holes for warm oil (100°F). Upper holes for hot oil (180°F). 8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill tube. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill > Page 3433 Fluid Filter - A/T: Service and Repair Fluid & Filter Change 3 Speed Automatic Fluid and filter changes are not required for average vehicle use. Severe usage such as commercial type usage or prolonged operation in city traffic requires that fluid be changed and bands adjusted every 15,000 miles. 1. Raise vehicle and support vehicle. Place a suitable drain pan below transmission oil pan. 2. Loosen transmission oil pan attaching bolts and allow fluid to drain, then remove oil pan. 3. Replace filter and adjust bands, if necessary. 4. Install oil pan and gasket. Torque attaching bolts to 40 inch lbs. 5. Add four quarts of approved automatic transmission fluid. 6. Start engine and allow to idle for approximately six minutes, then with parking brake applied, move selector lever momentarily to each position. Place selector lever in Park and check fluid level. Add fluid to bring level to Add mark. 7. Recheck fluid level after transmission has reached normal operating temperature. 4 Speed Automatic When the factory fill fluid is changed, only fluids labeled MOPAR ATF Plus 4 (Automatic Transmission fluid) Type 7176, or equivalent should be used. A filter change should be made at the time of the oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a clean, dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Fittings Fluid Line/Hose: Specifications Cooler Line Fittings 110 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Fittings > Page 3438 Fluid Line/Hose: Specifications Cooler Hose To Radiator Connector 110 in.lb Cooler Line Connector Assembly 250 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Transmission Oil Pan To Case 165 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3450 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3451 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3452 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-09-97 > Feb > 97 > Converter Clutch Vehicle Shudder on Lock Up Fluid Pump: Customer Interest Converter Clutch - Vehicle Shudder on Lock Up NO: 18-09-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Vehicle Shudder During Torque Convertor EMCC (Lock-up) Operation/Diagnostic Trouble Code 38 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-17-96 REV. B, DATED OCT. 4, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE LABOR OPERATION CHANGES. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1990 - 1991 (AQ) Chrysler TC 1989 - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Avenger/Sebring/Talon 1996 (GS) Chrysler Voyager (International Market) 1995 - 1996 (JA) Cirrus/Stratus 1996 (JX) Sebring Convertible 1993 - 1996 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: NOTE: DIAGNOSTIC TROUBLE CODE (DTC) 38 (TORQUE CONVERTER CONTROL OUT OF RANGE) MUST BE PRESENT FOR THIS BULLETIN TO APPLY. IF DTC 38 IS NOT PRESENT AND THE VEHICLE IS A 1989-95 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 18-24-95 DATED JUNE 24, 1995 AND PERFORM AS NECESSARY. IF DTC 38 IS NOT PRESENT AND THE VEHICLE IS A 1996 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 21-05-96 DATED APR. 26, 1996 AND PERFORM AS NECESSARY. Vehicle shudders during full lock-up Electronically Modulated Convertor Clutch (EMCC) operation and DTC 38 is present. Full lock-up EMCC is indicated by 3LU or 4LU on the DRB III RPM display screen. DIAGNOSIS: This shudder condition can be the result of leakage in the transmission front pump caused by a worn pump bushing. It is sometimes accompanied by pump whine. Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC 38 is present, perform the Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-09-97 > Feb > 97 > Converter Clutch Vehicle Shudder on Lock Up > Page 3457 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the transmission front pump assembly and the transmission torque converter with one that has bonded converter clutch friction material and verifying the Transmission Control Module (TCM) part number. 1. Following the procedures outlined in the appropriate Service Manual, replace the torque converter and the transmission front pump assembly with the parts identified in the Parts Required section of this bulletin. 2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as outlined in the appropriate Service Manual. 3. Verify the TCM is the appropriate part number listed: 4. For 1989 - 1995 vehicles that do not have the appropriate TCM part number listed above, perform REPAIR PROCEDURE NO. 1 of Technical Service Bulletin 18-24-95. For 1996 vehicles that do not have the appropriate TCM part number listed above, perform the Repair Procedure of Technical Service Bulletin 21-05-96. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-60-05-91 1989 - 1995 AA,AC,AG,AJ,AP,AQ,AS,AY,ES,GS,NS **4.0** Hrs. 1993 - 1996 FJ,LH **4.7** Hrs. 1995 - 1996 JA,JX **5.7** Hrs. Supplemental Labor Operation No.'s 21-00-05-63 1989 - 1995 AS (Anti-Lock Brake System Equipped) 0.2 Hrs. 21-00-05-64 1991 - 1995 AS (All Wheel Drive Equipped) 1.2 Hrs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-09-97 > Feb > 97 > Converter Clutch Vehicle Shudder on Lock Up > Page 3458 If it is necessary to perform step 4, use the Labor Operation No. called out in the appropriate referenced Technical Service Bulletin. FAILURE CODE: 52 - Improperly Machined Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 250189 > Sep > 89 > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 250189 > Sep > 89 > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3468 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 250189 > Sep > 89 > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3469 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 250189 > Sep > 89 > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3470 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 250189 > Sep > 89 > Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up Fluid Pump: Customer Interest Converter Clutch - Vehicle Shudder on Lock Up NO: 18-09-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Vehicle Shudder During Torque Convertor EMCC (Lock-up) Operation/Diagnostic Trouble Code 38 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-17-96 REV. B, DATED OCT. 4, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE LABOR OPERATION CHANGES. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1990 - 1991 (AQ) Chrysler TC 1989 - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Avenger/Sebring/Talon 1996 (GS) Chrysler Voyager (International Market) 1995 - 1996 (JA) Cirrus/Stratus 1996 (JX) Sebring Convertible 1993 - 1996 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: NOTE: DIAGNOSTIC TROUBLE CODE (DTC) 38 (TORQUE CONVERTER CONTROL OUT OF RANGE) MUST BE PRESENT FOR THIS BULLETIN TO APPLY. IF DTC 38 IS NOT PRESENT AND THE VEHICLE IS A 1989-95 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 18-24-95 DATED JUNE 24, 1995 AND PERFORM AS NECESSARY. IF DTC 38 IS NOT PRESENT AND THE VEHICLE IS A 1996 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 21-05-96 DATED APR. 26, 1996 AND PERFORM AS NECESSARY. Vehicle shudders during full lock-up Electronically Modulated Convertor Clutch (EMCC) operation and DTC 38 is present. Full lock-up EMCC is indicated by 3LU or 4LU on the DRB III RPM display screen. DIAGNOSIS: This shudder condition can be the result of leakage in the transmission front pump caused by a worn pump bushing. It is sometimes accompanied by pump whine. Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC 38 is present, perform the Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 250189 > Sep > 89 > Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up > Page 3475 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the transmission front pump assembly and the transmission torque converter with one that has bonded converter clutch friction material and verifying the Transmission Control Module (TCM) part number. 1. Following the procedures outlined in the appropriate Service Manual, replace the torque converter and the transmission front pump assembly with the parts identified in the Parts Required section of this bulletin. 2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as outlined in the appropriate Service Manual. 3. Verify the TCM is the appropriate part number listed: 4. For 1989 - 1995 vehicles that do not have the appropriate TCM part number listed above, perform REPAIR PROCEDURE NO. 1 of Technical Service Bulletin 18-24-95. For 1996 vehicles that do not have the appropriate TCM part number listed above, perform the Repair Procedure of Technical Service Bulletin 21-05-96. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-60-05-91 1989 - 1995 AA,AC,AG,AJ,AP,AQ,AS,AY,ES,GS,NS **4.0** Hrs. 1993 - 1996 FJ,LH **4.7** Hrs. 1995 - 1996 JA,JX **5.7** Hrs. Supplemental Labor Operation No.'s 21-00-05-63 1989 - 1995 AS (Anti-Lock Brake System Equipped) 0.2 Hrs. 21-00-05-64 1991 - 1995 AS (All Wheel Drive Equipped) 1.2 Hrs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 250189 > Sep > 89 > Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up > Page 3476 If it is necessary to perform step 4, use the Labor Operation No. called out in the appropriate referenced Technical Service Bulletin. FAILURE CODE: 52 - Improperly Machined Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 3487 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 3488 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 3489 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up Fluid Pump: Customer Interest Converter Clutch - Vehicle Shudder on Lock Up NO: 18-09-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Vehicle Shudder During Torque Convertor EMCC (Lock-up) Operation/Diagnostic Trouble Code 38 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-17-96 REV. B, DATED OCT. 4, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE LABOR OPERATION CHANGES. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1990 - 1991 (AQ) Chrysler TC 1989 - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Avenger/Sebring/Talon 1996 (GS) Chrysler Voyager (International Market) 1995 - 1996 (JA) Cirrus/Stratus 1996 (JX) Sebring Convertible 1993 - 1996 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: NOTE: DIAGNOSTIC TROUBLE CODE (DTC) 38 (TORQUE CONVERTER CONTROL OUT OF RANGE) MUST BE PRESENT FOR THIS BULLETIN TO APPLY. IF DTC 38 IS NOT PRESENT AND THE VEHICLE IS A 1989-95 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 18-24-95 DATED JUNE 24, 1995 AND PERFORM AS NECESSARY. IF DTC 38 IS NOT PRESENT AND THE VEHICLE IS A 1996 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 21-05-96 DATED APR. 26, 1996 AND PERFORM AS NECESSARY. Vehicle shudders during full lock-up Electronically Modulated Convertor Clutch (EMCC) operation and DTC 38 is present. Full lock-up EMCC is indicated by 3LU or 4LU on the DRB III RPM display screen. DIAGNOSIS: This shudder condition can be the result of leakage in the transmission front pump caused by a worn pump bushing. It is sometimes accompanied by pump whine. Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC 38 is present, perform the Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up > Page 3494 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the transmission front pump assembly and the transmission torque converter with one that has bonded converter clutch friction material and verifying the Transmission Control Module (TCM) part number. 1. Following the procedures outlined in the appropriate Service Manual, replace the torque converter and the transmission front pump assembly with the parts identified in the Parts Required section of this bulletin. 2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as outlined in the appropriate Service Manual. 3. Verify the TCM is the appropriate part number listed: 4. For 1989 - 1995 vehicles that do not have the appropriate TCM part number listed above, perform REPAIR PROCEDURE NO. 1 of Technical Service Bulletin 18-24-95. For 1996 vehicles that do not have the appropriate TCM part number listed above, perform the Repair Procedure of Technical Service Bulletin 21-05-96. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-60-05-91 1989 - 1995 AA,AC,AG,AJ,AP,AQ,AS,AY,ES,GS,NS **4.0** Hrs. 1993 - 1996 FJ,LH **4.7** Hrs. 1995 - 1996 JA,JX **5.7** Hrs. Supplemental Labor Operation No.'s 21-00-05-63 1989 - 1995 AS (Anti-Lock Brake System Equipped) 0.2 Hrs. 21-00-05-64 1991 - 1995 AS (All Wheel Drive Equipped) 1.2 Hrs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up > Page 3495 If it is necessary to perform step 4, use the Labor Operation No. called out in the appropriate referenced Technical Service Bulletin. FAILURE CODE: 52 - Improperly Machined Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3501 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3502 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3503 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up Fluid Pump: All Technical Service Bulletins Converter Clutch - Vehicle Shudder on Lock Up NO: 18-09-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Vehicle Shudder During Torque Convertor EMCC (Lock-up) Operation/Diagnostic Trouble Code 38 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-17-96 REV. B, DATED OCT. 4, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE LABOR OPERATION CHANGES. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1990 - 1991 (AQ) Chrysler TC 1989 - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Avenger/Sebring/Talon 1996 (GS) Chrysler Voyager (International Market) 1995 - 1996 (JA) Cirrus/Stratus 1996 (JX) Sebring Convertible 1993 - 1996 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: NOTE: DIAGNOSTIC TROUBLE CODE (DTC) 38 (TORQUE CONVERTER CONTROL OUT OF RANGE) MUST BE PRESENT FOR THIS BULLETIN TO APPLY. IF DTC 38 IS NOT PRESENT AND THE VEHICLE IS A 1989-95 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 18-24-95 DATED JUNE 24, 1995 AND PERFORM AS NECESSARY. IF DTC 38 IS NOT PRESENT AND THE VEHICLE IS A 1996 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 21-05-96 DATED APR. 26, 1996 AND PERFORM AS NECESSARY. Vehicle shudders during full lock-up Electronically Modulated Convertor Clutch (EMCC) operation and DTC 38 is present. Full lock-up EMCC is indicated by 3LU or 4LU on the DRB III RPM display screen. DIAGNOSIS: This shudder condition can be the result of leakage in the transmission front pump caused by a worn pump bushing. It is sometimes accompanied by pump whine. Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC 38 is present, perform the Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up > Page 3508 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the transmission front pump assembly and the transmission torque converter with one that has bonded converter clutch friction material and verifying the Transmission Control Module (TCM) part number. 1. Following the procedures outlined in the appropriate Service Manual, replace the torque converter and the transmission front pump assembly with the parts identified in the Parts Required section of this bulletin. 2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as outlined in the appropriate Service Manual. 3. Verify the TCM is the appropriate part number listed: 4. For 1989 - 1995 vehicles that do not have the appropriate TCM part number listed above, perform REPAIR PROCEDURE NO. 1 of Technical Service Bulletin 18-24-95. For 1996 vehicles that do not have the appropriate TCM part number listed above, perform the Repair Procedure of Technical Service Bulletin 21-05-96. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-60-05-91 1989 - 1995 AA,AC,AG,AJ,AP,AQ,AS,AY,ES,GS,NS **4.0** Hrs. 1993 - 1996 FJ,LH **4.7** Hrs. 1995 - 1996 JA,JX **5.7** Hrs. Supplemental Labor Operation No.'s 21-00-05-63 1989 - 1995 AS (Anti-Lock Brake System Equipped) 0.2 Hrs. 21-00-05-64 1991 - 1995 AS (All Wheel Drive Equipped) 1.2 Hrs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up > Page 3509 If it is necessary to perform step 4, use the Labor Operation No. called out in the appropriate referenced Technical Service Bulletin. FAILURE CODE: 52 - Improperly Machined Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 182188 > Dec > 88 > Component Information > Technical Service Bulletins > Page 3510 Fluid Pump: Description and Operation The oil pump is located in the pump housing inside of the bell housing of the transaxle case, and is similar to oil pumps used in other Chrysler applications. The inner gear is driven by the torque converter impeller hub. Torque is supplied to the impeller hub by the engine crankshaft through the flex plate and converter housing. As the gears rotate, the clearance between the gear teeth increases in the crescent area, and creates a suction at the inlet side of the pump. Fluid is pulled through the pump inlet from the oil pan. As the clearance between the gear teeth in the crescent area decreases, it forces fluid into the pump outlet. The pressurized oil from the outlet operates the torque converter, clutches and the lubrication system. The pump is held in the housing by the reaction shaft support Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > Page 3511 Valve Clearance: Adjustments This engine uses hydraulic lash adjusters. No provision for adjustment is provided. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > System Information > Specifications > Page 3514 Valve Clearance: Adjustments This engine uses hydraulic lash adjusters. No provision for adjustment is provided. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair Governor: Service and Repair 1. Remove fluid pan, filter and valve body. 2. Remove bolts attaching governor to governor support, then the governor assembly from transaxle. 3. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T > Component Information > Specifications Input Shaft: Specifications Speed Sensor Torque Speed Sensor Torque Input Speed Sensor 20 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications Output Shaft: Specifications Output Sensor Torque Output Sensor Torque Output Speed Sensor 20 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Technical Service Bulletins > A/T - Extreme Gearshift Effort Out of Park Parking Pawl: Technical Service Bulletins A/T - Extreme Gearshift Effort Out of Park Models 1989 AA, AC & AS Bodies 3.0L A/T Subject High Gearshift Effort Out Of Park Index TRANSMISSION Date July 10, 1989 No. 21-25-89 (C21-24-9) P-2700 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Technical Service Bulletins > A/T - Extreme Gearshift Effort Out of Park > Page 3528 BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AA - SPIRIT/ACCLAIM AS CARAVAN/VOYAGER/CARAVAN C/V SYMPTOM/CONDITION High effort required to move the gear shift selector out of the PARK position. PARTS REQUIRED 1 Transmission Park Guide Bracket Package PN 4549239 REPAIR PROCEDURE Effective May 1, 1989, a new park sprag guide bracket entered production on the A-604 Ultradrive 4-speed automatic transmission. This new sprag guide bracket reduces the effort required to move the gearshift selector out of the PARK position. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Technical Service Bulletins > A/T - Extreme Gearshift Effort Out of Park > Page 3529 This new service parts park sprag guide package PN 4549239 can be used to update earlier built A-604 transmissions to reduce the effort needed to move the transmission selector out of park. NOTE: DO NOT INTERCHANGE PARTS BETWEEN THE OLD AND NEW ASSEMBLIES. POLICY: For Information only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > General Information Planetary Gears: Description and Operation General Information The entire planetary gear-train is located behind the input clutch assembly and is inside the 2-4 and L/R clutch assemblies. The planetary gear-train consists of two sun gears, two planetary carriers, two annulus (ring) gears and one output shaft which is part of the rear carrier. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > General Information > Page 3534 Planetary Gears: Description and Operation Front Carrier Assembly The front planetary carrier and gear annulus (ring) gear are splined together as one unit. When the overdrive clutch is applied, it drives the front carrier assembly by the overdrive hub. When the low/reverse clutch is applied, it holds or prevents the front carrier assembly from rotating. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > General Information > Page 3535 Planetary Gears: Description and Operation Rear Carrier Assembly The rear planetary carrier, front annulus (ring) gear and output shaft are all one assembly. The rear carrier assembly provides all output power for the transaxle assembly. In other words, all output from the transaxle must go through the rear carrier. The lugs around the outside of the assembly have two purposes: - To engage the parking pawl when the driver selects park - To generate an output speed signal used by the TCM There are no clutches splined or connected to this unit in any way. The rear carrier assembly is supported to the case by two tapered roller bearings, which must be set up with specific preload and measured by turning torque. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3545 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3546 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3547 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3548 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3549 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3550 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift Control Module: Customer Interest A/T - 41TE Harsh 2nd - 1st Gear Downshift NO.: 21-16-93 Rev. A GROUP: Transmission DATE: Oct 8, 1993 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED. CHANGES ARE HIGHLIGHTED BY **ASTERISKS**. MODELS: 1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue 1992 (AP) Shadow/Sundance SYMPTOM/CONDITION: Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service Manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 3555 TIME ALLOWANCE: Labor Operation No. **08-19-05-99** 0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift Control Module: Customer Interest A/T - 41TE Harsh 2-1 Gear Downshift NO.: 21-16-92 GROUP: Transmission DATE: Nov. 2, 1992 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle MODELS: 1989-1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990-1992 (AY) Imperial/New Yorker Fifth Avenue SYMPTOM/CONDITION: Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 3560 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting Control Module: Customer Interest A/T - A604 Excessive Upshifting/Downshifting Models 1989-90 AA, AC, AG, AJ, AS, & AY Bodies Subject A-604 Transmission Excessive Upshifting/ Downshifting Index TRANSMISSION Date April 9, 1990 No. 21-12-90 (C21-06-0) P-1042 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY AY - IMPERIAL/NEW YORKER FIFTH AVENUE SYMPTOM/CONDITION Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition when the vehicle is fully loaded, driving up a grade or into a head wind. This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior (1989) model year A-604 controllers. A new A-604 controller, PN 4557585, entered production late March 1990. The new controller allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle torque load changes. DIAGNOSIS Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does not apply. Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain Diagnostic Procedure Manual. If no fault codes are present, perform the following repair procedure. If fault codes are present, they must be corrected and the corrections verified before performing the following repair procedure. PARTS REQUIRED 1. 1 - Controller PN 4557585 REPAIR PROCEDURE This repair involves the replacement of the transaxle controller. 1. Disconnect the negative battery cable. 2. Disconnect the 60-way connector from the controller. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 3565 3. Remove the controller. 4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds. 5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds. 6. Reconnect the negative battery cable. 7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-05-96 0.6 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3571 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3572 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3573 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3574 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3575 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 3576 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2nd - 1st Gear Downshift NO.: 21-16-93 Rev. A GROUP: Transmission DATE: Oct 8, 1993 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED. CHANGES ARE HIGHLIGHTED BY **ASTERISKS**. MODELS: 1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue 1992 (AP) Shadow/Sundance SYMPTOM/CONDITION: Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service Manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 3581 TIME ALLOWANCE: Labor Operation No. **08-19-05-99** 0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2-1 Gear Downshift NO.: 21-16-92 GROUP: Transmission DATE: Nov. 2, 1992 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle MODELS: 1989-1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990-1992 (AY) Imperial/New Yorker Fifth Avenue SYMPTOM/CONDITION: Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 3586 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting Control Module: All Technical Service Bulletins A/T - A604 Excessive Upshifting/Downshifting Models 1989-90 AA, AC, AG, AJ, AS, & AY Bodies Subject A-604 Transmission Excessive Upshifting/ Downshifting Index TRANSMISSION Date April 9, 1990 No. 21-12-90 (C21-06-0) P-1042 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY AY - IMPERIAL/NEW YORKER FIFTH AVENUE SYMPTOM/CONDITION Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition when the vehicle is fully loaded, driving up a grade or into a head wind. This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior (1989) model year A-604 controllers. A new A-604 controller, PN 4557585, entered production late March 1990. The new controller allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle torque load changes. DIAGNOSIS Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does not apply. Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain Diagnostic Procedure Manual. If no fault codes are present, perform the following repair procedure. If fault codes are present, they must be corrected and the corrections verified before performing the following repair procedure. PARTS REQUIRED 1. 1 - Controller PN 4557585 REPAIR PROCEDURE This repair involves the replacement of the transaxle controller. 1. Disconnect the negative battery cable. 2. Disconnect the 60-way connector from the controller. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 3591 3. Remove the controller. 4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds. 5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds. 6. Reconnect the negative battery cable. 7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-05-96 0.6 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision Technical Service Bulletin # 210889 Date: 890403 A/T Reaction Shaft Support - Revision Models 1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle Subject Revised Reaction Shaft Support Index TRANSMISSION Date April 3, 1989 No. 21-08-89 P-1408 (C21-16-9) Description BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER SYMPTOM/CONDITION NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE AUTOMATIC TRANSAXLE, PART NUMBER 4446659. The procedure outlined in this bulletin should be followed if removal and disassembly of the transaxle is required. DIAGNOSIS 1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual (#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A) to determine if disassembly is required. Use the following procedure when the transaxle is disassembled for repair. PARTS REQUIRED 1 Repair package P/N 4549248 1 Gasket Package P/N 4504558 1 Controller (AS REQUIRED) P/N 5234678 NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT CLUTCH HUB IS REQUIRED. Input Clutch Retainer P/N 4431609 REPAIR PROCEDURE 1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the following guidelines. 2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or subsequent) controller. Always check input shaft end play before disassembling the transaxle. Step A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3596 FIGURE 1 - FRONT PUMP REACTION SHAFT 1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves, replace it with the four ring reaction support supplied in the repair package (Figure 1). If the reaction support that is removed from the transaxle has four ring grooves, the repair package is not needed. Step B FIGURE 2 - INPUT CLUTCH RETAINER 1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer as shown. If the bump is present, replace the retainer with a new one (P/N 4431609). 2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package. When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the compression of the Orings. 3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is no difference in any of the O-rings. The color was added to facilitate assembly. 4. Inspect and replace any distressed (burned) clutch components as required. Step C 1. Remove and discard the steel separator plate from the valve body. 2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow to the overdrive clutch circuit. Step D Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3597 1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play to the service preferred setting of .005" to .015". The actual total end play specification is .005" to .025" and is acceptable if the service preferred setting cannot be obtained. Other Recommendations 1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not use other kinds of petroleum based greases such as chassis grease that could plug critical orifices or might be incompatible with transmission fluid. 2. Replace the torque convertor if a clutch failure has occurred. 3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY. Replace it if necessary. 4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has occurred. 5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be used if ATF Plus is not available. POLICY: Reimbursable within the limits of the warranty. TIME ALLOWANCE: Labor Operation No. 21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs. FAILURE CODE: 7H - Reaction shaft/supt. assy. failed Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3598 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision Technical Service Bulletin # 210889 Date: 890403 A/T Reaction Shaft Support - Revision Models 1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle Subject Revised Reaction Shaft Support Index TRANSMISSION Date April 3, 1989 No. 21-08-89 P-1408 (C21-16-9) Description BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER SYMPTOM/CONDITION NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE AUTOMATIC TRANSAXLE, PART NUMBER 4446659. The procedure outlined in this bulletin should be followed if removal and disassembly of the transaxle is required. DIAGNOSIS 1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual (#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A) to determine if disassembly is required. Use the following procedure when the transaxle is disassembled for repair. PARTS REQUIRED 1 Repair package P/N 4549248 1 Gasket Package P/N 4504558 1 Controller (AS REQUIRED) P/N 5234678 NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT CLUTCH HUB IS REQUIRED. Input Clutch Retainer P/N 4431609 REPAIR PROCEDURE 1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the following guidelines. 2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or subsequent) controller. Always check input shaft end play before disassembling the transaxle. Step A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3604 FIGURE 1 - FRONT PUMP REACTION SHAFT 1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves, replace it with the four ring reaction support supplied in the repair package (Figure 1). If the reaction support that is removed from the transaxle has four ring grooves, the repair package is not needed. Step B FIGURE 2 - INPUT CLUTCH RETAINER 1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer as shown. If the bump is present, replace the retainer with a new one (P/N 4431609). 2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package. When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the compression of the Orings. 3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is no difference in any of the O-rings. The color was added to facilitate assembly. 4. Inspect and replace any distressed (burned) clutch components as required. Step C 1. Remove and discard the steel separator plate from the valve body. 2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow to the overdrive clutch circuit. Step D Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3605 1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play to the service preferred setting of .005" to .015". The actual total end play specification is .005" to .025" and is acceptable if the service preferred setting cannot be obtained. Other Recommendations 1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not use other kinds of petroleum based greases such as chassis grease that could plug critical orifices or might be incompatible with transmission fluid. 2. Replace the torque convertor if a clutch failure has occurred. 3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY. Replace it if necessary. 4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has occurred. 5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be used if ATF Plus is not available. POLICY: Reimbursable within the limits of the warranty. TIME ALLOWANCE: Labor Operation No. 21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs. FAILURE CODE: 7H - Reaction shaft/supt. assy. failed Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 3606 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 3609 Control Module: Locations Power Distribution Center Power Distribution Center Fuse Block Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3610 Control Module: Diagrams Part 1 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3611 Part 2 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3612 Part 3 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3613 Part 4 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3614 Part 5 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3615 Part 6 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3616 Part 7 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3617 Part 8 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3618 Part 9 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3619 Part 10 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3620 Part 11 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 Control Module: Description and Operation A604 DESCRIPTION This computer is dedicated to the control of the A-604 Transaxle. It has a connector shaped similarly to the one on the Engine Controller. It contains on-board diagnostics and fault code memory which is accessed by the DRBII Diagnostic Tool through Chrysler's C2D Bus. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 > Page 3623 Control Module: Description and Operation 41TE Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 > Page 3624 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 - Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 3627 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3631 Back Up Lamp Relay / Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3632 Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3633 Transmission Control System Relay: Description and Operation DESCRIPTION This relay is operated by the A-604 controller. Its purpose is to make operating voltage available to the solenoids and switches located in the Solenoid Pack. When the Controller opens the relay, voltage is taken away from the solenoids and the transmission goes into a limp-in mode. While in this mode, only second gear, reverse and neutral are available. This relay may also be referred to as the Safety Shutdown Relay. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations Transmission Position Relay: Component Locations Back Up Lamp Relay / Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page 3638 Back Up Lamp Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3647 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3648 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3649 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep > 99 > A/T Pan Gasket - Reusable Design/Installation Technical Service Bulletin # 21-05-99A Date: 990903 A/T Pan Gasket - Reusable Design/Installation NUMBER: 21-05-99 Rev. A GROUP: Transmission DATE: Sep. 03, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL COVERAGE. SUBJECT: Reusable Automatic Transmission Oil Pan Gasket OVERVIEW: This bulletin announces availability and installation of a reusable automatic transmission oil pan gasket. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon **1989** - 1993 (AG) Daytona **1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (European Market) 1995 - **2000** (JA) Cirrus/Stratus/Breeze 1996 - **2000** (JX) Sebring Convertible **1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M** 1996 - **2000** (NS) Town & Country/Caravan/Voyager **1995 - 2000 (PL) Neon** **1997 - 2000 (PR) Prowler** DISCUSSION: A reusable silicone gasket has been developed to replace the RTV method of sealing the automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is recommended that this gasket be used in all applications. NOTE: THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES. PARTS REQUIRED: **1 05011113AA Gasket, Transmission Oil Pan, 31TH** **1 05011114AA Gasket, Transmission Oil Pan, 42LE** 1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE POLICY: INFORMATION ONLY POLICY: Information Only Installation Procedure 1. With oil pan removed from transmission case for routine service or transmission repair proceed to step # 2. 2. Clean any residue from oil pan and magnet. 3. Replace O-ring and filter on bottom of valve body. 4. Using a plastic or wooden scraper, remove old RTV from transmission case rails. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep > 99 > A/T Pan Gasket - Reusable Design/Installation > Page 3655 CAUTION: ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING THESE COMPONENTS. 5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails. 6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission case. Tighten oil pan bolts to 19 Nm (165 in lbs.). 7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles. CAUTION: DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3660 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3661 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3662 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep > 99 > A/T Pan Gasket - Reusable Design/Installation Technical Service Bulletin # 21-05-99A Date: 990903 A/T Pan Gasket - Reusable Design/Installation NUMBER: 21-05-99 Rev. A GROUP: Transmission DATE: Sep. 03, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL COVERAGE. SUBJECT: Reusable Automatic Transmission Oil Pan Gasket OVERVIEW: This bulletin announces availability and installation of a reusable automatic transmission oil pan gasket. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon **1989** - 1993 (AG) Daytona **1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (European Market) 1995 - **2000** (JA) Cirrus/Stratus/Breeze 1996 - **2000** (JX) Sebring Convertible **1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M** 1996 - **2000** (NS) Town & Country/Caravan/Voyager **1995 - 2000 (PL) Neon** **1997 - 2000 (PR) Prowler** DISCUSSION: A reusable silicone gasket has been developed to replace the RTV method of sealing the automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is recommended that this gasket be used in all applications. NOTE: THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES. PARTS REQUIRED: **1 05011113AA Gasket, Transmission Oil Pan, 31TH** **1 05011114AA Gasket, Transmission Oil Pan, 42LE** 1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE POLICY: INFORMATION ONLY POLICY: Information Only Installation Procedure 1. With oil pan removed from transmission case for routine service or transmission repair proceed to step # 2. 2. Clean any residue from oil pan and magnet. 3. Replace O-ring and filter on bottom of valve body. 4. Using a plastic or wooden scraper, remove old RTV from transmission case rails. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep > 99 > A/T Pan Gasket - Reusable Design/Installation > Page 3668 CAUTION: ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING THESE COMPONENTS. 5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails. 6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission case. Tighten oil pan bolts to 19 Nm (165 in lbs.). 7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles. CAUTION: DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3669 Seals and Gaskets: By Symptom Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3670 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3671 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3672 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3673 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3674 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3675 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3676 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Page 3677 Seals and Gaskets: Service and Repair Remove Oil Pump Seal Install Oil Pump Seal Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation A604 (41TE) 4 Speed Transaxle DESCRIPTION The PRNDL switch is similar in appearance to the Neutral Safety Switch. Its purpose is to help the transaxle controller sense the shifter position (manual valve), and help operate the reverse lamps. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3690 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3691 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3692 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 3698 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 3699 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3704 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3705 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3706 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3712 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3713 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3716 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3717 Transmission Position Switch/Sensor: Locations 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3718 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 3721 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 3724 Transmission Position Switch/Sensor: Description and Operation PRNDL The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. It may have been replaced by a transmission range sensor (TRS). Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3727 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3728 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3729 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3738 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3743 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3744 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3745 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3751 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3756 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3757 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3758 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3759 Input / Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Transmission Speed Sensor: Description and Operation Output Speed Sensor DESCRIPTION This is a two wire, magnetic pick-up device used to sense the output speed of the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor > Page 3762 Transmission Speed Sensor: Description and Operation Turbine Speed Sensor A604 (41TE) 4 Speed Transaxle DESCRIPTION This is a two wire, magnetic pick-up device used to sense the input speed of the transaxle (torque convertor turbine). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 3763 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T Ratcheting Sound When Coming To Stop Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T Ratcheting Sound When Coming To Stop > Page 3775 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 3781 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3782 Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3783 Transmission Solenoid Connector Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair Selector Shaft: Service and Repair REMOVAL 1. Remove shift cable from lever. 2. Loosen the lever mounting bolt. Do not remove bolt (not necessary). 3. Pull up on lever and remove. INSTALLATION For installation, reverse removal procedure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair Shift Cable: Service and Repair REMOVAL 1. Remove cable eyelet attachment from transaxle operating lever pin. 2. Using pliers, squeeze ears of cable conduit attachment at mounting bracket and push through hole to remove. 3. At the steering column attachment, remove the cable eyelet attachment from the shift lever pin. 4. Using pliers, squeeze ears of cable attachment at mounting bracket then push through hole to remove. 5. Unseat the dash grommet and remove the cable from the vehicle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Page 3791 6. Remove the under instrument panel silencer. INSTALLATION 1. Install cable into steering column attachment bracket. Verify conduit ears are fully engaged. Verify cable does not interfere with brake pedal actuation. 2. Attach cable eyelet fitting onto shift lever pin. 3. Insert transaxle end of cable through dash panel hole and fully seat grommet 4. Install instrument panel silencer. Verify gearshift cable is routed through the slot in the silencer. CAUTION: Failure to route the cable properly at the silencer may cause brake pedal interference. 5. Attach transaxle end of cable to the mounting bracket on the transaxle. Assure the conduit attachment ears are fully seated. 6. Attach cable eyelet fitting onto the transaxle operating lever. 7. Complete adjustment using the gearshift cable adjustment procedure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Specifications > Cable and Pinion Speedometer Gear, A/T: Specifications Speedometer Cable 35 ft.lb Speedometer Pinion Bolt 60 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Specifications > Cable and Pinion > Page 3796 Speedometer Gear, A/T: Specifications Speedometer To Extension Bolt 60 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Specifications > Page 3797 Speedometer Gear, A/T: Service and Repair 1. Remove bolt and washer assembly securing speedometer pinion adapter in extension housing. 2. With cable housing connected, carefully work adapter and pinion out of extension housing. 3. Remove retainer and pinion from adapter. 4. If transmission fluid is found in cable housing, install new speedometer pinion and seal assembly. If fluid is found leaking between cable and adapter, replace O-ring on cable. 5. Prior to installation, ensure adapter flange and mating areas on extension housing are clean. 6. Install pinion on adapter with new O-ring, then the retainer on pinion and adapter. Ensure retainer is properly seated. 7. Install bolt and washer assembly and torque to specifications. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Description and Operation > Front Sun Gear Assembly Sun Gear: Description and Operation Front Sun Gear Assembly The front sun gear assembly rides in the center of the front carrier, and is welded to the center of two hubs that are arranged back to back. Each of the hubs are splined to a clutch. The front-most hub is splined to the reverse clutch which turns the front sun gear when it is applied. The rearward hub is splined to the 2-4 clutch which prevents the front sun gear from turning when it is applied. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Description and Operation > Front Sun Gear Assembly > Page 3802 Sun Gear: Description and Operation Rear Sun Gear The rear sun gear is located in the center of the rear carrier assembly. There are two thrust bearings located on either side of the sun gear. When the underdrive clutch is applied, it drives the rear sun gear through the underdrive hub and shaft. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > Rod Adjustment - Torqueflite Throttle Valve Cable/Linkage: Adjustments Rod Adjustment - Torqueflite Fig. 3 Throttle cable linkage 1. Ensure engine is at normal operating temperature. 2. Loosen adjustment swivel lock screw, Fig. 3. 3. To ensure Proper adjustment, swivel must be free to slide along flat end of throttle rod so that preload spring action is not restricted. Disassemble and clean or repair parts as necessary. 4. Hold transaxle throttle lever firmly toward engine against its internal stop and torque swivel lock screw to 100 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > Rod Adjustment - Torqueflite > Page 3807 Throttle Valve Cable/Linkage: Adjustments Throttle Control Cable Adjustment Fig. 3 Throttle cable linkage 1. Ensure engine is at normal operating temperature. 2. Loosen adjusting bracket lock screw, Fig. 3. 3. Position bracket with both alignment tabs touching transaxle cast surface. 4. Torque adjusting bracket lock screw to 105 inch lbs. 5. Release cross-lock on cable assembly by pulling upward. 6. To ensure proper adjustment, cable must be free to slide completely towards engine, against its stop, after cross-lock is released. 7. Move transaxle throttle control lever fully clockwise against its internal stop, then press cross-lock downward into locked position. 8. Connect choke, if disconnected, then test cable operation for freedom by moving transaxle throttle lever forward, then slowly release it to ensure full return. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications A-413 / A-670 Flex plate to torque converter bolts ......................................................................................................................................................... 74 Nm ( 55 ft-lbs ) A-604 Drive plate to torque converter bolts ....................................................................................................................................................... 94 Nm ( 70 ft-lbs ) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3811 Torque Converter: Description and Operation The torque converter is similar in function and design to other Chrysler torque converters. The torque converter clutch engages or disengages the turbine assembly to the impeller housing. The application of the converter clutch is controlled electronically by the solenoid assembly and valve body. The torque converter transmits torque from the engine crankshaft to the input shaft of the transaxle. The torque converter clutch may engage (under the right conditions) in either 2nd, 3rd or 4th gears. The torque converter clutch engagement is normally very smooth and may even be undetectable by the driver. There are two types of torque converter engagement: partial and full engagement. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging Torque Converter Clutch Solenoid: Customer Interest Converter Lock Up Solenoid Bucking/Surging Models 1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies Subject Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines. Index DRIVEABILITY Date February 12, 1990 No. 18-02-90 P-205 (C18-27-9) BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ - LEBARON COUPE/LEBARON CONVERTIBLE AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4 speed automatic transmission. SYMPTOM/CONDITION A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur under light deceleration conditions, especially when cresting a hill. DIAGNOSIS The above conditions can be diagnosed by disconnecting the transmission lock-up torque converter solenoid, and driving the vehicle under the above conditions. If the problem goes away, follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test Procedure for correction. PARTS REQUIRED Driveability Kit PN 4419447 Consists of: 1 Wiring Jumper Assembly PN 4400768 1 Lock-Up Solenoid Cap PN 4419446 2 Tie Wrap PN 6015756 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE The following procedure involves disconnecting the lock-up torque convertor solenoid. The customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2 miles per gallon may be noticed, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3820 FIGURE A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3821 FIGURE B 1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located directly behind the transmission dipstick (Figures A and B). 2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in Step 1. 3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A). 3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places using tie wrap, PN 6015756 (Figure B). 4. Install supplied cap, PN 4419446, onto lock-up solenoid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3822 FIGURE C 5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and attach near VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 21-96-01-90 0.2 Hrs. FAILURE CODE: AM - Authorized modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging Torque Converter Clutch Solenoid: All Technical Service Bulletins Converter Lock Up Solenoid Bucking/Surging Models 1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies Subject Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines. Index DRIVEABILITY Date February 12, 1990 No. 18-02-90 P-205 (C18-27-9) BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ - LEBARON COUPE/LEBARON CONVERTIBLE AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4 speed automatic transmission. SYMPTOM/CONDITION A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur under light deceleration conditions, especially when cresting a hill. DIAGNOSIS The above conditions can be diagnosed by disconnecting the transmission lock-up torque converter solenoid, and driving the vehicle under the above conditions. If the problem goes away, follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test Procedure for correction. PARTS REQUIRED Driveability Kit PN 4419447 Consists of: 1 Wiring Jumper Assembly PN 4400768 1 Lock-Up Solenoid Cap PN 4419446 2 Tie Wrap PN 6015756 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE The following procedure involves disconnecting the lock-up torque convertor solenoid. The customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2 miles per gallon may be noticed, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3828 FIGURE A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3829 FIGURE B 1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located directly behind the transmission dipstick (Figures A and B). 2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in Step 1. 3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A). 3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places using tie wrap, PN 6015756 (Figure B). 4. Install supplied cap, PN 4419446, onto lock-up solenoid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 3830 FIGURE C 5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and attach near VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 21-96-01-90 0.2 Hrs. FAILURE CODE: AM - Authorized modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations Part Throttle Unlock Solenoid (3speed) LH Side Of Engine Compartment 3 Speed Automatic RH Side Of Transaxle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3833 Applicable to: 3 Speed A-413 Automatic Transaxle 4 Speed Automatic Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3834 Electrical Connections, 3 Speed Automatic Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3835 Torque Converter Clutch Solenoid: Description and Operation Part Throttle Unlock Solenoid (3 Speed Automatic) This solenoid is controlled by the engine controller. The engine controller applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. The lock-up torque converter is only locked up when the transmission is in direct drive and when the throttle position is not fluctuating. If the engine controller receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the engine controller will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3839 Back Up Lamp Relay / Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3840 Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3841 Transmission Control System Relay: Description and Operation DESCRIPTION This relay is operated by the A-604 controller. Its purpose is to make operating voltage available to the solenoids and switches located in the Solenoid Pack. When the Controller opens the relay, voltage is taken away from the solenoids and the transmission goes into a limp-in mode. While in this mode, only second gear, reverse and neutral are available. This relay may also be referred to as the Safety Shutdown Relay. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve Technical Service Bulletin # 281T Date: 891201 Original TSB No. 281T December, 1989 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 281T Transmission Oil Cooler Bypass Valve Models: 1988 and 1989 S-Body Models Equipped With Heavy Duty Trailer Tow Package -Plymouth Voyager and Grand Voyager, Dodge Caravan, Grand Caravan, Caravan C/V and Grand Caravan C/V The listed model vehicles equipped with the trailer tow package may experience restricted transmission fluid flow through the oil cooler at low temperature (-15 degrees F and below). This may result in lack of lubrication to the transmission and possible transmission failure. To ensure adequate lubrication, a transmission oil cooler bypass valve system must be installed. Important: Some of the involved vehicles may still be in dealer inventory. Be sure to complete the service on these vehicles before delivery to customers. Because of the cold weather nature of the condition, only those vehicles invoiced to dealers in the Northern U.S. are included in this notification and service action. The following Zones are included: Boston, Chicago, Denver, Detroit, Kansas City, Milwaukee, Minneapolis, Pittsburgh and Syracuse; also the State of Alaska. Parts distribution and Vehicle Lists will be limited to these dealers. However, vehicles in other areas are eligible for the repair as needed to meet cold weather operation requirements upon owner request. Details of this service action are explained in the following sections. As an additional service aid, a videotape demonstrating the service procedure is included in the December, 1989 Master Tech program. Vehicle, Parts, and Owner Info. VEHICLE LIST Each dealer to whom involved vehicles were invoiced (or the current dealer at the same location) will receive a listing of them with this letter, arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Each Dodge or Chrysler-Plymouth dealer without a Vehicle List will receive an information copy of this letter by Compak Mall for use in performing the service on involved vehicles upon request. Parts Parts packages, PN C3940361, are being shipped free of charge to all involved dealers for service of affected vehicles. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same location) will receive enough parts packages to service 75% of those vehicles. Parts (Continued) Each recall parts package contains the following components: Quantity Description (1) Bypass valve (2) Brass tees (4) Nipple connectors (4) Hose clamps (1) Foam tube (1) Tie strap (1) Tie strap (with "push-in" retainer) Also included in each package is an instruction summary for convenient reference by the servicing technician. Additional parts may be ordered without charge from Parts Depots if required. Order only as needed for scheduled repairs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3850 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is attached. Enclosed with each owner notification is an Owner Recall Notification Form # 83- 295-0019. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure Figure 1 Prior to performing this service, it is important to understand that the bypass valve, to function properly, must be located and connected to the transmission oil cooler hoses in the correct oil flow direction (Figure 1). Figure 2 1. Using Chrysler Mopar Thread Sealant PN 4318034 or equivalent at all connections, assemble the supplied bypass valve, tees and connectors as shown in Figure 2. Tighten the tees and connectors to 12 N-m (110 in.lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3851 Figure 3 2. Raise vehicle on hoist for working access to the transmission oil cooler hoses routed along the inboard side of the left front frame rail. 3. Measure 5-1/2 inches rearward from the front edge of the frame rail and 2 inches up from the bottom of rail (Figure 3) and drill a 1/4 inch diameter hole in the rail. Figure 4(3-Speed Transmission) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3852 Figure 5(4-Speed Transmission) 4. Referring to Figures 4 and 5, follow the cooler hoses routed from the transmission to clearly identify the cooler "in" hose. Figure 6 5. Place an oil pan under the vehicle to catch fluid leakage. (Oil loss will be minimal.) 6. Pushing the cooler hoses against the frame, cut the cooler "in" hose at the drilled hole (Figure 6) and allow oil to drain. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3853 Figure 4(3-Speed Transmission) Figure 5(4-Speed Transmission) IMPORTANT: Illustration is typical of 4-speed hose routing. 3-speed hose routing differs; therefore it is important to identify the cooler "in" and "out" hoses per Figures 4 and 5. Figure 1 7. Slide 2 of the supplied clamps over the hose ends and install the cooler "in" end connectors of the bypass valve assembly to the cut hose ends. NOTE: Refer to Figure 1 to identify the male (pipe nipple) end of the valve. This end of the assembly.must be connected to the cooler "in" Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3854 hose. Figure 7(3-Speed Transmission Installation) Figure 8(4-Speed Transmission Installation) 8. Cut the other hose (cooler "out") at the drilled hole, allow oil to drain, and connect the hose ends to the valve assembly connectors in the Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3855 same manner. 9. Cut the supplied foam tube and wrap it around the bypass valve (Figures 7 and 8). 10. Tighten the supplied "push-in" tie strap around the foam tubing and cut off excess strap. 11. Engage the push-in tie strap in the drilled 1/4 inch hole (Figures 7 and 8). NOTE: Because the hoses and hose routing differ on the 3-speed and 4- speed transmission, the valve assembly must be positioned differently for each -- valve mounted vertically for the 4-speed and at an angle for the 3- speed. 12. Tighten all hose clamps to 2 N-m (15 in.lbs). 13. Install the other supplied tie strap to secure the assembly to the frame rail (Figures 7 and 8). Cut off excess strap. 14. Check and, if necessary, adjust transmission oil level. Completion Information Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted by DIAL dealers on the DIAL System. Non DIAL dealers may submit WROS. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Enter only one VIN per claim on a WRO. Fill in the labor operation number and time allowance and write on the WRO "Customer Satisfaction Notification # 281T --Transmission Oil Cooler Bypass Valve." Do not enter other service claims on the same WRO. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Install transmission oil cooler bypass valve. 21281282 0.5 Hour Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing instructions. Parts Return Not applicable. Vehicle Not Available If a vehicle is not available for this service for a known reason, let us know by filling outthe pre-addressed Vehicle Disposition Form portion of the Owner Recall Notification Form or describe the reason on a postcard and mall to: Chrysler Motors 416-15-19 Recall Coordination P.O. Box 1919 Detroit, Michigan 48231-9986 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Letter CUSTOMER SATISFACTION NOTIFICATION -- TRANSMISSION OIL COOLER BYPASS VALVE Dear Chrysler Motors Vehicle Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are offering a free repair service to owners of certain 1988 and 1989 model vehicles equipped with the heavy duty trailer tow package. Included are the Plymouth Voyager and Grand Voyager, Dodge Caravan, Grand Caravan, Caravan C/V and Grand Caravan C/V. Your vehicle, whose Vehicle Identification Number is shown on the enclosed form, is included in this offer. This service and the required parts as described in this letter will be provided without charge. The service is needed to prevent possible transmission damage in extremely cold weather resulting from restricted flow of transmission fluid through the oil cooler. We ask that you arrange for this important service without delay. To correct the condition, your dealer will install a bypass valve to ensure an adequate fluid supply to the transmission at all times. The work will take less than one hour to complete. However, additional time may be required depending on how service appointments are scheduled and processed. To arrange for this service: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3856 ^ Contact your dealer as soon as possible to schedule an appointment for the free service. ^ Take the enclosed Owner Recall Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and condition for which service is required. If you have any problem obtaining the needed service, please contact the Chrysler Zone Service Office in your area. (It is listed under "Service Assistance" in your Operator's Manual.) A Zone representative will arrange for prompt servicing of your vehicle. We regret any inconvenience that this action may cause you. However, we believe that this special service will help to ensure your continuing satisfaction with your Voyager or Caravan. Thank you for your attention to this important matter. SERVICE AND PARTS OPERATIONS CHRYSLER MOTORS CORPORATION Supplement # 1 No. 281T March, 1990 SUPPLEMENT CUSTOMER SATISFACTION NOTIFICATION # 281 -TRANSMISSION OIL COOLER BYPASS VALVE: THIS PROGRAM HAS BEEN EXTENDED TO INCLUDE ADDITIONAL VEHICLES IN SPECIFIED FRIGID CLIMATE STATES To: All Dodge and Chrysler-Plymouth Dealers in Involved Zones; All Regional and Zone Service and Parts Managers Subject: Customer Satisfaction Notification # 281T -- Transmission Oil Cooler Bypass Valve -Additional Vehicles in Specified States Models: The Following Additional Models Equipped With the A604 4-Speed Automatic Transmission and External Transmission Oil-To-Air Cooler: ^ 1989 AC-Body Cars -- Chrysler New Yorker, New Yorker Landau and Dodge Dynasty ^ 1989 AS-Body Models Without Heavy Duty Trailer Tow Package - - Voyager, Grand Voyager, Caravan, Grand Caravan, Caravan CN Van and Extended Van ^ 1990 AC & AY-Body Cars -- Chrysler Salon, New Yorker Landau, New Yorker Fifth Avenue, Imperial and Dodge Dynasty ^ 1990 AS-Body Models Equipped With Heavy Duty Trailer Tow Package -- Voyager, Grand Voyager, Caravan, Grand Caravan, Caravan CN Van and Extended Van ^ 1990 AS Body Chrysler Town & Country Location: This Service Action Applies Only to Vehicles in the Following Frigid Climate States: ^ Minneapolis Zone -- Minnesota, North Dakota, South Dakota ^ Milwaukee Zone -- Wisconsin, Michigan (U.P.) ^ Detroit Zone -- Michigan ^ Denver Zone -- Montana, Wyoming ^ Portland Zone -- Alaska Reference: Dealer notification letter # 281T, December, 1989, for 1988-9 AS-Body vehicles with heavy duty trailer tow package and located in Northern U.S. The initial notification for recall # 281T involved 1988 and 1989 model year AS-Body vehicles equipped with trailer tow and operating in cold climates. The action was taken to eliminate the potential for transmission damage due to oil flow restriction through the oil cooler during cold weather. The recall population is now being expanded to also include certain additional 4- speed transmission equipped AS, AC and AY-Body vehicles with external transmission oil-to-air coolers operating in frigid climate regions. Note: Vehicles already equipped with oil cooler bypass valve systems under Technical Service Bulletin # 21-28-89 do not require further service for this condition. All service requirements for the additional vehicles are the same as for the original Recall # 281T except as noted in the following sections. A copy of the original dealer notification letter of December, 1989 is enclosed for your reference. Parts The same parts package used for previously involved vehicles, PN C3940361, is required for the added models. Parts sufficient to repair 75% of the involved vehicles will be shipped free of charge to involved dealers as supplies become available. Note: For 1990 AS-Body models only, an additional bracket, PN C3940385, is require to complete the recall package installation. Six of these Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3857 brackets will be provided free of charge to involved dealers for use as required. Additional brackets, if needed, are available for ordering from the parts depot. Owner Notification and Service Scheduling Owners will be notified of the service requirement aftershipment of the recall parts to involved dealers. Service Procedure ^ The procedure for installing the bypass valve assembly on 1989 AS-Body models without trailer tow is the same as shown in the instructions already provided in the dealer recall notification letter (# 281T) for trailer tow vehicles. ^ For 1989 AC-Body models, the procedure is the same as previously described for recall # 281T except there is no drilling required (procedure step 3). A 1/4 inch hole already exists in the frame rail for the push-in tie strap to retain the valve assembly. ^ The procedure for 1990 AC and AY-Body models is also the same as previously described for recall # 281T except as follows: FIGURE 11990 AC AND AY-BODY CARS - A plate is attached to the frame rail where the valve assembly is to be located. Therefore, a 1/4 inch hole must be drilled through the plate (at the location shown in Figure 1 of this letter to accommodate the pushin tie strap. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3858 FIGURE 21990 AC AND AY-BODY CARS - Install the other retaining tie strap by routing the strap through the two existing frame holes as shown in Figure 2. Figure 31990 AS-Body with External Cooler (Trailer Tow or Town & Country) ^ Installation of the bypass valve assembly on 1990 AS-Body models differs as follows (see Figure 3): - To install the valve assembly, cut the cooler hoses in line with the center of the large hole in the bottom of the frame. - Install bracket PN C3940385 to retain the upper cooler hose, using the existing lower battery tray attaching bolt. - Since the valve assembly will be clear of the frame rail with this installation, the anti-rattle foam tube and tie straps are not required. Important: Remember that the bypass valve must be installed in the proper flow direction. Be sure to identify the transmission fluid out (outlet and in (inlet) fittings at the transmission as shown in Figure 5 of the original Recall # 281T service procedure. Then follow the hoses from the transmission to the valve mounting location to ensure that the valve is attached properly to the "in" and "out" hoses as shown in Figure 8 of the original recall service procedure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3859 Owner Letter CUSTOMER SATISFACTION NOTIFICATION -- TRANSMISSION OIL COOLER BYPASS VALVE Dear Chrysler Corporation Vehicle Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are offering a free service at this time to owners of certain 1989 and 1990 model vehicles equipped with 4-speed automatic transmissions. The vehicle whose Vehicle Identification Number is shown on the enclosed form is included in this offer. The service and requiredpartsas describedin this letter will be provided to you without charge. This service will prevent possible transmission damage in extremely cold weather resulting from restricted flow of transmission fluid through the oil cooler. We ask that you arrange for this important service without delay. To correct the condition, your dealer will install a bypass valve to ensure an adequate fluid supply to the transmission at all times. If your vehicle has already had this service performed, please disregard this notice. Otherwise, to obtain this service: ^ Contact your dealer promptly to schedule an appointment for the free service. ^ Take the enclosed Owner Recall Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and condition for which service is required. The work will take less than one hour to complete. However, additional time may be required depending on how service appointments are scheduled and processed. If you have any problem obtaining the needed service, please contact the Chrysler Zone Service Office in your area. (it is listed under "Service Assistance" in your Operator's Manual.) A Zone representative will arrange for prompt servicing of your vehicle. We regret any inconvenience that this action may cause you. However, we believe that this special service will help to ensure your continuing satisfaction with your Chrysler product. Thank you for your attention to this important matter. Supplement # 2 NO. 281T October, 1990 SUPPLEMENT # 2 CUSTOMER SATISFACTION NOTIFICATION # 281T -TRANSMISSION OIL COOLER BYPASS VALVE: THIS PROGRAM HAS BEEN EXTENDED TO INCLUDE ADDITIONAL 1990 MODEL YEAR VEHICLES IN SPECIFIED FRIGID CLIMATE STATES AND TO REVISE PARTS AND PROCEDURES FOR SPECIFIED MODELS To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 281T -- Transmission Oil Cooler Bypass Valve -Additional 1990 Vehicles in Specified States and Revised Parts/Procedures Models: All Following Vehicles Equipped With A604 4-Speed Automatic Transmission and Locate in States Specified Below: ^ 1989 AC -- Chrysler New Yorker, New Yorker Landau and Dodge Dynasty ^ 1990 AC & AY -- Chrysler Salon, New Yorker Landau, New Yorker Fifth Avenue, Imperial and Dodge Dynasty ^ 1990 AS -- Voyager, Grand Voyager, Caravan, Grand Caravan, Caravan CN Van and Extended Van -- Equipped With Heavy Duty Trailer Tow Package ^ 1990 AS -- Chrysler Town & Country -- All Location: This Service Action Applies Only to Vehicles in the Following Frigid Climate States: ^ Minneapolis Zone -- Minnesota, North Dakota, South Dakota ^ Milwaukee Zone -- Wisconsin, Michigan (U.P.) ^ Detroit Zone -- Michigan ^ Denver Zone -- Montana, Wyoming ^ Portland Zone -- Alaska Reference: ^ Dealer notification letter # 281T, December, 1989. ^ Dealer notification letter # 281T supplement, March, 1990. The Recall # 281T Supplement dated March, 1990 applied to specific 1989 and 1990 model year vehicles built throu h February 11, 1990 and located in frigid climate states. The service action is nowleing extended to include 1990 model year vehicles in the same states which were built from February 12, 1990 through the end of 1990 model year production. Important: Some of the involved vehicles may still be in dealer stock. Be sure to complete the service on these vehicles before retail delivery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3860 Revised parts packages have been developed for 1989 and 1990 model year AC/AYBody cars and for 1990 AS-Body minivans and wagons. These packages contain preassembled bypass valve and oil cooler hose components. All 1988 and 1989 AS-Body vehicles will continue to use the previous parts package. Details of this service action are explained in the following sections. Note: Vehicles already equipped with oil cooler bypass valve systems under Technical Service Bulletin # 21-28-89 or previously serviced for this recall with the original parts package do not require further service for this condition. Vehicle List Each dealer to whom additional later-built 1990 model year vehicles were invoiced (or the current dealer at the same location) will receive a vehicle list with this letter arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Each Dodge or Chrysler-Plymouth dealer without a Vehicle List will receive an information copy of this letter by Compak Mail for use in performing the service on involved vehicles upon request. Parts Parts packages are being distributed free of charge to all involved dealers for service of affected vehicles. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same location) will receive enough parts packages to service 50% of those vehicles. Two new parts packages have been released for specific models as follows: Included in each package is an instruction summary for convenient reference by the servicing technician. Note: For 1988 and 1989 AS-Body vehicles involved in the original Recall # 281T notification of December, 1989, and the Recall # 281T Supplement of March, 1990, continue to use the original parts package, PN C3940361. Additional parts may be ordered without charge from Parts Depots if required. Order only as needed for scheduled repairs. Owner Notification and Service Scheduling All involved owners of additional 1990 vehicles who are known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is attached. Enclosed with each owner notification is an Owner Recall Notification Form # 83-295-0019. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure A. 1989 and 1990 AC/AY-Body Passenger Cars 1. Place an oil pan under the vehicle to catch fluid leakage (oil loss will be minimal). 2. Disconnect the existing cooler hoses from the fittings at the transmission and at the external oil cooler mounted at the front of the radiator. Save the clamps for reinstallation. 3. Install the supplied valve and hose assembly (PN C3940405) in place of the removed hoses as follows. Note: The hoses on the new assembly are banded together with tape and the ends are pre-molded to align them for installation to the appropriate transmission and cooler fittings. Do not disturb the tape wrappings. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3861 Figure 1 Vehicles not equipped with Bendix Anti-Lock Brake System -Install the supplied bracket on the valve (with the bracket mounting holes toward the front as shown in Figure 1). Loosely attach the bracket to the left front frame rail with the supplied screw, using the existing hole in the rail. Figure 2 Figure 3 ^ Vehicles equipped with Bendix Anti-Lock Brake System (ABS) -There is an existing cooler line clip at the ABS controller module mounted to the left front frame rail (Figure 2). Use this existing clip to support the valve and hose assembly as shown in Figure 3. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3862 Figure 4 Figure 5 ^ All Vehicles -- Attach the hoses to the fittinqs at the external oil cooler (Figure 4) and at the transmission (Figure 5). Secure with the original clamps. ^ Tighten the valve support bracket screw (non ABS cars) or clip screw (Bendix ABS equipped cars). ^ Start the engine and check for leaks. ^ Check and, if necessary, adjust the transmission oil level. Figure 2 Figure 3 B. 1990 AS-Body Mini Vans/Wagons With Heavy Duty Trailer Tow Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3863 1. Place an oil pan under the vehicle to catch fluid leakage (oil loss will be minimal). 2. Disconnect the existing cooler hoses from the fittings at the base of the radiator (Figure 2) and from the transmission fittings (Figure 3). Save the clamps for reinstallation. 3. Install the supplied valve, hose and bracket assembly (PN C3940406) in place of the removed hoses as follows. Note: The hoses on the new assembly are banded together with tape and the ends are pre-molded to align them for installation to the appropriate transmission and cooler fittings. Do not disturb the tape wrappings. Figure 1 ^ Support the valve and hose assembly by loosely attaching the valve support bracket to the left front frame rail with the supplied screw, using the existing hole in the rail (Figure 1). Figure 2 ^ Attach the hoses to the fittings at the base of the radiator and secure with the original clamps (Figure 2). Important: Note that bolh hoses do not attach to the lower radiator tank fittings. As shown in Figure 2, one hose attaches to the lower radiator tank fitting and the other hose attaches to the external cooler tube. Figure 3 ^ ^ Attach the hoses to the transmission fittings and secure with the original clamps (Figure 3). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3864 ^ ^ Tighten the valve support bracket screw. ^ ^ Start engine and check for leaks. ^ ^ Check and, if necessary, adjust the transmission oil level. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance ^ Install transmission oil cooler 21281282 0.5 Hour bypass valve -- 1990 AS-Body with heavy duty trailer tow. Note: This is the same labor operation number and time allowance as specified for vehicles involved in the original recall # 281T notification of December, 1989. ^ Install transmission oil cooler 21281283 0.3 Hour bypass valve -- 1989 and 1990 AC/AY-Body cars Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H, for complete recall claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for this service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Recall Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation 416-15-19 Recall Coordination P.O. Box 1919 Detroit, Michigan 48231-9986 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Owner Letter CUSTOMER SATISFACTION NOTIFICATION -- TRANSMISSION OIL COOLER BYPASS VALVE Dear Chrysler Motors Vehicle Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are offering a free service at this time to owners of certain 1990 model vehicles equipped with 4-speed automatic transmissions. The vehicle whose Vehicle Identification Number is shown on the enclosed form is included in this offer. The service and required parts as described in this letter will be provided to you without charge. This service will prevent possible transmission damage in extremely cold weather resulting from restricted flow of transmission fluid through the oil cooler. We ask that you arrange for this important service without delay. To correct the condition, your dealer will install a bypass valve to ensure an adequate fluid supply to the transmission at all times. If your vehicle has already had this service performed, please disregard this notice. Otherwise, to obtain this service: ^ Contact your dealer promptly to schedule an appointment for the free service. ^ Take the enclosed Owner Recall Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and condition for which service is required. The work will take less than one hour to complete. However, additional time may be required depending on how service appointments are scheduled and processed. If you have any problem obtaining the needed service, please contact the Chrysler Zone Service Office in your area. (It is listed under "Service Assistance" in your Operator's Manual.) A Zone representative will arrange for prompt servicing of your vehicle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3865 We regret any inconvenience that this action may cause you. However, we believe that this special service will help to ensure your continuing satisfaction with your Chrysler product. Thank you for your attention to this important matter. Dealer Instructions IMPORTANT DEALER INSTRUCTIONS CUSTOMER SATISFACTION NOTIFICATION # 281T, SUPPLEMENT # 2 -- TRANSMISSION OIL COOLER BYPASS VALVE ^ The recall # 281T Supplement Notification dated March, 1990 applied to specific 1989 and 1990 model year vehicles built through February 11, 1990. The service action is now being extended to include those 1990 model year vehicles built from February 12, 1990 through the end of 1990 model year production. As in the March, 1990 Supplement Notification, only those additional 1990 model year vehicles operating in frigid climate regions are involved. Refer to the attached dealer notification letter for a listing of the involved states. ^ Two new parts packages have been released for this recall. These new packages contain the oil cooler hoses already assembled to the bypass valve. With the new valve and hose assemblies, it is no longer necessary to cut the existing hoses to install the valve. Simply remove the existing transmission-to-cooler hoses and install the new valve and hose assembly in their place. The new parts packages, and the previous package (PN C3940361), are to be used for the following applications: - New package, PN C3940405, is to be used only for 1989 and 1990 AC and AY-B cars. - New package, PN C3940406, is to be used only for 1990 AS-Body minivans/wagons. - The previous package, PN C3940361, should continue to be used only for 1988 and 1989 AS-Body mini vans/wagons. IMPORTANT: ^ Service procedures for the 1989 and 1990 cars and 1990 mini vans/wagons are included in this dealer notification. ^ The service procedure for 1988 and 1989 mini vans/wagons remains the same as specified in the December, 1989 Recall # 281T instructions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 211690 > Jun > 90 > A-604 A/T Oil Cooler - Flushing & Flow Testing Technical Service Bulletin # 211690 Date: 900604 A-604 A/T Oil Cooler - Flushing & Flow Testing Models 1989-1990 AA, AC, AG, AJ, AS, & AY Bodies Subject A-604 Transaxle Oil Cooler Flushing And Flow Testing Index TRANSMISSION Date June 4, 1990 No. 21-16-90 (C21-10-0) P-1649 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTY AY - IMPERIAL/NEW YORKER FIFTH AVENUE Discussion The purpose of this bulletin is to emphasize the IMPORTANCE OF PROPERLY FLUSHING AND FLOW TESTING THE TRANSAXLE OIL COOLER SYSTEM FOLLOWING ANY A-604 REPAIR WHICH REQUIRES THE REMOVAL OR REPLACEMENT OF THE TRANSAXLE. A clogged or restricted transaxle oil cooler system can be the cause of recurring transaxle failures. Restriction of transaxle fluid flow through the oil cooler system can result in overheating of the fluid and reduce lubrication flow to internal rotating parts. Three types of transaxle oil cooler systems are used; oil to air, oil to engine coolant and a combination oil to air and oil to engine coolant. When flushing a cooler system with a combination of both, it will be necessary to flush each cooler separately. Vehicles equipped with the Bypass valve, installed from Recall 281-T or Technical Service Bulletin 21- 28-89 must have the Bypass valve cleaned separately. This bulletin should be reviewed with all service personnel performing repairs to the A-604 transaxle. NOTE: THERE ARE TWO DIFFERENT FLUSHING PROCEDURES FOR VEHICLES EQUIPPED WITH THE DIFFERENT TYPE COOLER SYSTEMS. MAKE SURE YOU USE THE PROCEDURE THAT APPLIES TO THE VEHICLE SYSTEM YOU ARE WORKING ON. UNDER NO CIRCUMSTANCES SHOULD COMPRESSED AIR BE SUBSTITUTED FOR THE FLUSHING PROCEDURE OUTLINED BELOW. Tools and Material Required to Flush System Hand suction gun. Mineral spirits. Shop air and blow gun. Gallon container ATF fluid. Parts Required Use only on vehicles equipped with pressure actuated bypass valve. 1 - Tie Strap PN 6016076 1 - Tie Strap PN 6016240 Flushing Procedure FLUSHING PROCEDURE: FOR VEHICLES EQUIPPED WITH OIL TO AIR COOLER AND/OR VEHICLES EQUIPPED WITH OIL TO ENGINE COOLANT COOLER. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 211690 > Jun > 90 > A-604 A/T Oil Cooler - Flushing & Flow Testing > Page 3871 Figure 1 1. Locate the inlet and outlet lines at the transaxle, Figure 1. 2. Disconnect both cooler lines at the transaxle. 3. Using a hand suction gun filled with mineral spirits, reverse flush the cooler by forcing mineral spirits into the transaxle inlet hose while catching the fluid coming from the transaxle outlet line. Observe for the presence of debris in the exiting fluid. 4. Repeat the flushing procedure until the exiting mineral spirits are clear and free of debris. 5. Use compressed air in intermittent spurts to blow out the remaining mineral spirits, again in the reverse direction. 6. To remove any remaining mineral spirits, 1 Quart of ATF should be pumped through the cooler system using the hand suction gun. NOTE: IF AT ANY STAGE OF THE FLUSHING PROCESS, THE FLUIDS DO NOT FLOW FREELY THROUGH THE SYSTEM, THE COOLER MUST BE REPLACED. NOTE: IF THE VEHICLE IS EQUIPPED WITH A BYPASS VALVE, IT MUST BE REMOVED FROM THE SYSTEM AND FLUSHED SEPARATELY. TO ASSURE THE VALVE IS THOROUGHLY CLEANED, IT MUST BE REMOVED FROM THE H-FITTING ASSEMBLY. PAY PARTICULAR ATTENTION TO THE WAY THE BYPASS VALVE WAS INSTALLED BEFORE DISASSEMBLY, THE INLET SIDE OF THE BYPASS VALVE MUST BE CONNECTED TO THE OUTLET LINE COMING FROM THE TRANSAXLE. SHOULD THERE BE ANY QUESTION OF HOW TO REINSTALL THE BYPASS VALVE, REFER TO TSB 21-28-89. 7. Connect the cooler lines to the transaxle. Fill the transaxle to the proper level. 8. Complete the flow testing procedure outlined below. Flushing Procedure For Trailer Tow Package FLUSHING PROCEDURE: FOR VEHICLES EQUIPPED WITH TRAILER TOW PACKAGE, INCLUDING A COMBINATION OF AN OIL TO AIR COOLER AND OIL TO ENGINE COOLANT COOLER. 2. Locate the inlet and outlet cooler lines at the transmission, Figure 1. 2. Disconnect both cooler lines at the transmission. 3. Remove the hose connecting the two transmission oil coolers together. 4. Using a hand suction gun filled with mineral spirits, reverse flush the coolers separately by forcing mineral spirits into the transaxle inlet hose while catching the fluid coming from the other end of the cooler. Observe for the presence of debris in the exiting fluid. 5. Repeat the flushing procedure with each cooler until the exiting mineral spirits is clear and free of debris. 6. Use compressed air in intermittent spurts to blow out the remaining mineral spirits, again in the reverse direction. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 211690 > Jun > 90 > A-604 A/T Oil Cooler - Flushing & Flow Testing > Page 3872 3. To remove any remaining mineral spirits, 1 Quart of ATF should be pumped through each cooler using the hand suction gun. NOTE: IF AT ANY STAGE OF THE FLUSHING PROCESS, THE FLUIDS DO NOT FLOW FREELY THROUGH THE COOLER, IT WILL BE NECESSARY TO DETERMINE WHICH COOLER(S) IS RESTRICTED AND REPLACE IT. NOTE: IF THE VEHICLE IS EQUIPPED WITH A BYPASS VALVE, IT MUST BE REMOVED FROM THE SYSTEM AND FLUSHED SEPARATELY. TO ASSURE THE VALVE IS THOROUGHLY IT MUST BE REMOVED FROM THE H-FITTING ASSEMBLY. PAY PARTICULAR ATTENTION TO THE WAY THE BYPASS VALVE WAS INSTALLED BEFORE DISASSEMBLY, THE INLET SIDE OF THE BYPASS VALVE MUST BE CONNECTED TO THE OUTLET LINE COMING FROM THE TRANSAXLE. SHOULD THERE BE ANY QUESTION OF HOW TO REINSTALL THE BYPASS VALVE, REFER TO TSB 21-28-89. 8. Connect the cooler lines to the transaxle. Fill the transaxle to the proper level. 9. Complete the flow testing procedure outlined below. Flow Testing Procedure 1. Disconnect the transaxle inlet cooler line at the transaxle, place the line in an empty gallon container. 2. Shift the transaxle into neutral, start engine and run at curb idle for 20 seconds, while observing the fluid flow. If the flow is intermittent or it takes longer than 20 seconds to collect one quart of ATF, locate and replace the restricted cooler(s). CAUTION: DO NOT FLOW MORE THAN ONE (1) QUART OF ATF OR INTERNAL DAMAGE MAY OCCUR. 3. If fluid flow is within the acceptable limits, connect the transaxle cooler line to the transaxle and fill it to the proper level. Warranty and Labor Info. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. Reverse flush cooler system with single cooler 21-33-41-55 0.5 Hrs. Reverse flush cooler system with dual coolers 21-33-41-57 0.7 Hrs. optional bypass valve equipped 21-33-41-60 0.2 Hrs. Cooler system flow check 21-33-40-56 0.4 Hrs. FAILURE CODE: 38 - Fluid wrong/contaminated Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve Technical Service Bulletin # 281T Date: 891201 Original TSB No. 281T December, 1989 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 281T Transmission Oil Cooler Bypass Valve Models: 1988 and 1989 S-Body Models Equipped With Heavy Duty Trailer Tow Package -Plymouth Voyager and Grand Voyager, Dodge Caravan, Grand Caravan, Caravan C/V and Grand Caravan C/V The listed model vehicles equipped with the trailer tow package may experience restricted transmission fluid flow through the oil cooler at low temperature (-15 degrees F and below). This may result in lack of lubrication to the transmission and possible transmission failure. To ensure adequate lubrication, a transmission oil cooler bypass valve system must be installed. Important: Some of the involved vehicles may still be in dealer inventory. Be sure to complete the service on these vehicles before delivery to customers. Because of the cold weather nature of the condition, only those vehicles invoiced to dealers in the Northern U.S. are included in this notification and service action. The following Zones are included: Boston, Chicago, Denver, Detroit, Kansas City, Milwaukee, Minneapolis, Pittsburgh and Syracuse; also the State of Alaska. Parts distribution and Vehicle Lists will be limited to these dealers. However, vehicles in other areas are eligible for the repair as needed to meet cold weather operation requirements upon owner request. Details of this service action are explained in the following sections. As an additional service aid, a videotape demonstrating the service procedure is included in the December, 1989 Master Tech program. Vehicle, Parts, and Owner Info. VEHICLE LIST Each dealer to whom involved vehicles were invoiced (or the current dealer at the same location) will receive a listing of them with this letter, arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Each Dodge or Chrysler-Plymouth dealer without a Vehicle List will receive an information copy of this letter by Compak Mall for use in performing the service on involved vehicles upon request. Parts Parts packages, PN C3940361, are being shipped free of charge to all involved dealers for service of affected vehicles. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same location) will receive enough parts packages to service 75% of those vehicles. Parts (Continued) Each recall parts package contains the following components: Quantity Description (1) Bypass valve (2) Brass tees (4) Nipple connectors (4) Hose clamps (1) Foam tube (1) Tie strap (1) Tie strap (with "push-in" retainer) Also included in each package is an instruction summary for convenient reference by the servicing technician. Additional parts may be ordered without charge from Parts Depots if required. Order only as needed for scheduled repairs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3877 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is attached. Enclosed with each owner notification is an Owner Recall Notification Form # 83- 295-0019. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure Figure 1 Prior to performing this service, it is important to understand that the bypass valve, to function properly, must be located and connected to the transmission oil cooler hoses in the correct oil flow direction (Figure 1). Figure 2 1. Using Chrysler Mopar Thread Sealant PN 4318034 or equivalent at all connections, assemble the supplied bypass valve, tees and connectors as shown in Figure 2. Tighten the tees and connectors to 12 N-m (110 in.lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3878 Figure 3 2. Raise vehicle on hoist for working access to the transmission oil cooler hoses routed along the inboard side of the left front frame rail. 3. Measure 5-1/2 inches rearward from the front edge of the frame rail and 2 inches up from the bottom of rail (Figure 3) and drill a 1/4 inch diameter hole in the rail. Figure 4(3-Speed Transmission) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3879 Figure 5(4-Speed Transmission) 4. Referring to Figures 4 and 5, follow the cooler hoses routed from the transmission to clearly identify the cooler "in" hose. Figure 6 5. Place an oil pan under the vehicle to catch fluid leakage. (Oil loss will be minimal.) 6. Pushing the cooler hoses against the frame, cut the cooler "in" hose at the drilled hole (Figure 6) and allow oil to drain. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3880 Figure 4(3-Speed Transmission) Figure 5(4-Speed Transmission) IMPORTANT: Illustration is typical of 4-speed hose routing. 3-speed hose routing differs; therefore it is important to identify the cooler "in" and "out" hoses per Figures 4 and 5. Figure 1 7. Slide 2 of the supplied clamps over the hose ends and install the cooler "in" end connectors of the bypass valve assembly to the cut hose ends. NOTE: Refer to Figure 1 to identify the male (pipe nipple) end of the valve. This end of the assembly.must be connected to the cooler "in" Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3881 hose. Figure 7(3-Speed Transmission Installation) Figure 8(4-Speed Transmission Installation) 8. Cut the other hose (cooler "out") at the drilled hole, allow oil to drain, and connect the hose ends to the valve assembly connectors in the Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3882 same manner. 9. Cut the supplied foam tube and wrap it around the bypass valve (Figures 7 and 8). 10. Tighten the supplied "push-in" tie strap around the foam tubing and cut off excess strap. 11. Engage the push-in tie strap in the drilled 1/4 inch hole (Figures 7 and 8). NOTE: Because the hoses and hose routing differ on the 3-speed and 4- speed transmission, the valve assembly must be positioned differently for each -- valve mounted vertically for the 4-speed and at an angle for the 3- speed. 12. Tighten all hose clamps to 2 N-m (15 in.lbs). 13. Install the other supplied tie strap to secure the assembly to the frame rail (Figures 7 and 8). Cut off excess strap. 14. Check and, if necessary, adjust transmission oil level. Completion Information Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted by DIAL dealers on the DIAL System. Non DIAL dealers may submit WROS. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Enter only one VIN per claim on a WRO. Fill in the labor operation number and time allowance and write on the WRO "Customer Satisfaction Notification # 281T --Transmission Oil Cooler Bypass Valve." Do not enter other service claims on the same WRO. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Install transmission oil cooler bypass valve. 21281282 0.5 Hour Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing instructions. Parts Return Not applicable. Vehicle Not Available If a vehicle is not available for this service for a known reason, let us know by filling outthe pre-addressed Vehicle Disposition Form portion of the Owner Recall Notification Form or describe the reason on a postcard and mall to: Chrysler Motors 416-15-19 Recall Coordination P.O. Box 1919 Detroit, Michigan 48231-9986 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Letter CUSTOMER SATISFACTION NOTIFICATION -- TRANSMISSION OIL COOLER BYPASS VALVE Dear Chrysler Motors Vehicle Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are offering a free repair service to owners of certain 1988 and 1989 model vehicles equipped with the heavy duty trailer tow package. Included are the Plymouth Voyager and Grand Voyager, Dodge Caravan, Grand Caravan, Caravan C/V and Grand Caravan C/V. Your vehicle, whose Vehicle Identification Number is shown on the enclosed form, is included in this offer. This service and the required parts as described in this letter will be provided without charge. The service is needed to prevent possible transmission damage in extremely cold weather resulting from restricted flow of transmission fluid through the oil cooler. We ask that you arrange for this important service without delay. To correct the condition, your dealer will install a bypass valve to ensure an adequate fluid supply to the transmission at all times. The work will take less than one hour to complete. However, additional time may be required depending on how service appointments are scheduled and processed. To arrange for this service: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3883 ^ Contact your dealer as soon as possible to schedule an appointment for the free service. ^ Take the enclosed Owner Recall Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and condition for which service is required. If you have any problem obtaining the needed service, please contact the Chrysler Zone Service Office in your area. (It is listed under "Service Assistance" in your Operator's Manual.) A Zone representative will arrange for prompt servicing of your vehicle. We regret any inconvenience that this action may cause you. However, we believe that this special service will help to ensure your continuing satisfaction with your Voyager or Caravan. Thank you for your attention to this important matter. SERVICE AND PARTS OPERATIONS CHRYSLER MOTORS CORPORATION Supplement # 1 No. 281T March, 1990 SUPPLEMENT CUSTOMER SATISFACTION NOTIFICATION # 281 -TRANSMISSION OIL COOLER BYPASS VALVE: THIS PROGRAM HAS BEEN EXTENDED TO INCLUDE ADDITIONAL VEHICLES IN SPECIFIED FRIGID CLIMATE STATES To: All Dodge and Chrysler-Plymouth Dealers in Involved Zones; All Regional and Zone Service and Parts Managers Subject: Customer Satisfaction Notification # 281T -- Transmission Oil Cooler Bypass Valve -Additional Vehicles in Specified States Models: The Following Additional Models Equipped With the A604 4-Speed Automatic Transmission and External Transmission Oil-To-Air Cooler: ^ 1989 AC-Body Cars -- Chrysler New Yorker, New Yorker Landau and Dodge Dynasty ^ 1989 AS-Body Models Without Heavy Duty Trailer Tow Package - - Voyager, Grand Voyager, Caravan, Grand Caravan, Caravan CN Van and Extended Van ^ 1990 AC & AY-Body Cars -- Chrysler Salon, New Yorker Landau, New Yorker Fifth Avenue, Imperial and Dodge Dynasty ^ 1990 AS-Body Models Equipped With Heavy Duty Trailer Tow Package -- Voyager, Grand Voyager, Caravan, Grand Caravan, Caravan CN Van and Extended Van ^ 1990 AS Body Chrysler Town & Country Location: This Service Action Applies Only to Vehicles in the Following Frigid Climate States: ^ Minneapolis Zone -- Minnesota, North Dakota, South Dakota ^ Milwaukee Zone -- Wisconsin, Michigan (U.P.) ^ Detroit Zone -- Michigan ^ Denver Zone -- Montana, Wyoming ^ Portland Zone -- Alaska Reference: Dealer notification letter # 281T, December, 1989, for 1988-9 AS-Body vehicles with heavy duty trailer tow package and located in Northern U.S. The initial notification for recall # 281T involved 1988 and 1989 model year AS-Body vehicles equipped with trailer tow and operating in cold climates. The action was taken to eliminate the potential for transmission damage due to oil flow restriction through the oil cooler during cold weather. The recall population is now being expanded to also include certain additional 4- speed transmission equipped AS, AC and AY-Body vehicles with external transmission oil-to-air coolers operating in frigid climate regions. Note: Vehicles already equipped with oil cooler bypass valve systems under Technical Service Bulletin # 21-28-89 do not require further service for this condition. All service requirements for the additional vehicles are the same as for the original Recall # 281T except as noted in the following sections. A copy of the original dealer notification letter of December, 1989 is enclosed for your reference. Parts The same parts package used for previously involved vehicles, PN C3940361, is required for the added models. Parts sufficient to repair 75% of the involved vehicles will be shipped free of charge to involved dealers as supplies become available. Note: For 1990 AS-Body models only, an additional bracket, PN C3940385, is require to complete the recall package installation. Six of these Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3884 brackets will be provided free of charge to involved dealers for use as required. Additional brackets, if needed, are available for ordering from the parts depot. Owner Notification and Service Scheduling Owners will be notified of the service requirement aftershipment of the recall parts to involved dealers. Service Procedure ^ The procedure for installing the bypass valve assembly on 1989 AS-Body models without trailer tow is the same as shown in the instructions already provided in the dealer recall notification letter (# 281T) for trailer tow vehicles. ^ For 1989 AC-Body models, the procedure is the same as previously described for recall # 281T except there is no drilling required (procedure step 3). A 1/4 inch hole already exists in the frame rail for the push-in tie strap to retain the valve assembly. ^ The procedure for 1990 AC and AY-Body models is also the same as previously described for recall # 281T except as follows: FIGURE 11990 AC AND AY-BODY CARS - A plate is attached to the frame rail where the valve assembly is to be located. Therefore, a 1/4 inch hole must be drilled through the plate (at the location shown in Figure 1 of this letter to accommodate the pushin tie strap. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3885 FIGURE 21990 AC AND AY-BODY CARS - Install the other retaining tie strap by routing the strap through the two existing frame holes as shown in Figure 2. Figure 31990 AS-Body with External Cooler (Trailer Tow or Town & Country) ^ Installation of the bypass valve assembly on 1990 AS-Body models differs as follows (see Figure 3): - To install the valve assembly, cut the cooler hoses in line with the center of the large hole in the bottom of the frame. - Install bracket PN C3940385 to retain the upper cooler hose, using the existing lower battery tray attaching bolt. - Since the valve assembly will be clear of the frame rail with this installation, the anti-rattle foam tube and tie straps are not required. Important: Remember that the bypass valve must be installed in the proper flow direction. Be sure to identify the transmission fluid out (outlet and in (inlet) fittings at the transmission as shown in Figure 5 of the original Recall # 281T service procedure. Then follow the hoses from the transmission to the valve mounting location to ensure that the valve is attached properly to the "in" and "out" hoses as shown in Figure 8 of the original recall service procedure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3886 Owner Letter CUSTOMER SATISFACTION NOTIFICATION -- TRANSMISSION OIL COOLER BYPASS VALVE Dear Chrysler Corporation Vehicle Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are offering a free service at this time to owners of certain 1989 and 1990 model vehicles equipped with 4-speed automatic transmissions. The vehicle whose Vehicle Identification Number is shown on the enclosed form is included in this offer. The service and requiredpartsas describedin this letter will be provided to you without charge. This service will prevent possible transmission damage in extremely cold weather resulting from restricted flow of transmission fluid through the oil cooler. We ask that you arrange for this important service without delay. To correct the condition, your dealer will install a bypass valve to ensure an adequate fluid supply to the transmission at all times. If your vehicle has already had this service performed, please disregard this notice. Otherwise, to obtain this service: ^ Contact your dealer promptly to schedule an appointment for the free service. ^ Take the enclosed Owner Recall Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and condition for which service is required. The work will take less than one hour to complete. However, additional time may be required depending on how service appointments are scheduled and processed. If you have any problem obtaining the needed service, please contact the Chrysler Zone Service Office in your area. (it is listed under "Service Assistance" in your Operator's Manual.) A Zone representative will arrange for prompt servicing of your vehicle. We regret any inconvenience that this action may cause you. However, we believe that this special service will help to ensure your continuing satisfaction with your Chrysler product. Thank you for your attention to this important matter. Supplement # 2 NO. 281T October, 1990 SUPPLEMENT # 2 CUSTOMER SATISFACTION NOTIFICATION # 281T -TRANSMISSION OIL COOLER BYPASS VALVE: THIS PROGRAM HAS BEEN EXTENDED TO INCLUDE ADDITIONAL 1990 MODEL YEAR VEHICLES IN SPECIFIED FRIGID CLIMATE STATES AND TO REVISE PARTS AND PROCEDURES FOR SPECIFIED MODELS To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 281T -- Transmission Oil Cooler Bypass Valve -Additional 1990 Vehicles in Specified States and Revised Parts/Procedures Models: All Following Vehicles Equipped With A604 4-Speed Automatic Transmission and Locate in States Specified Below: ^ 1989 AC -- Chrysler New Yorker, New Yorker Landau and Dodge Dynasty ^ 1990 AC & AY -- Chrysler Salon, New Yorker Landau, New Yorker Fifth Avenue, Imperial and Dodge Dynasty ^ 1990 AS -- Voyager, Grand Voyager, Caravan, Grand Caravan, Caravan CN Van and Extended Van -- Equipped With Heavy Duty Trailer Tow Package ^ 1990 AS -- Chrysler Town & Country -- All Location: This Service Action Applies Only to Vehicles in the Following Frigid Climate States: ^ Minneapolis Zone -- Minnesota, North Dakota, South Dakota ^ Milwaukee Zone -- Wisconsin, Michigan (U.P.) ^ Detroit Zone -- Michigan ^ Denver Zone -- Montana, Wyoming ^ Portland Zone -- Alaska Reference: ^ Dealer notification letter # 281T, December, 1989. ^ Dealer notification letter # 281T supplement, March, 1990. The Recall # 281T Supplement dated March, 1990 applied to specific 1989 and 1990 model year vehicles built throu h February 11, 1990 and located in frigid climate states. The service action is nowleing extended to include 1990 model year vehicles in the same states which were built from February 12, 1990 through the end of 1990 model year production. Important: Some of the involved vehicles may still be in dealer stock. Be sure to complete the service on these vehicles before retail delivery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3887 Revised parts packages have been developed for 1989 and 1990 model year AC/AYBody cars and for 1990 AS-Body minivans and wagons. These packages contain preassembled bypass valve and oil cooler hose components. All 1988 and 1989 AS-Body vehicles will continue to use the previous parts package. Details of this service action are explained in the following sections. Note: Vehicles already equipped with oil cooler bypass valve systems under Technical Service Bulletin # 21-28-89 or previously serviced for this recall with the original parts package do not require further service for this condition. Vehicle List Each dealer to whom additional later-built 1990 model year vehicles were invoiced (or the current dealer at the same location) will receive a vehicle list with this letter arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Each Dodge or Chrysler-Plymouth dealer without a Vehicle List will receive an information copy of this letter by Compak Mail for use in performing the service on involved vehicles upon request. Parts Parts packages are being distributed free of charge to all involved dealers for service of affected vehicles. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same location) will receive enough parts packages to service 50% of those vehicles. Two new parts packages have been released for specific models as follows: Included in each package is an instruction summary for convenient reference by the servicing technician. Note: For 1988 and 1989 AS-Body vehicles involved in the original Recall # 281T notification of December, 1989, and the Recall # 281T Supplement of March, 1990, continue to use the original parts package, PN C3940361. Additional parts may be ordered without charge from Parts Depots if required. Order only as needed for scheduled repairs. Owner Notification and Service Scheduling All involved owners of additional 1990 vehicles who are known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is attached. Enclosed with each owner notification is an Owner Recall Notification Form # 83-295-0019. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure A. 1989 and 1990 AC/AY-Body Passenger Cars 1. Place an oil pan under the vehicle to catch fluid leakage (oil loss will be minimal). 2. Disconnect the existing cooler hoses from the fittings at the transmission and at the external oil cooler mounted at the front of the radiator. Save the clamps for reinstallation. 3. Install the supplied valve and hose assembly (PN C3940405) in place of the removed hoses as follows. Note: The hoses on the new assembly are banded together with tape and the ends are pre-molded to align them for installation to the appropriate transmission and cooler fittings. Do not disturb the tape wrappings. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3888 Figure 1 Vehicles not equipped with Bendix Anti-Lock Brake System -Install the supplied bracket on the valve (with the bracket mounting holes toward the front as shown in Figure 1). Loosely attach the bracket to the left front frame rail with the supplied screw, using the existing hole in the rail. Figure 2 Figure 3 ^ Vehicles equipped with Bendix Anti-Lock Brake System (ABS) -There is an existing cooler line clip at the ABS controller module mounted to the left front frame rail (Figure 2). Use this existing clip to support the valve and hose assembly as shown in Figure 3. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3889 Figure 4 Figure 5 ^ All Vehicles -- Attach the hoses to the fittinqs at the external oil cooler (Figure 4) and at the transmission (Figure 5). Secure with the original clamps. ^ Tighten the valve support bracket screw (non ABS cars) or clip screw (Bendix ABS equipped cars). ^ Start the engine and check for leaks. ^ Check and, if necessary, adjust the transmission oil level. Figure 2 Figure 3 B. 1990 AS-Body Mini Vans/Wagons With Heavy Duty Trailer Tow Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3890 1. Place an oil pan under the vehicle to catch fluid leakage (oil loss will be minimal). 2. Disconnect the existing cooler hoses from the fittings at the base of the radiator (Figure 2) and from the transmission fittings (Figure 3). Save the clamps for reinstallation. 3. Install the supplied valve, hose and bracket assembly (PN C3940406) in place of the removed hoses as follows. Note: The hoses on the new assembly are banded together with tape and the ends are pre-molded to align them for installation to the appropriate transmission and cooler fittings. Do not disturb the tape wrappings. Figure 1 ^ Support the valve and hose assembly by loosely attaching the valve support bracket to the left front frame rail with the supplied screw, using the existing hole in the rail (Figure 1). Figure 2 ^ Attach the hoses to the fittings at the base of the radiator and secure with the original clamps (Figure 2). Important: Note that bolh hoses do not attach to the lower radiator tank fittings. As shown in Figure 2, one hose attaches to the lower radiator tank fitting and the other hose attaches to the external cooler tube. Figure 3 ^ ^ Attach the hoses to the transmission fittings and secure with the original clamps (Figure 3). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3891 ^ ^ Tighten the valve support bracket screw. ^ ^ Start engine and check for leaks. ^ ^ Check and, if necessary, adjust the transmission oil level. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance ^ Install transmission oil cooler 21281282 0.5 Hour bypass valve -- 1990 AS-Body with heavy duty trailer tow. Note: This is the same labor operation number and time allowance as specified for vehicles involved in the original recall # 281T notification of December, 1989. ^ Install transmission oil cooler 21281283 0.3 Hour bypass valve -- 1989 and 1990 AC/AY-Body cars Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H, for complete recall claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for this service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Recall Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation 416-15-19 Recall Coordination P.O. Box 1919 Detroit, Michigan 48231-9986 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Owner Letter CUSTOMER SATISFACTION NOTIFICATION -- TRANSMISSION OIL COOLER BYPASS VALVE Dear Chrysler Motors Vehicle Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are offering a free service at this time to owners of certain 1990 model vehicles equipped with 4-speed automatic transmissions. The vehicle whose Vehicle Identification Number is shown on the enclosed form is included in this offer. The service and required parts as described in this letter will be provided to you without charge. This service will prevent possible transmission damage in extremely cold weather resulting from restricted flow of transmission fluid through the oil cooler. We ask that you arrange for this important service without delay. To correct the condition, your dealer will install a bypass valve to ensure an adequate fluid supply to the transmission at all times. If your vehicle has already had this service performed, please disregard this notice. Otherwise, to obtain this service: ^ Contact your dealer promptly to schedule an appointment for the free service. ^ Take the enclosed Owner Recall Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and condition for which service is required. The work will take less than one hour to complete. However, additional time may be required depending on how service appointments are scheduled and processed. If you have any problem obtaining the needed service, please contact the Chrysler Zone Service Office in your area. (It is listed under "Service Assistance" in your Operator's Manual.) A Zone representative will arrange for prompt servicing of your vehicle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 281T > Dec > 89 > Campaign - A/T Oil Cooler Bypass Valve > Page 3892 We regret any inconvenience that this action may cause you. However, we believe that this special service will help to ensure your continuing satisfaction with your Chrysler product. Thank you for your attention to this important matter. Dealer Instructions IMPORTANT DEALER INSTRUCTIONS CUSTOMER SATISFACTION NOTIFICATION # 281T, SUPPLEMENT # 2 -- TRANSMISSION OIL COOLER BYPASS VALVE ^ The recall # 281T Supplement Notification dated March, 1990 applied to specific 1989 and 1990 model year vehicles built through February 11, 1990. The service action is now being extended to include those 1990 model year vehicles built from February 12, 1990 through the end of 1990 model year production. As in the March, 1990 Supplement Notification, only those additional 1990 model year vehicles operating in frigid climate regions are involved. Refer to the attached dealer notification letter for a listing of the involved states. ^ Two new parts packages have been released for this recall. These new packages contain the oil cooler hoses already assembled to the bypass valve. With the new valve and hose assemblies, it is no longer necessary to cut the existing hoses to install the valve. Simply remove the existing transmission-to-cooler hoses and install the new valve and hose assembly in their place. The new parts packages, and the previous package (PN C3940361), are to be used for the following applications: - New package, PN C3940405, is to be used only for 1989 and 1990 AC and AY-B cars. - New package, PN C3940406, is to be used only for 1990 AS-Body minivans/wagons. - The previous package, PN C3940361, should continue to be used only for 1988 and 1989 AS-Body mini vans/wagons. IMPORTANT: ^ Service procedures for the 1989 and 1990 cars and 1990 mini vans/wagons are included in this dealer notification. ^ The service procedure for 1988 and 1989 mini vans/wagons remains the same as specified in the December, 1989 Recall # 281T instructions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 211690 > Jun > 90 > A-604 A/T Oil Cooler - Flushing & Flow Testing Technical Service Bulletin # 211690 Date: 900604 A-604 A/T Oil Cooler - Flushing & Flow Testing Models 1989-1990 AA, AC, AG, AJ, AS, & AY Bodies Subject A-604 Transaxle Oil Cooler Flushing And Flow Testing Index TRANSMISSION Date June 4, 1990 No. 21-16-90 (C21-10-0) P-1649 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTY AY - IMPERIAL/NEW YORKER FIFTH AVENUE Discussion The purpose of this bulletin is to emphasize the IMPORTANCE OF PROPERLY FLUSHING AND FLOW TESTING THE TRANSAXLE OIL COOLER SYSTEM FOLLOWING ANY A-604 REPAIR WHICH REQUIRES THE REMOVAL OR REPLACEMENT OF THE TRANSAXLE. A clogged or restricted transaxle oil cooler system can be the cause of recurring transaxle failures. Restriction of transaxle fluid flow through the oil cooler system can result in overheating of the fluid and reduce lubrication flow to internal rotating parts. Three types of transaxle oil cooler systems are used; oil to air, oil to engine coolant and a combination oil to air and oil to engine coolant. When flushing a cooler system with a combination of both, it will be necessary to flush each cooler separately. Vehicles equipped with the Bypass valve, installed from Recall 281-T or Technical Service Bulletin 21- 28-89 must have the Bypass valve cleaned separately. This bulletin should be reviewed with all service personnel performing repairs to the A-604 transaxle. NOTE: THERE ARE TWO DIFFERENT FLUSHING PROCEDURES FOR VEHICLES EQUIPPED WITH THE DIFFERENT TYPE COOLER SYSTEMS. MAKE SURE YOU USE THE PROCEDURE THAT APPLIES TO THE VEHICLE SYSTEM YOU ARE WORKING ON. UNDER NO CIRCUMSTANCES SHOULD COMPRESSED AIR BE SUBSTITUTED FOR THE FLUSHING PROCEDURE OUTLINED BELOW. Tools and Material Required to Flush System Hand suction gun. Mineral spirits. Shop air and blow gun. Gallon container ATF fluid. Parts Required Use only on vehicles equipped with pressure actuated bypass valve. 1 - Tie Strap PN 6016076 1 - Tie Strap PN 6016240 Flushing Procedure FLUSHING PROCEDURE: FOR VEHICLES EQUIPPED WITH OIL TO AIR COOLER AND/OR VEHICLES EQUIPPED WITH OIL TO ENGINE COOLANT COOLER. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 211690 > Jun > 90 > A-604 A/T Oil Cooler - Flushing & Flow Testing > Page 3898 Figure 1 1. Locate the inlet and outlet lines at the transaxle, Figure 1. 2. Disconnect both cooler lines at the transaxle. 3. Using a hand suction gun filled with mineral spirits, reverse flush the cooler by forcing mineral spirits into the transaxle inlet hose while catching the fluid coming from the transaxle outlet line. Observe for the presence of debris in the exiting fluid. 4. Repeat the flushing procedure until the exiting mineral spirits are clear and free of debris. 5. Use compressed air in intermittent spurts to blow out the remaining mineral spirits, again in the reverse direction. 6. To remove any remaining mineral spirits, 1 Quart of ATF should be pumped through the cooler system using the hand suction gun. NOTE: IF AT ANY STAGE OF THE FLUSHING PROCESS, THE FLUIDS DO NOT FLOW FREELY THROUGH THE SYSTEM, THE COOLER MUST BE REPLACED. NOTE: IF THE VEHICLE IS EQUIPPED WITH A BYPASS VALVE, IT MUST BE REMOVED FROM THE SYSTEM AND FLUSHED SEPARATELY. TO ASSURE THE VALVE IS THOROUGHLY CLEANED, IT MUST BE REMOVED FROM THE H-FITTING ASSEMBLY. PAY PARTICULAR ATTENTION TO THE WAY THE BYPASS VALVE WAS INSTALLED BEFORE DISASSEMBLY, THE INLET SIDE OF THE BYPASS VALVE MUST BE CONNECTED TO THE OUTLET LINE COMING FROM THE TRANSAXLE. SHOULD THERE BE ANY QUESTION OF HOW TO REINSTALL THE BYPASS VALVE, REFER TO TSB 21-28-89. 7. Connect the cooler lines to the transaxle. Fill the transaxle to the proper level. 8. Complete the flow testing procedure outlined below. Flushing Procedure For Trailer Tow Package FLUSHING PROCEDURE: FOR VEHICLES EQUIPPED WITH TRAILER TOW PACKAGE, INCLUDING A COMBINATION OF AN OIL TO AIR COOLER AND OIL TO ENGINE COOLANT COOLER. 2. Locate the inlet and outlet cooler lines at the transmission, Figure 1. 2. Disconnect both cooler lines at the transmission. 3. Remove the hose connecting the two transmission oil coolers together. 4. Using a hand suction gun filled with mineral spirits, reverse flush the coolers separately by forcing mineral spirits into the transaxle inlet hose while catching the fluid coming from the other end of the cooler. Observe for the presence of debris in the exiting fluid. 5. Repeat the flushing procedure with each cooler until the exiting mineral spirits is clear and free of debris. 6. Use compressed air in intermittent spurts to blow out the remaining mineral spirits, again in the reverse direction. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 211690 > Jun > 90 > A-604 A/T Oil Cooler - Flushing & Flow Testing > Page 3899 3. To remove any remaining mineral spirits, 1 Quart of ATF should be pumped through each cooler using the hand suction gun. NOTE: IF AT ANY STAGE OF THE FLUSHING PROCESS, THE FLUIDS DO NOT FLOW FREELY THROUGH THE COOLER, IT WILL BE NECESSARY TO DETERMINE WHICH COOLER(S) IS RESTRICTED AND REPLACE IT. NOTE: IF THE VEHICLE IS EQUIPPED WITH A BYPASS VALVE, IT MUST BE REMOVED FROM THE SYSTEM AND FLUSHED SEPARATELY. TO ASSURE THE VALVE IS THOROUGHLY IT MUST BE REMOVED FROM THE H-FITTING ASSEMBLY. PAY PARTICULAR ATTENTION TO THE WAY THE BYPASS VALVE WAS INSTALLED BEFORE DISASSEMBLY, THE INLET SIDE OF THE BYPASS VALVE MUST BE CONNECTED TO THE OUTLET LINE COMING FROM THE TRANSAXLE. SHOULD THERE BE ANY QUESTION OF HOW TO REINSTALL THE BYPASS VALVE, REFER TO TSB 21-28-89. 8. Connect the cooler lines to the transaxle. Fill the transaxle to the proper level. 9. Complete the flow testing procedure outlined below. Flow Testing Procedure 1. Disconnect the transaxle inlet cooler line at the transaxle, place the line in an empty gallon container. 2. Shift the transaxle into neutral, start engine and run at curb idle for 20 seconds, while observing the fluid flow. If the flow is intermittent or it takes longer than 20 seconds to collect one quart of ATF, locate and replace the restricted cooler(s). CAUTION: DO NOT FLOW MORE THAN ONE (1) QUART OF ATF OR INTERNAL DAMAGE MAY OCCUR. 3. If fluid flow is within the acceptable limits, connect the transaxle cooler line to the transaxle and fill it to the proper level. Warranty and Labor Info. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. Reverse flush cooler system with single cooler 21-33-41-55 0.5 Hrs. Reverse flush cooler system with dual coolers 21-33-41-57 0.7 Hrs. optional bypass valve equipped 21-33-41-60 0.2 Hrs. Cooler system flow check 21-33-40-56 0.4 Hrs. FAILURE CODE: 38 - Fluid wrong/contaminated Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation A604 (41TE) 4 Speed Transaxle DESCRIPTION The PRNDL switch is similar in appearance to the Neutral Safety Switch. Its purpose is to help the transaxle controller sense the shifter position (manual valve), and help operate the reverse lamps. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Relay, A/T > Component Information > Locations > Component Locations Transmission Position Relay: Component Locations Back Up Lamp Relay / Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page 3907 Back Up Lamp Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3916 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3917 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3918 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3924 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3925 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3930 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3931 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3932 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3938 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3939 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3942 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3943 Transmission Position Switch/Sensor: Locations 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3944 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 3947 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 3950 Transmission Position Switch/Sensor: Description and Operation PRNDL The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. It may have been replaced by a transmission range sensor (TRS). Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3953 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3954 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3955 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations 41 TE/AE Transaxle Pressure And Cooler Ports Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3967 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3972 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3973 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3974 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3980 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3985 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3986 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3987 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3988 Input / Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Transmission Speed Sensor: Description and Operation Output Speed Sensor DESCRIPTION This is a two wire, magnetic pick-up device used to sense the output speed of the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor > Page 3991 Transmission Speed Sensor: Description and Operation Turbine Speed Sensor A604 (41TE) 4 Speed Transaxle DESCRIPTION This is a two wire, magnetic pick-up device used to sense the input speed of the transaxle (torque convertor turbine). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 3992 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4004 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4005 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4006 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4012 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4013 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4014 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4015 A604 (41TE) 4 Speed Transaxle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information Valve Body: Description and Operation General Information The 41TE has a cast aluminum valve body that uses five or seven valves to control five transaxle clutches and the torque converter clutch. It also directs pressurized fluid for lubrication. The oil pump is the source of pressurized fluid for the valve body and solenoid assembly. The pump is a positive displacement, gear and crescent type pump. It is driven by the engine through the torque converter hub. The valve body has two major functions: - Control line pressure and TCC pressure - Direct fluid to the clutches, torque converter, lubrication system and the solenoids by means of the manual and switch valves Fluid for the pump is drawn through the transaxle filter, through the valve body housing and into the pump. The pump pressurizes the fluid and sends it back through the valve body to the regulator valve. The valve body uses five valves along with four solenoids in the solenoid assembly to provide control of the transaxle through all of its gear ranges. They perform all functions needed to operate the transaxle for each of its gear ranges. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4018 Valve Body: Description and Operation Manual Valve The manual valve operates by mechanical shift linkage only. Its job is to send line pressure to the appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions. The valve shifts to the left position when OD, Drive or Low is selected. The valve shifts to the middle position in both Park and Neutral. The valve moves to the right position when Reverse is selected. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4019 Valve Body: Description and Operation Regulator Valve The regulator valve has one-function: to regulate or control-hydraulic pressure in the transaxle. The pump supplies unregulated pressure to the regulator valve. The regulator valve controls, or limits, pump pressure. Regulated pressure is referred to as "line pressure." The regulator valve has a spring on one end that pushes the valve to the right. This closes a dump (vent) to lower pressure. Closing the dump will cause oil pressure to increase. Oil pressure on the opposite end of the valve pushes the valve to the left, opening the dump and lowering oil pressure. The result is spring tension working against oil pressure to keep or maintain the oil at specific pressures. Regulated.pressure varies depending on the gear range the transaxle is operating in. A system of sleeves and ports allows the regulator valve to work at one of three different predetermined pressure levels. The oil that is dumped by the regulator valve is directed back to the intake side of the oil pump. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4020 Valve Body: Description and Operation Solenoid Pack DESCRIPTION This is an electrical assembly that has an 8-way connector. It contains four electro-magnetic solenoids that are used to control (under the direction of the controller) the hydraulic circuits within the transaxle. Also inside are three switches that are used to sense when hydraulic pressure is present in various circuits. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4021 Valve Body: Description and Operation General Information The 41TE has a cast aluminum valve body that uses five or seven valves to control five transaxle clutches and the torque converter clutch. It also directs pressurized fluid for lubrication. The oil pump is the source of pressurized fluid for the valve body and solenoid assembly. The pump is a positive displacement, gear and crescent type pump. It is driven by the engine through the torque converter hub. The valve body has two major functions: - Control line pressure and TCC pressure - Direct fluid to the clutches, torque converter, lubrication system and the solenoids by means of the manual and switch valves Fluid for the pump is drawn through the transaxle filter, through the valve body housing and into the pump. The pump pressurizes the fluid and sends it back through the valve body to the regulator valve. The valve body uses five valves along with four solenoids in the solenoid assembly to provide control of the transaxle through all of its gear ranges. They perform all functions needed to operate the transaxle for each of its gear ranges. Manual Valve Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4022 The manual valve operates by mechanical shift linkage only. Its job is to send line pressure to the appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions. The valve shifts to the left position when OD, Drive or Low is selected. The valve shifts to the middle position in both Park and Neutral. The valve moves to the right position when Reverse is selected. Regulator Valve The regulator valve has one-function: to regulate or control-hydraulic pressure in the transaxle. The pump supplies unregulated pressure to the regulator valve. The regulator valve controls, or limits, pump pressure. Regulated pressure is referred to as "line pressure." The regulator valve has a spring on one end that pushes the valve to the right. This closes a dump (vent) to lower pressure. Closing the dump will cause oil pressure to increase. Oil pressure on the opposite end of the valve pushes the valve to the left, opening the dump and lowering oil pressure. The result is spring tension working against oil pressure to keep or maintain the oil at specific pressures. Regulated.pressure varies depending on the gear range the transaxle is operating in. A system of sleeves and ports allows the regulator valve to work at one of three different predetermined pressure levels. The oil that is dumped by the regulator valve is directed back to the intake side of the oil pump. Solenoid Pack Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4023 DESCRIPTION This is an electrical assembly that has an 8-way connector. It contains four electro-magnetic solenoids that are used to control (under the direction of the controller) the hydraulic circuits within the transaxle. Also inside are three switches that are used to sense when hydraulic pressure is present in various circuits. Solenoid Switch Valve The solenoid switch valve controls the direction of line pressure from the LR/CC solenoid. When the valve is shifted to the right, it allows the low/reverse clutch to be pressurized. When it is shifted to the left, it directs line pressure to the TC and CC control valves to operate the TC clutch. The Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4024 valve is shifted to the right in all positions except 2nd, 3rd and 4th gear. When the transaxle upshifts to 2nd gear, the valve moves to the left, which allows converter clutch engagement when needed. The valve must return to the right before a downshift to 1st gear can occur. Torque Converter Clutch Control Valve The Torque Converter Clutch (TCC) control valve controls the back (ON) side of the torque converter clutch. When the TCM energizes the LR/CC solenoid to engage the converter clutch piston, the TCC control valve and torque converter control valves move to the left. The oil on the front (OFF) side of the converter clutch piston is vented to the sump. Line pressure enters the TCC control valve through the manual valve, and then passes through the TCC control valve and the torque converter control valve to the back (ON) side of the converter clutch piston. Line pressure forces the piston forward, which engages the torque converter clutch. This action effectively connects the torque converter turbine with the impeller. Line pressure also flows from the regulator valve, through the torque converter control valve, to the cooler and cooler bypass, for improved fluid and transaxle cooling. Torque Converter Control Valve Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4025 The torque converter control valves main responsibility is to control. hydraulic pressure applied to the front (OFF) side of the converter clutch. Line pressure from the regulator valve is fed to the torque converter control valve, where it passes through the valve. The torque converter control valve reduces, or regulates, the pressure slightly. The torque converter control valve pressure is then directed to the converter clutch control valve and to the front side of the converter clutch piston. The pressure that is being fed to the front of the piston pushes the piston back. This disengages the converter clutch. The oil then passes around the outside of the piston, flowing out of the torque converter and back to the torque converter control valve. From the torque converter control valve, the oil flows to the transaxle oil cooler and cooler bypass valve. It returns to the transaxle as lube oil pressure. Beginning in 1996, the torque converter control valve was modified to delete the function of regulating the flow to the torque converter when the converter clutch is not applied. The valve switches the direction of fluid flow when the converter clutch is applied and vents the release side of the torque converter clutch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation Valve Body: Service and Repair Removal and Installation 3 Speed Automatic Transmission VALVE BODY RECONDITION NOTE: Prior to removing any transaxle subassemblies, plug all openings and thoroughly clean exterior of the unit, preferably by steam. Cleanliness through entire disassembly and assembly cannot be overemphasized. When disassembling, each part should be washed in a suitable solvent, then dried by compressed air. Do not wipe parts with shop towels. All mating surfaces in the transaxles are accurately machined; therefore, careful handling of all parts must be exercised to avoid nicks or burrs. Remove all old R.T.V. sealant before applying new R.T.V. sealant. Use only R.T.V. sealant when installing oil pan. 1. Remove or install neutral starting and back-up lamp switch. Oil Pan Bolts Oil Pan Oil Filter Screws Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4028 Oil Filter Parking Rod E-Clip Parking Rod Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4029 Valve Body Attaching Bolts Valve Body And Governor Tubes CAUTION: Do not clamp any portion of valve body or transfer plate in a vise. Any slight distortion of the aluminum body or transfer plate will result in sticking valves, excessive leakage, or both. When removing or installing valves or plugs, slide them in or out carefully. Do not use force. Detent Spring Attaching Screw And Spring WARNING: Tag all springs as they are removed for reassembly identification. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4030 Valve Body Screws Valve Body Screws Transfer Plate And Separator Plate Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4031 Steel Ball Locations Throttle Shaft E-Clip E-Clip, Washer And Oil Seal Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4032 Manual Valve Lever And Assembly Throttle Valve Lever And Assembly Manual Valve Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4033 Pressure Regulator And Adjusting Screw Bracket Pressure Regulators And Manual Controls Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4034 Governor Plugs Pressure Regulator Valve Plugs Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4035 Shift And Shuttle Valves CLEANING AND INSPECTION 1. Allow all parts to soak a few minutes in a suitable clean solvent. Wash thoroughly and blow dry with compressed air. Make sure all passages are clean and free from obstructions. 2. Inspect manual and throttle valve operating levers and shafts for being bent, worn or loose. If a lever is loose on its shaft, it should be replaced. Do not attempt to straighten bent levers. 3. Inspect all mating surfaces for burrs, nicks and scratches. Minor blemishes may be removed with crocus cloth, using only a very light pressure. Using a straightedge, inspect all mating surfaces for warpage or distortion. Slight distortion may be corrected, using a surface plate. Make sure all metering holes in steel plate are open. Using a pen light, inspect bores in valve body for scores scratches, pits and irregularities. 4. Inspect all valve springs for distortion and collapsed coils. Inspect all valves and plugs for burrs, nicks, and scores. Small nicks and scores may be removed with crocus cloth, providing extreme care is taken not to round off sharp edges. The sharpness of these edges is vitally important because it prevents foreign matter from lodging between valve and valve body, thus reducing possibility of sticking. Inspect all valves and plugs for freedom of operation in valve body bores. 5. When bores, valves, and plugs are clean and dry, the valves and plugs should fall freely in the bores. The valve body bores do not change dimensionally with use. Therefore, a valve body that was functioning properly when vehicle was new, will operate correctly if it is properly and thoroughly cleaned. There is no need to replace valve body unless it is damaged in handling. 6. Installation is the reverse of removal. Tighten all valve body screws to 5 Nm (40 in.lbs.). Fill transaxle to the proper level with ATF. 4 Speed Automatic Transmission Removal Oil Pan Bolts Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4036 Oil Pan Oil Filter Valve Body Attaching Bolts NOTE: To ease installation of the valve body, turn the manual valve lever fully clockwise. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4037 Push Park Rollers From Guide Bracket Remove Valve Body Valve Body Removed Installation To install valve body, reverse removal procedure. CAUTION: The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped. NOTE: To ease installation of the valve body, turn the manual valve lever fully clockwise. Guide park rod rollers into guide bracket, while shifting manual lever assembly out of the installation position. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4038 Valve Body: Service and Repair Solenoid Assembly Replacement REMOVAL Input Speed Sensor Removed Remove Sound Cover Remove Attaching Screws Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4039 Remove Solenoid Assembly INSTALLATION To install solenoid assembly, reverse removal procedure. Tighten screws to 12 Nm (105 inch lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4040 Valve Body: Service and Repair 41TE 4-Speed Transmission Range Sensor Screw Transmission Range Sensor Removed Manual Shaft And Rooster Comb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4041 2-4 Accumulator Plate TRS, Manual Shaft, And 2-4 Accumulator Valve Body Screws Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4042 Valve Body And Transfer Plate Transfer Plate And Separator Plate Ball Check Location Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4043 Springs And Valves Location Remove Or Install Dual Retainer Plate TC Limit Valve And Low/Reverse Switch Valve Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Clutch (Inhibitor) Switch Test 1. Disconnect double connector at switch pigtail, then connect a 12 volt power source to either end of switch terminal. 2. Connect a test light to remaining terminal end and ground. 3. Test light should be on when pedal is in normal position and off when pedal is depressed. 4. If above step is not as specified, replace clutch switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Technical Service Bulletins > Clutch Splines & Pilot Bushing - Lubrication Pilot Bearing: Technical Service Bulletins Clutch Splines & Pilot Bushing - Lubrication Models AA, AB, AD, AG, AH, AJ, AK, AL, AN, AP, AQ, AS Bodies Through 1989 Subject Clutch Splines/Pilot Bushing Lubrication Index CLUTCH Date January 16, 1989 No. 06-01-89 P-0046 (C06-01-9) BODY CODE LEGEND AA - Spirit/Acclaim AB - Dodge Ram Van/Wagon AD - Dodge Ram Pickup/Ram Charger AG - Daytona AH - LeBaron/LeBaron GTS AJ - LeBaron AK - Aries/Reliant AL - Omni/Horizon AN - Dodge Dakota/Dakota Sport AP - Shadow/Sundance AQ - Chrysler TC AS - Caravan/Voyager This Technical Service Bulletin supersedes ALL previous Service Technical Publications through 1989 covering the lubrication of the clutch splines and pilot bushing. The procedures outlined in this bulletin apply to all domestic cars and trucks equipped with manual transmissions and transaxles. SERVICE PROCEDURE NOTE: THIS PROCEDURE SHOULD BE PERFORMED ANYTIME THE TRANSMISSION/TRANSAXLE IS REMOVED FROM THE ENGINE AND/OR CLUTCH SERVICE IS PERFORMED. CLUTCH SPLINES 1. Thoroughly clean the input shaft clutch splines and clutch disc splines, they must be free of any dirt or rust. 2. Apply a light coat of wheel bearing grease PN 4318064 evenly to the entire length of the exposed input shaft splines. Be sure all excessive lubricant is removed. NOTE: THE USE OF ALTERNATIVE OIL BASED LUBRICANTS IS NOT RECOMMENDED AS THESE LUBRICANTS WILL EVENTUALLY DRY UP OR BURN OFF LEAVING ONLY A DRY RESIDUE. REAR WHEEL DRIVE VEHICLES - PILOT BUSHING 1. Thoroughly clean the pilot bearing journal at the end of the input shaft and the inside of the pilot bushing. 2. Apply a light coat of multi-purpose grease PN 4318063 to the inside of the pilot bushing. NOTE: FAILURE TO PERFORM THIS PROCEDURE MAY RESULT IN ONE OR MORE OF THE FOLLOWING SYMPTOMS/CONDITIONS - HIGH SHIFTING EFFORT INTO FIRST AND SECOND GEAR, GEAR CLASH INTO REVERSE AND LOW GEARS, PILOT BUSHING NOISE AND CLUTCH DRAG. POLICY: INFORMATION ONLY Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Component Information > Testing and Inspection Fig. 4 Rear Axle & Differential Diagnosis Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Component Information > Service and Repair > Differential Bearing Retainer Differential Assembly: Service and Repair Differential Bearing Retainer Fig. 14 Differential bearing retainer 1. Using suitable screwdriver, remove differential bearing retainer seal. Do not damage oil baffle. 2. Using suitable press, handle No. C-4171 and seal installer L-4520 (inverted), install differential bearing retainer seal. 3. Using tool L-4518, remove differential bearing retainer cup. Do not damage oil baffle. 4. Using suitable press, handle No. C-4171 and seal installer L-4520 (inverted), install oil baffle. 5. Select suitable shim. Refer to ADJUSTMENT PROCEDURES. 6. Using suitable press, handle No. C-4171 and seal installer L-4520 (inverted), install shim and differential bearing retainer cup. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Component Information > Service and Repair > Differential Bearing Retainer > Page 4057 Differential Assembly: Service and Repair Differential Fig. 17 Checking side gear endplay If transaxle case, differential bearing retainer, extension housing, differential case or differential bearings are being replaced, the shim thickness must be determined. Refer to Transmission and Drivetrain/Differential/Adjustments. 1. Using suitable puller, remove differential bearing cones. 2. Install differential bearing cones using suitable press. 3. If necessary, remove ring gear attaching bolts and ring gear. If ring gear bolts are removed, they must be replaced. Torque ring gear attaching bolts to 65 ft. lbs. 4. Remove pinion shaft roll pin using suitable punch and hammer, then the pinion shaft. 5. Remove pinion gears, side gears and thrust washers from differential case. 6. Clean and inspect all parts. Replace as necessary. 7. Install thrust washers, side gears and pinion gears. 8. Install spacer tool C-4996. Move side gear up and down to determine side gear endplay. Endplay should be within 0.001-0.013 inch. If not within specifications, replace thrust washers. Thrust washers are available in 0.032, 0.037, 0.042 and 0.047 inch thicknesses. 9. Repeat step 8 for other side gear. 10. Reverse steps 1 through 4 to complete assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair Axle Shaft: Service and Repair REMOVAL 1. Remove cotter pin, locknut and spring washer from wheel hub. 2. Loosen hub nut with brakes applied. 3. Raise and support vehicle, then remove wheel and tire assembly. Fig. 18 Speedometer pinion removal 4. If removing right driveshaft, speedometer pinion must be removed prior to driveshaft removal. 5. Remove ball joint stud to steering knuckle clamp bolt, then separate ball joint stud from steering knuckle using a suitable pry bar. CAUTION: Use caution not to damage ball joint or CV joint boots. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 4063 6. Separate outer CV joint splined shaft from hub by holding CV housing while moving knuckle/hub assembly away. CAUTION: Do not use pry bar to separate hub from shaft or damage to outer wear sleeve on CV joint may occur. 7. Support driveshaft assembly at CV joint housing and remove by pulling outward on inner CV joint housing. Do not pull on shaft. 8. Remove driveshaft assembly from vehicle. INSTALLATION Caution: During any service procedures where knuckle and driveshaft are separated, clean seal and wear sleeve with suitable solvent, and apply a suitable lubricant to both components. Solvent must not touch the boot. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 4064 1. Hold inner joint assembly at housing while aligning and guiding inner joint spline into transaxle. 2. Push knuckle/hub assembly out and install outer CV joint shaft into hub. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 4065 3. Install knuckle assembly on ball joint stud, then clamp bolt. Tighten bolt to 70 ft lbs. Steering knuckle clamp bolt is prevailing torque type. Original, or equivalent bolt must be installed during assembly. 4. Install speedometer pinion, right driveshaft only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 4066 5. Fill transaxle with suitable transaxle fluid. 6. Install washer and hub nut, then tighten hub nut to 200 ft lbs. Install nut lock and cotter pin. 7. If inboard boot appears collapsed or deformed following installation, vent inner boot by inserting a round tipped, small diameter rod between boot and shaft. As venting occurs, boot will return to normal shape. 8. Install wheel and tire assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Service Constant Velocity Joint: Service and Repair Inner CV Joint Service DISASSEMBLY Driveshaft assembly should be identified before starting service procedure. Refer to SYSTEM I.D.. Fig. 7 Driveshaft components 1. Remove boot clamps, then pull back boot to gain access to the tripod Fig. 8 Removing inner CV joint tripod. G.K.N units 2. On G.K.N. units, place driveshaft assembly in vise and hold housing as shown. Lightly compress CV joint retention spring while bending tabs back with suitable pliers, then remove tripod from housing. Fig. 9 Removing inner CV joint tripod. Citroen units 3. On CITROEN units, separate tripod from housing by slightly deforming retaining ring at three locations. If necessary, cut retaining ring from housing and install replacement retaining ring by rolling the edge into machined groove in housing with suitable punch. When removing tripod Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Service > Page 4071 from housing, secure rollers. After tripod has been removed, secure assembly with tape. 4. On all models, remove snap ring from end of shaft, then remove tripod using brass punch. Inspection Remove grease from assembly and inspect bearing race, tripod components, spring, spring cup and spherical end of connecting shaft for excessive wear or damage and replace if necessary. ASSEMBLY 1. Slide small end of boot over shaft, then place clamp over groove on boot. 2. Install tripod on shaft, then lock tripod assembly on shaft by installing retaining ring in shaft groove. On G.K.N. units, slide tripod on shaft with non-chamfered end facing tripod retainer ring groove. 3. Distribute packets of special grease provided in boot clamp kit as follows: a. On G.K.N. units, distribute one packet of grease in the housing and remaining packets into the boot. b. On CITROEN units, distribute 2/3 of a packet of grease into the boot and remaining amount in the housing. 4. Position spring, with spring cup attached to exposed end, into spring pocket. Place a small amount of grease on spring cup. 5. Install tripod into housing as follows: a. On G.K.N. units, slip tripod into housing and bend retaining tabs down to their original position. Ensure retaining tabs hold tripod in housing. b. On CITROEN units, remove tape holding rollers and needle bearings in place, then install tripod assembly into housing. Reform old ring or install new retainer ring. Ensure retaining collar holds tripod in housing. If new retainer ring is installed, hold ring in position with two C-clamps and roll the edge into machined groove in housing using a suitable punch. 6. On all models, ensure proper spring positioning. The spring must remain centered in the housing spring pocket when tripod is installed and seated in the spring cup. 7. Position boot over boot groove in housing, then install clamp. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Service > Page 4072 Constant Velocity Joint: Service and Repair Outer CV Joint Service Disassembly Driveshaft assembly should be identified before starting service procedure. Refer to SYSTEM I.D.. Fig. 7 Driveshaft components 1. Remove boot clamps, then pull back boot to gain access to joint. 2. Clean grease from joint. Fig. 16 Removing outer CV joint from shaft 3. On all models except S.S.G. units, place driveshaft assembly in suitable vise and support outer joint. Remove outer joint from shaft by tapping top of joint body with a soft hammer. 4. Remove circlip from shaft groove and discard. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Service > Page 4073 Fig. 17 Circlip retainer in cross. S.S.G. units 5. On S.S.G. units, loosen damper weight bolts, slide it and boot towards inner joint. Remove circlip, then joint from shaft. 6. On all units, if constant velocity joint is operating satisfactorily and grease does not appear contaminated, refer to ASSEMBLY. 7. If constant velocity joint is noisy or badly worn, replace entire unit. The repair kit will include boot, clamps, circlip and lubricant. Clean and inspect joint outlined in the following steps. Fig. 18 Ball removal. Outer CV joint 8. Clean surplus grease and mark relative position of inner cross, cage and housing with a dab of paint. 9. Hold joint vertically in a soft jawed vise. 10. Press downward on one side of the inner race to tilt cage and remove ball from opposite side. If joint is tight, use a hammer and brass drift to tap inner race. Do not strike the cage. Repeat this step until all balls have been removed. A screwdriver may be used to pry balls loose. Fig. 19 Cage & cross assembly removal. Outer CV joint 11. Tilt cage assembly vertically and position the two opposing, elongated cage windows in area between ball grooves. Remove cage and inner race assembly by pulling upward from the housing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Service > Page 4074 Fig. 20 Removing cross from cage. Outer CV joint 12. Rotate inner cross 90° to cage and align one of the race spherical lands with an elongated cage window. Raise land into cage window and remove inner race by swinging outward. Inspection 1. Check housing ball races for excessive wear. 2. Check splined shaft and nut threads for damage. 3. Inspect the balls for pitting, cracks, scouring and wearing. Dulling of the surface is normal. 4. Inspect cage for excessive wear on inner and outer spherical surfaces, heavy brinnelling of the cage, window cracks and chipping. 5. Inspect inner race (cross) for excessive wear or scoring of ball races. 6. If any of the defects listed in steps 1 through 5 are found, replace the CV joint assembly as a unit. Polished areas in races (cross and housing) and cage spheres are normal and do not indicate a need for joint replacement unless they are suspected of causing noise and vibration. Assembly 1. If removed, position wear sleeve on joint housing, then tap sleeve onto housing using oil seal installer tool No. C-4698 or equivalent. 2. Lightly oil components, then align marks made during disassembly. Fig. 21 Cage & cross assembled. G.K.N. units Fig. 22 Cage & cross assembled. Citroen units Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Service > Page 4075 3. Align one of the inner race (cross) lands into cage window, then insert race into cage and pivot 90°. Fig. 23 Installing cage & cross assembly into housing. Outer CV joint Fig. 24 Cage & cross installed in housing. G.K.N. units Fig. 25 Cage & cross installed in housing. Citroen units Fig. 26 Cage & cross assembled. S.S.G. units 4. Align opposite elongated cage windows with housing land and insert cage assembly into housing. Pivot cage 90° to complete installation. When properly assembled, the cross counterbore should be facing outward from the joint on G.K.N. units. On CITROEN units, the cross and cage Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Service > Page 4076 chamfers will be facing outward from the joint, on S.S.G. joint the internal clip in cross will be facing outward from the housing. 5. Apply lubricant to ball races between all sides of ball grooves. 6. Insert balls into raceway by tilting cage and inner race assembly. Fig. 7 Driveshaft components 7. Slide small end of boot over shaft, then place clamp over groove on boot. Fig. 27 Installing circlip. Outer CV joint 8. Insert new circlip in shaft groove. Do not over expand or twist circlip during assembly. On S.S.G. unit has a reusable circlip retainer that is part of driver assembly. 9. Position joint housing on shaft, then engage by tapping sharply with a soft faced mallet. 10. Ensure snap ring is properly seated by attempting to pull joint from shaft. 11. Position boot over boot groove in housing, then install clamp. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service Constant Velocity Joint Boot: Service and Repair Inner CV Joint Service DISASSEMBLY Driveshaft assembly should be identified before starting service procedure. Refer to SYSTEM I.D.. Fig. 7 Driveshaft components 1. Remove boot clamps, then pull back boot to gain access to the tripod Fig. 8 Removing inner CV joint tripod. G.K.N units 2. On G.K.N. units, place driveshaft assembly in vise and hold housing as shown. Lightly compress CV joint retention spring while bending tabs back with suitable pliers, then remove tripod from housing. Fig. 9 Removing inner CV joint tripod. Citroen units 3. On CITROEN units, separate tripod from housing by slightly deforming retaining ring at three locations. If necessary, cut retaining ring from housing and install replacement retaining ring by rolling the edge into machined groove in housing with suitable punch. When removing tripod Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service > Page 4081 from housing, secure rollers. After tripod has been removed, secure assembly with tape. 4. On all models, remove snap ring from end of shaft, then remove tripod using brass punch. Inspection Remove grease from assembly and inspect bearing race, tripod components, spring, spring cup and spherical end of connecting shaft for excessive wear or damage and replace if necessary. ASSEMBLY 1. Slide small end of boot over shaft, then place clamp over groove on boot. 2. Install tripod on shaft, then lock tripod assembly on shaft by installing retaining ring in shaft groove. On G.K.N. units, slide tripod on shaft with non-chamfered end facing tripod retainer ring groove. 3. Distribute packets of special grease provided in boot clamp kit as follows: a. On G.K.N. units, distribute one packet of grease in the housing and remaining packets into the boot. b. On CITROEN units, distribute 2/3 of a packet of grease into the boot and remaining amount in the housing. 4. Position spring, with spring cup attached to exposed end, into spring pocket. Place a small amount of grease on spring cup. 5. Install tripod into housing as follows: a. On G.K.N. units, slip tripod into housing and bend retaining tabs down to their original position. Ensure retaining tabs hold tripod in housing. b. On CITROEN units, remove tape holding rollers and needle bearings in place, then install tripod assembly into housing. Reform old ring or install new retainer ring. Ensure retaining collar holds tripod in housing. If new retainer ring is installed, hold ring in position with two C-clamps and roll the edge into machined groove in housing using a suitable punch. 6. On all models, ensure proper spring positioning. The spring must remain centered in the housing spring pocket when tripod is installed and seated in the spring cup. 7. Position boot over boot groove in housing, then install clamp. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service > Page 4082 Constant Velocity Joint Boot: Service and Repair Outer CV Joint Service Assembly 1. If removed, position wear sleeve on joint housing, then tap sleeve onto housing using oil seal installer tool No. C-4698 or equivalent. 2. Lightly oil components, then align marks made during disassembly. Fig. 21 Cage & cross assembled. G.K.N. units Fig. 22 Cage & cross assembled. Citroen units 3. Align one of the inner race (cross) lands into cage window, then insert race into cage and pivot 90°. Fig. 23 Installing cage & cross assembly into housing. Outer CV joint Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service > Page 4083 Fig. 24 Cage & cross installed in housing. G.K.N. units Fig. 25 Cage & cross installed in housing. Citroen units Fig. 26 Cage & cross assembled. S.S.G. units 4. Align opposite elongated cage windows with housing land and insert cage assembly into housing. Pivot cage 90° to complete installation. When properly assembled, the cross counterbore should be facing outward from the joint on G.K.N. units. On CITROEN units, the cross and cage chamfers will be facing outward from the joint, on S.S.G. joint the internal clip in cross will be facing outward from the housing. 5. Apply lubricant to ball races between all sides of ball grooves. 6. Insert balls into raceway by tilting cage and inner race assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service > Page 4084 Fig. 7 Driveshaft components 7. Slide small end of boot over shaft, then place clamp over groove on boot. Fig. 27 Installing circlip. Outer CV joint 8. Insert new circlip in shaft groove. Do not over expand or twist circlip during assembly. On S.S.G. unit has a reusable circlip retainer that is part of driver assembly. 9. Position joint housing on shaft, then engage by tapping sharply with a soft faced mallet. 10. Ensure snap ring is properly seated by attempting to pull joint from shaft. 11. Position boot over boot groove in housing, then install clamp. Disassembly Driveshaft assembly should be identified before starting service procedure. Refer to SYSTEM I.D.. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service > Page 4085 Fig. 7 Driveshaft components 1. Remove boot clamps, then pull back boot to gain access to joint. 2. Clean grease from joint. Fig. 16 Removing outer CV joint from shaft 3. On all models except S.S.G. units, place driveshaft assembly in suitable vise and support outer joint. Remove outer joint from shaft by tapping top of joint body with a soft hammer. 4. Remove circlip from shaft groove and discard. Fig. 17 Circlip retainer in cross. S.S.G. units 5. On S.S.G. units, loosen damper weight bolts, slide it and boot towards inner joint. Remove circlip, then joint from shaft. 6. On all units, if constant velocity joint is operating satisfactorily and grease does not appear contaminated, refer to ASSEMBLY. 7. If constant velocity joint is noisy or badly worn, replace entire unit. The repair kit will include boot, clamps, circlip and lubricant. Clean and inspect joint outlined in the following steps. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service > Page 4086 Fig. 18 Ball removal. Outer CV joint 8. Clean surplus grease and mark relative position of inner cross, cage and housing with a dab of paint. 9. Hold joint vertically in a soft jawed vise. 10. Press downward on one side of the inner race to tilt cage and remove ball from opposite side. If joint is tight, use a hammer and brass drift to tap inner race. Do not strike the cage. Repeat this step until all balls have been removed. A screwdriver may be used to pry balls loose. Fig. 19 Cage & cross assembly removal. Outer CV joint 11. Tilt cage assembly vertically and position the two opposing, elongated cage windows in area between ball grooves. Remove cage and inner race assembly by pulling upward from the housing. Fig. 20 Removing cross from cage. Outer CV joint 12. Rotate inner cross 90° to cage and align one of the race spherical lands with an elongated cage window. Raise land into cage window and remove inner race by swinging outward. Inspection 1. Check housing ball races for excessive wear. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner CV Joint Service > Page 4087 2. Check splined shaft and nut threads for damage. 3. Inspect the balls for pitting, cracks, scouring and wearing. Dulling of the surface is normal. 4. Inspect cage for excessive wear on inner and outer spherical surfaces, heavy brinnelling of the cage, window cracks and chipping. 5. Inspect inner race (cross) for excessive wear or scoring of ball races. 6. If any of the defects listed in steps 1 through 5 are found, replace the CV joint assembly as a unit. Polished areas in races (cross and housing) and cage spheres are normal and do not indicate a need for joint replacement unless they are suspected of causing noise and vibration. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Nut Torque Nut Torque Front Axle Nut Torque 180 ft.lb Rear Bearing Nut Torque 270 in.lb +/- 30 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4091 Wheel Bearing: Adjustments Fig. 3 Wheel bearing assembly 1. Raise and support rear of vehicle. 2. Tighten adjusting nut to 27 to 34nm (240 to 300 in. lbs.) while rotating wheel. 3. Stop wheel and loosen adjusting nut. 4. Tighten adjusting nut finger tight. End play should be 0.0001-0.0020 inch. 5. Install castle lock with slots aligned with cotter pin hole. 6. Install cotter pin and grease cap. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Permanent Bearings REMOVAL Fig. 15 Removing hub & bearing assembly 1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub and drive shaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6. Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor, then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV joint during this procedure. Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported. 9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as shown. 10. Remove hub and bearing assembly. INSTALLATION Fig. 16 Seal installation 1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve using a suitable lubricant. 4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install rotor, then position caliper over rotor and guide hold-down spring below machined guides on knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut, then with brakes applied, tighten nut to specifications. 10. Install spring washer, locknut and cotter pin. Replaceable Bearings REMOVAL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4094 Fig. 14 Hub removal Fig. 12 Removing bearing from knuckle 1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer. 4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle using tool No. C-4811-2 or equivalent. INSTALLATION Fig. 13 Installing bearing into knuckle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4095 Fig. 14 Installing hub into knuckle 1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer. Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No. C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No. C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4096 Wheel Bearing: Service and Repair Rear REMOVAL 1. Raise and support vehicle, then remove rear wheel and brake drum. 2. Remove cotter pin, nut lock, spring washer and hub nut. 3. Remove half shaft flange retaining bolts. 4. Half shaft is spring loaded, compress inner half shaft joint slightly pulling down to clear rear carrier output shaft. 5. Remove half shaft by pulling half shaft assembly inboard. 6. Remove wheel bearing mounting bolts, then wheel bearing and hub assembly. 7. Replace grease seal if needed. INSTALLATION 1. If grease seal was removed, install a new seal using installer tool No. 6536-A or equivalent. Lubricate circumference of seal before installation. 2. Install washer and hub nut. With brakes applied, torque to 180 ft. lbs. 3. Install spring washer, nut lock and cotter pin. 4. Install hub and bearing assembly. Torque bolts in a crossing pattern to 96 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Permanent Bearings Wheel Hub: Service and Repair Permanent Bearings REMOVAL Fig. 15 Removing hub & bearing assembly 1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub and drive shaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6. Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor, then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV joint during this procedure. Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported. 9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as shown. 10. Remove hub and bearing assembly. INSTALLATION Fig. 16 Seal installation 1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve using a suitable lubricant. 4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install rotor, then position caliper over rotor and guide hold-down spring below machined guides on knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut, then with brakes applied, tighten nut to specifications. 10. Install spring washer, locknut and cotter pin. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Permanent Bearings > Page 4101 Wheel Hub: Service and Repair Replaceable Bearings REMOVAL Fig. 14 Hub removal Fig. 12 Removing bearing from knuckle 1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer. 4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle using tool No. C-4811-2 or equivalent. INSTALLATION Fig. 13 Installing bearing into knuckle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Permanent Bearings > Page 4102 Fig. 14 Installing hub into knuckle 1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer. Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No. C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No. C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications A-413 / A-670 Flex plate to crankshaft bolts ............................................................................................................... .................................................... 95 Nm ( 70 ft-lbs ) A-604 Drive plate to crankshft bolts ............................................................................................................... ................................................... 95 Nm ( 70 ft-lbs ) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Service and Repair Case: Service and Repair Fig. 8 Intermediate bearing retaining strap removal 1. Remove input shaft front bearing cup using suitable press, then press in new bearing cup. 2. Remove intermediate shaft front bearing retaining strap, then using puller tool C-4660 and screw C-4660-2A, remove front bearing and oil feeder. When installing bearing, letters on bearing should face away from case. 3. Install intermediate shaft front bearing and oil feeder with suitable press. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Service and Repair Extension Housing: Service and Repair Fig. 15 Extension housing 1. Pry extension housing seal from extension housing using suitable screwdriver. 2. Using suitable hammer, handle No. C-4171 and seal installer L-4520 (inverted), install extension housing oil seal. 3. Remove extension housing bearing cup using tool L-4518. Do not damage oil baffle. 4. Using suitable press, handle No. C-4171 and seal installer L-4520, install oil baffle and extension housing bearing cup. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications Fluid - M/T: Specifications All.......................................................................................................................................................... .........................5W-30 SF/CC, SF/CD, SG/CD, SG CAPACITY, Refill: 5-speed A525......................................................................................................... ................................................................................2.1 Liters 4.6 Pints 5-speed A520, A555, A569 ................................................................................................................. .................................................2.3 Liters 4.8 Pints Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Technical Service Bulletins > Clutch Splines & Pilot Bushing - Lubrication Input Shaft: Technical Service Bulletins Clutch Splines & Pilot Bushing - Lubrication Models AA, AB, AD, AG, AH, AJ, AK, AL, AN, AP, AQ, AS Bodies Through 1989 Subject Clutch Splines/Pilot Bushing Lubrication Index CLUTCH Date January 16, 1989 No. 06-01-89 P-0046 (C06-01-9) BODY CODE LEGEND AA - Spirit/Acclaim AB - Dodge Ram Van/Wagon AD - Dodge Ram Pickup/Ram Charger AG - Daytona AH - LeBaron/LeBaron GTS AJ - LeBaron AK - Aries/Reliant AL - Omni/Horizon AN - Dodge Dakota/Dakota Sport AP - Shadow/Sundance AQ - Chrysler TC AS - Caravan/Voyager This Technical Service Bulletin supersedes ALL previous Service Technical Publications through 1989 covering the lubrication of the clutch splines and pilot bushing. The procedures outlined in this bulletin apply to all domestic cars and trucks equipped with manual transmissions and transaxles. SERVICE PROCEDURE NOTE: THIS PROCEDURE SHOULD BE PERFORMED ANYTIME THE TRANSMISSION/TRANSAXLE IS REMOVED FROM THE ENGINE AND/OR CLUTCH SERVICE IS PERFORMED. CLUTCH SPLINES 1. Thoroughly clean the input shaft clutch splines and clutch disc splines, they must be free of any dirt or rust. 2. Apply a light coat of wheel bearing grease PN 4318064 evenly to the entire length of the exposed input shaft splines. Be sure all excessive lubricant is removed. NOTE: THE USE OF ALTERNATIVE OIL BASED LUBRICANTS IS NOT RECOMMENDED AS THESE LUBRICANTS WILL EVENTUALLY DRY UP OR BURN OFF LEAVING ONLY A DRY RESIDUE. REAR WHEEL DRIVE VEHICLES - PILOT BUSHING 1. Thoroughly clean the pilot bearing journal at the end of the input shaft and the inside of the pilot bushing. 2. Apply a light coat of multi-purpose grease PN 4318063 to the inside of the pilot bushing. NOTE: FAILURE TO PERFORM THIS PROCEDURE MAY RESULT IN ONE OR MORE OF THE FOLLOWING SYMPTOMS/CONDITIONS - HIGH SHIFTING EFFORT INTO FIRST AND SECOND GEAR, GEAR CLASH INTO REVERSE AND LOW GEARS, PILOT BUSHING NOISE AND CLUTCH DRAG. POLICY: INFORMATION ONLY Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Technical Service Bulletins > Page 4120 Input Shaft: Service and Repair Fig. 16 Input shaft rear bearing cone installation If transaxle case, input shaft seal retainer, bearing retainer plate, rear end cover, input shaft or input shaft bearings are being replaced, the shim thickness must be determined. Refer to Transmission and Drivetrain/Manual Transmission/Transaxle/Input Shaft/Adjustments. 1. Using puller C-293 and adapters C-293-45, remove input shaft rear bearing cone. 2. Install input shaft rear bearing cone, using suitable press and tool L-4171. 3. Using puller C-293 and adapter C-293-50, remove input shaft front bearing cone. 4. Install input shaft front bearing cone, using suitable press and tool L-4462. 5. Remove input shaft rear bearing cup, using suitable press, handle C-4171 and installer L-4520. 6. Bolt on bearing support plate, then install input shaft rear bearing cup, using suitable press, handle C-4171 and installer L-4520. Press in bearing cup until it bottoms. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Component Information > Adjustments Shift Linkage: Adjustments Fig. 4 Lock pin replacement 1. Remove lock pin from transaxle selector shaft housing. 2. Reverse lock pin so long end is facing downward, then insert lock pin into same threaded hole while pushing selector shaft into selector housing. Fig. 5 Gear shift linkage 3. Remove gearshift knob, retaining nut and pull-up ring. 4. Remove boot assembly from console, then the console. Fig. 6 Cable adjusting pins 5. Fabricate two cable adjusting pins as shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Component Information > Adjustments > Page 4124 Fig. 7 Selector cable adjustment 6. Adjust selector cable and torque adjusting screw to 55 inch lb. Selector cable adjusting screw must be properly tightened. Fig. 8 Crossover cable adjustment 7. Adjust crossover cable and torque adjusting screw to 55 inch lbs. Crossover cable adjusting screw must be properly tighten. 8. Install console and boot assembly, then the pull-up ring, retaining nut and gearshift knob. Apply suitable locking compound to retaining nut and tighten finger tight plus one turn. 9. Remove lock pin from selector shaft housing, then reinstall lock pin so long end is up in selector shaft housing. Torque lock pin to 105 inch lbs. 10. Check for proper operation. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Component Information > Adjustments > Page 4125 Shift Linkage: Service and Repair Fig. 13 Selector shaft housing 1. Remove selector shaft snap ring and boot, then selector shaft seal. 2. Remove selector shaft E-clip, then slide selector shaft from housing. 3. Disassemble selector shaft housing as necessary. 4. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4136 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4137 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4138 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4139 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4140 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4141 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift Control Module: Customer Interest A/T - 41TE Harsh 2nd - 1st Gear Downshift NO.: 21-16-93 Rev. A GROUP: Transmission DATE: Oct 8, 1993 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED. CHANGES ARE HIGHLIGHTED BY **ASTERISKS**. MODELS: 1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue 1992 (AP) Shadow/Sundance SYMPTOM/CONDITION: Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service Manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 4146 TIME ALLOWANCE: Labor Operation No. **08-19-05-99** 0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift Control Module: Customer Interest A/T - 41TE Harsh 2-1 Gear Downshift NO.: 21-16-92 GROUP: Transmission DATE: Nov. 2, 1992 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle MODELS: 1989-1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990-1992 (AY) Imperial/New Yorker Fifth Avenue SYMPTOM/CONDITION: Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 4151 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting Control Module: Customer Interest A/T - A604 Excessive Upshifting/Downshifting Models 1989-90 AA, AC, AG, AJ, AS, & AY Bodies Subject A-604 Transmission Excessive Upshifting/ Downshifting Index TRANSMISSION Date April 9, 1990 No. 21-12-90 (C21-06-0) P-1042 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY AY - IMPERIAL/NEW YORKER FIFTH AVENUE SYMPTOM/CONDITION Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition when the vehicle is fully loaded, driving up a grade or into a head wind. This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior (1989) model year A-604 controllers. A new A-604 controller, PN 4557585, entered production late March 1990. The new controller allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle torque load changes. DIAGNOSIS Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does not apply. Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain Diagnostic Procedure Manual. If no fault codes are present, perform the following repair procedure. If fault codes are present, they must be corrected and the corrections verified before performing the following repair procedure. PARTS REQUIRED 1. 1 - Controller PN 4557585 REPAIR PROCEDURE This repair involves the replacement of the transaxle controller. 1. Disconnect the negative battery cable. 2. Disconnect the 60-way connector from the controller. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 4156 3. Remove the controller. 4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds. 5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds. 6. Reconnect the negative battery cable. 7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-05-96 0.6 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4162 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4163 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4164 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4165 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4166 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4167 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2nd - 1st Gear Downshift NO.: 21-16-93 Rev. A GROUP: Transmission DATE: Oct 8, 1993 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED. CHANGES ARE HIGHLIGHTED BY **ASTERISKS**. MODELS: 1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue 1992 (AP) Shadow/Sundance SYMPTOM/CONDITION: Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service Manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 4172 TIME ALLOWANCE: Labor Operation No. **08-19-05-99** 0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2-1 Gear Downshift NO.: 21-16-92 GROUP: Transmission DATE: Nov. 2, 1992 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle MODELS: 1989-1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990-1992 (AY) Imperial/New Yorker Fifth Avenue SYMPTOM/CONDITION: Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 4177 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting Control Module: All Technical Service Bulletins A/T - A604 Excessive Upshifting/Downshifting Models 1989-90 AA, AC, AG, AJ, AS, & AY Bodies Subject A-604 Transmission Excessive Upshifting/ Downshifting Index TRANSMISSION Date April 9, 1990 No. 21-12-90 (C21-06-0) P-1042 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY AY - IMPERIAL/NEW YORKER FIFTH AVENUE SYMPTOM/CONDITION Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition when the vehicle is fully loaded, driving up a grade or into a head wind. This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior (1989) model year A-604 controllers. A new A-604 controller, PN 4557585, entered production late March 1990. The new controller allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle torque load changes. DIAGNOSIS Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does not apply. Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain Diagnostic Procedure Manual. If no fault codes are present, perform the following repair procedure. If fault codes are present, they must be corrected and the corrections verified before performing the following repair procedure. PARTS REQUIRED 1. 1 - Controller PN 4557585 REPAIR PROCEDURE This repair involves the replacement of the transaxle controller. 1. Disconnect the negative battery cable. 2. Disconnect the 60-way connector from the controller. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 4182 3. Remove the controller. 4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds. 5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds. 6. Reconnect the negative battery cable. 7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-05-96 0.6 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision Technical Service Bulletin # 210889 Date: 890403 A/T Reaction Shaft Support - Revision Models 1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle Subject Revised Reaction Shaft Support Index TRANSMISSION Date April 3, 1989 No. 21-08-89 P-1408 (C21-16-9) Description BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER SYMPTOM/CONDITION NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE AUTOMATIC TRANSAXLE, PART NUMBER 4446659. The procedure outlined in this bulletin should be followed if removal and disassembly of the transaxle is required. DIAGNOSIS 1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual (#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A) to determine if disassembly is required. Use the following procedure when the transaxle is disassembled for repair. PARTS REQUIRED 1 Repair package P/N 4549248 1 Gasket Package P/N 4504558 1 Controller (AS REQUIRED) P/N 5234678 NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT CLUTCH HUB IS REQUIRED. Input Clutch Retainer P/N 4431609 REPAIR PROCEDURE 1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the following guidelines. 2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or subsequent) controller. Always check input shaft end play before disassembling the transaxle. Step A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 4187 FIGURE 1 - FRONT PUMP REACTION SHAFT 1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves, replace it with the four ring reaction support supplied in the repair package (Figure 1). If the reaction support that is removed from the transaxle has four ring grooves, the repair package is not needed. Step B FIGURE 2 - INPUT CLUTCH RETAINER 1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer as shown. If the bump is present, replace the retainer with a new one (P/N 4431609). 2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package. When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the compression of the Orings. 3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is no difference in any of the O-rings. The color was added to facilitate assembly. 4. Inspect and replace any distressed (burned) clutch components as required. Step C 1. Remove and discard the steel separator plate from the valve body. 2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow to the overdrive clutch circuit. Step D Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 4188 1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play to the service preferred setting of .005" to .015". The actual total end play specification is .005" to .025" and is acceptable if the service preferred setting cannot be obtained. Other Recommendations 1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not use other kinds of petroleum based greases such as chassis grease that could plug critical orifices or might be incompatible with transmission fluid. 2. Replace the torque convertor if a clutch failure has occurred. 3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY. Replace it if necessary. 4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has occurred. 5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be used if ATF Plus is not available. POLICY: Reimbursable within the limits of the warranty. TIME ALLOWANCE: Labor Operation No. 21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs. FAILURE CODE: 7H - Reaction shaft/supt. assy. failed Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 4189 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision Technical Service Bulletin # 210889 Date: 890403 A/T Reaction Shaft Support - Revision Models 1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle Subject Revised Reaction Shaft Support Index TRANSMISSION Date April 3, 1989 No. 21-08-89 P-1408 (C21-16-9) Description BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER SYMPTOM/CONDITION NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE AUTOMATIC TRANSAXLE, PART NUMBER 4446659. The procedure outlined in this bulletin should be followed if removal and disassembly of the transaxle is required. DIAGNOSIS 1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual (#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A) to determine if disassembly is required. Use the following procedure when the transaxle is disassembled for repair. PARTS REQUIRED 1 Repair package P/N 4549248 1 Gasket Package P/N 4504558 1 Controller (AS REQUIRED) P/N 5234678 NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT CLUTCH HUB IS REQUIRED. Input Clutch Retainer P/N 4431609 REPAIR PROCEDURE 1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the following guidelines. 2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or subsequent) controller. Always check input shaft end play before disassembling the transaxle. Step A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 4195 FIGURE 1 - FRONT PUMP REACTION SHAFT 1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves, replace it with the four ring reaction support supplied in the repair package (Figure 1). If the reaction support that is removed from the transaxle has four ring grooves, the repair package is not needed. Step B FIGURE 2 - INPUT CLUTCH RETAINER 1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer as shown. If the bump is present, replace the retainer with a new one (P/N 4431609). 2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package. When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the compression of the Orings. 3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is no difference in any of the O-rings. The color was added to facilitate assembly. 4. Inspect and replace any distressed (burned) clutch components as required. Step C 1. Remove and discard the steel separator plate from the valve body. 2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow to the overdrive clutch circuit. Step D Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 4196 1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play to the service preferred setting of .005" to .015". The actual total end play specification is .005" to .025" and is acceptable if the service preferred setting cannot be obtained. Other Recommendations 1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not use other kinds of petroleum based greases such as chassis grease that could plug critical orifices or might be incompatible with transmission fluid. 2. Replace the torque convertor if a clutch failure has occurred. 3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY. Replace it if necessary. 4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has occurred. 5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be used if ATF Plus is not available. POLICY: Reimbursable within the limits of the warranty. TIME ALLOWANCE: Labor Operation No. 21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs. FAILURE CODE: 7H - Reaction shaft/supt. assy. failed Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support - Revision > Page 4197 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4200 Control Module: Locations Power Distribution Center Power Distribution Center Fuse Block Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4201 Control Module: Diagrams Part 1 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4202 Part 2 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4203 Part 3 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4204 Part 4 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4205 Part 5 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4206 Part 6 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4207 Part 7 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4208 Part 8 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4209 Part 9 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4210 Part 10 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4211 Part 11 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 Control Module: Description and Operation A604 DESCRIPTION This computer is dedicated to the control of the A-604 Transaxle. It has a connector shaped similarly to the one on the Engine Controller. It contains on-board diagnostics and fault code memory which is accessed by the DRBII Diagnostic Tool through Chrysler's C2D Bus. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 > Page 4214 Control Module: Description and Operation 41TE Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 > Page 4215 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 - Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 4218 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4222 Back Up Lamp Relay / Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) 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 4223 Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4224 Transmission Control System Relay: Description and Operation DESCRIPTION This relay is operated by the A-604 controller. Its purpose is to make operating voltage available to the solenoids and switches located in the Solenoid Pack. When the Controller opens the relay, voltage is taken away from the solenoids and the transmission goes into a limp-in mode. While in this mode, only second gear, reverse and neutral are available. This relay may also be referred to as the Safety Shutdown Relay. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations Transmission Position Relay: Component Locations Back Up Lamp Relay / Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page 4229 Back Up Lamp Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation A604 (41TE) 4 Speed Transaxle DESCRIPTION The PRNDL switch is similar in appearance to the Neutral Safety Switch. Its purpose is to help the transaxle controller sense the shifter position (manual valve), and help operate the reverse lamps. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4243 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4244 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4245 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4251 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4252 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4257 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4258 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4259 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 4265 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 4266 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4269 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4270 Transmission Position Switch/Sensor: Locations 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4271 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 4274 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 4277 Transmission Position Switch/Sensor: Description and Operation PRNDL The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. It may have been replaced by a transmission range sensor (TRS). Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 4280 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 4281 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 4282 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 4291 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4296 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4297 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4298 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 4304 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4309 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4310 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4311 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4312 Input / Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Transmission Speed Sensor: Description and Operation Output Speed Sensor DESCRIPTION This is a two wire, magnetic pick-up device used to sense the output speed of the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor > Page 4315 Transmission Speed Sensor: Description and Operation Turbine Speed Sensor A604 (41TE) 4 Speed Transaxle DESCRIPTION This is a two wire, magnetic pick-up device used to sense the input speed of the transaxle (torque convertor turbine). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 4316 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 4331 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 4337 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 4338 Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 4339 Transmission Solenoid Connector Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging Torque Converter Clutch Solenoid: Customer Interest Converter Lock Up Solenoid Bucking/Surging Models 1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies Subject Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines. Index DRIVEABILITY Date February 12, 1990 No. 18-02-90 P-205 (C18-27-9) BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ - LEBARON COUPE/LEBARON CONVERTIBLE AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4 speed automatic transmission. SYMPTOM/CONDITION A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur under light deceleration conditions, especially when cresting a hill. DIAGNOSIS The above conditions can be diagnosed by disconnecting the transmission lock-up torque converter solenoid, and driving the vehicle under the above conditions. If the problem goes away, follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test Procedure for correction. PARTS REQUIRED Driveability Kit PN 4419447 Consists of: 1 Wiring Jumper Assembly PN 4400768 1 Lock-Up Solenoid Cap PN 4419446 2 Tie Wrap PN 6015756 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE The following procedure involves disconnecting the lock-up torque convertor solenoid. The customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2 miles per gallon may be noticed, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 4348 FIGURE A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 4349 FIGURE B 1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located directly behind the transmission dipstick (Figures A and B). 2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in Step 1. 3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A). 3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places using tie wrap, PN 6015756 (Figure B). 4. Install supplied cap, PN 4419446, onto lock-up solenoid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 4350 FIGURE C 5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and attach near VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 21-96-01-90 0.2 Hrs. FAILURE CODE: AM - Authorized modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging Torque Converter Clutch Solenoid: All Technical Service Bulletins Converter Lock Up Solenoid Bucking/Surging Models 1989-1990 AA, AC, AG, AH, AJ, AK, AL, AP, AS, Bodies Subject Surge/Buck at 35-55 MPH With Vehicles Equipped With 2.2, 2.5 And 3.0L Engines. Index DRIVEABILITY Date February 12, 1990 No. 18-02-90 P-205 (C18-27-9) BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON LANDAU AC - DYNASTY/NEW YORKER LANDAU/SALON AG - DAYTONA AH - LANCER/LEBARON GTS (4-DOOR HATCHBACK) AJ - LEBARON COUPE/LEBARON CONVERTIBLE AK - ARIES/RELIANT AL - OMNI/HORIZON AP - SHADOW/SUNDANCE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY This bulletin applies to 1989 and 1990 vehicles equipped with A413 and A670 3 speed automatic transmissions with lock up torque converters. It does not apply to vehicle equipped with the A604 4 speed automatic transmission. SYMPTOM/CONDITION A surge may be noticed at steady cruising speeds above 35 mph. In addition, bucking may occur under light deceleration conditions, especially when cresting a hill. DIAGNOSIS The above conditions can be diagnosed by disconnecting the transmission lock-up torque converter solenoid, and driving the vehicle under the above conditions. If the problem goes away, follow the repair procedure below. If either problem is still present, refer to the Diagnostic Test Procedure for correction. PARTS REQUIRED Driveability Kit PN 4419447 Consists of: 1 Wiring Jumper Assembly PN 4400768 1 Lock-Up Solenoid Cap PN 4419446 2 Tie Wrap PN 6015756 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE The following procedure involves disconnecting the lock-up torque convertor solenoid. The customer should be advised that after this repair is performed, a loss in fuel economy of 1 to 2 miles per gallon may be noticed, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 4356 FIGURE A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 4357 FIGURE B 1. Disconnect the wiring connector from the lock-up torque convertor solenoid. This is located directly behind the transmission dipstick (Figures A and B). 2. Install wiring jumper assembly, PN 4400768, to the lock-up solenoid wiring connector removed in Step 1. 3. 2.2 & 2.5L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) under battery so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places, using supplied tie wrap, PN 6015756 (Figure A). 3.0L Engines - Reroute new wiring assembly (jumper plugged into original lock-up wiring) so that it loops back along original lock-up wiring. Tie wrap looped harness to original lock-up wiring in two places using tie wrap, PN 6015756 (Figure B). 4. Install supplied cap, PN 4419446, onto lock-up solenoid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 180290 > Feb > 90 > Converter Lock Up Solenoid - Bucking/Surging > Page 4358 FIGURE C 5. Type information on Authorized Modification Label, PN 4275086, as shown in Figure C and attach near VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 21-96-01-90 0.2 Hrs. FAILURE CODE: AM - Authorized modification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations Part Throttle Unlock Solenoid (3speed) LH Side Of Engine Compartment 3 Speed Automatic RH Side Of Transaxle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 4361 Applicable to: 3 Speed A-413 Automatic Transaxle 4 Speed Automatic Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 4362 Electrical Connections, 3 Speed Automatic Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 4363 Torque Converter Clutch Solenoid: Description and Operation Part Throttle Unlock Solenoid (3 Speed Automatic) This solenoid is controlled by the engine controller. The engine controller applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. The lock-up torque converter is only locked up when the transmission is in direct drive and when the throttle position is not fluctuating. If the engine controller receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the engine controller will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4374 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4375 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4376 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4377 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4378 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4379 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift Control Module: Customer Interest A/T - 41TE Harsh 2nd - 1st Gear Downshift NO.: 21-16-93 Rev. A GROUP: Transmission DATE: Oct 8, 1993 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED. CHANGES ARE HIGHLIGHTED BY **ASTERISKS**. MODELS: 1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue 1992 (AP) Shadow/Sundance SYMPTOM/CONDITION: Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service Manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 4384 TIME ALLOWANCE: Labor Operation No. **08-19-05-99** 0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift Control Module: Customer Interest A/T - 41TE Harsh 2-1 Gear Downshift NO.: 21-16-92 GROUP: Transmission DATE: Nov. 2, 1992 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle MODELS: 1989-1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990-1992 (AY) Imperial/New Yorker Fifth Avenue SYMPTOM/CONDITION: Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 4389 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting Control Module: Customer Interest A/T - A604 Excessive Upshifting/Downshifting Models 1989-90 AA, AC, AG, AJ, AS, & AY Bodies Subject A-604 Transmission Excessive Upshifting/ Downshifting Index TRANSMISSION Date April 9, 1990 No. 21-12-90 (C21-06-0) P-1042 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY AY - IMPERIAL/NEW YORKER FIFTH AVENUE SYMPTOM/CONDITION Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition when the vehicle is fully loaded, driving up a grade or into a head wind. This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior (1989) model year A-604 controllers. A new A-604 controller, PN 4557585, entered production late March 1990. The new controller allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle torque load changes. DIAGNOSIS Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does not apply. Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain Diagnostic Procedure Manual. If no fault codes are present, perform the following repair procedure. If fault codes are present, they must be corrected and the corrections verified before performing the following repair procedure. PARTS REQUIRED 1. 1 - Controller PN 4557585 REPAIR PROCEDURE This repair involves the replacement of the transaxle controller. 1. Disconnect the negative battery cable. 2. Disconnect the 60-way connector from the controller. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 4394 3. Remove the controller. 4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds. 5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds. 6. Reconnect the negative battery cable. 7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-05-96 0.6 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4400 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4401 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4402 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4403 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4404 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4405 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2nd - 1st Gear Downshift NO.: 21-16-93 Rev. A GROUP: Transmission DATE: Oct 8, 1993 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-16-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NO. IS REVISED. CHANGES ARE HIGHLIGHTED BY **ASTERISKS**. MODELS: 1989 - 1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990 - 1992 (AY) Imperial/New Yorker Fifth Avenue 1992 (AP) Shadow/Sundance SYMPTOM/CONDITION: Some 41TE transaxies may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate Service Manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211693A > Oct > 93 > A/T - 41TE Harsh 2nd - 1st Gear Downshift > Page 4410 TIME ALLOWANCE: Labor Operation No. **08-19-05-99** 0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift Control Module: All Technical Service Bulletins A/T - 41TE Harsh 2-1 Gear Downshift NO.: 21-16-92 GROUP: Transmission DATE: Nov. 2, 1992 SUBJECT: Harsh 2-1 Downshift 41TE Transaxle MODELS: 1989-1992 (AA) Acclaim/Spirit/LeBaron Sedan (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona (AJ) LeBaron Coupe/LeBaron Convertible (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town and Country 1990-1992 (AY) Imperial/New Yorker Fifth Avenue SYMPTOM/CONDITION: Some 41TE transaxles may exhibit a harsh 2-1 downshift. This condition may occur when coasting to a stop or after applying pressure to the accelerator pedal at low vehicle speeds. Changes have been made to the Transmission Control Module (TCM) for the 1993 model year that significantly reduce 2-1 downshift harshness. These new service controllers should only be used to repair vehicles with specific customer dissatisfaction with harsh 2-1 downshifts. DIAGNOSIS: 1. Confirm the 41TE transaxle fluid level is correct using the procedure in the appropriate service manual. 2. Use the DRB II to read Diagnostic Trouble Codes (DTC) that may exist and Clutch Volume Indexes (CVI's) to determine if transaxle repair is appropriate. 3. Road test the vehicle to confirm 2-1 downshift harshness. PARTS REQUIRED REPAIR PROCEDURE: This bulletin involves replacing the Transmission Control Module (TCM). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211692 > Nov > 92 > A/T - 41TE Harsh 2-1 Gear Downshift > Page 4415 1. Use the procedure in the appropriate vehicle service manual to replace the TCM. 2. When returning the vehicle to the customer, advise him/her that for the full benefit of the new TCM to be realized, approximately one week of driving will need to be completed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-05-98 ......0.5 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting Control Module: All Technical Service Bulletins A/T - A604 Excessive Upshifting/Downshifting Models 1989-90 AA, AC, AG, AJ, AS, & AY Bodies Subject A-604 Transmission Excessive Upshifting/ Downshifting Index TRANSMISSION Date April 9, 1990 No. 21-12-90 (C21-06-0) P-1042 BODY CODE LEGEND AA - ACCLAIM/SPIRIT/LEBARON AC - DYNASTY/NEW YORKER LANDAU/SALON AG DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY AY - IMPERIAL/NEW YORKER FIFTH AVENUE SYMPTOM/CONDITION Some owners may complain of a transmission upshift/downshift hunting (3-4 busyness) condition when the vehicle is fully loaded, driving up a grade or into a head wind. This condition can occur on vehicles equipped with the A-604 controller PN 4557120 or prior (1989) model year A-604 controllers. A new A-604 controller, PN 4557585, entered production late March 1990. The new controller allows the torque converter to unlock, instead of initiating a 4-3 downshift during slight vehicle torque load changes. DIAGNOSIS Check the A-604 controller part number, if the PN is 4557585, this Technical Service Bulletin does not apply. Connect the DRB II and perform the diagnostic test as outlined in the appropriate Powertrain Diagnostic Procedure Manual. If no fault codes are present, perform the following repair procedure. If fault codes are present, they must be corrected and the corrections verified before performing the following repair procedure. PARTS REQUIRED 1. 1 - Controller PN 4557585 REPAIR PROCEDURE This repair involves the replacement of the transaxle controller. 1. Disconnect the negative battery cable. 2. Disconnect the 60-way connector from the controller. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 211290 > Apr > 90 > A/T - A604 Excessive Upshifting/Downshifting > Page 4420 3. Remove the controller. 4. Install the new controller PN 4557585 and torque the mounting bolts to 17 inch pounds. 5. Install the 60-way connector to the controller, torque the attachment bolt to 40 inch pounds. 6. Reconnect the negative battery cable. 7. Road test vehicle to verify controller function, check for fault codes and disconnect the DRB II. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-05-96 0.6 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision Technical Service Bulletin # 210889 Date: 890403 A/T Reaction Shaft Support - Revision Models 1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle Subject Revised Reaction Shaft Support Index TRANSMISSION Date April 3, 1989 No. 21-08-89 P-1408 (C21-16-9) Description BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER SYMPTOM/CONDITION NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE AUTOMATIC TRANSAXLE, PART NUMBER 4446659. The procedure outlined in this bulletin should be followed if removal and disassembly of the transaxle is required. DIAGNOSIS 1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual (#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A) to determine if disassembly is required. Use the following procedure when the transaxle is disassembled for repair. PARTS REQUIRED 1 Repair package P/N 4549248 1 Gasket Package P/N 4504558 1 Controller (AS REQUIRED) P/N 5234678 NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT CLUTCH HUB IS REQUIRED. Input Clutch Retainer P/N 4431609 REPAIR PROCEDURE 1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the following guidelines. 2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or subsequent) controller. Always check input shaft end play before disassembling the transaxle. Step A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 4425 FIGURE 1 - FRONT PUMP REACTION SHAFT 1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves, replace it with the four ring reaction support supplied in the repair package (Figure 1). If the reaction support that is removed from the transaxle has four ring grooves, the repair package is not needed. Step B FIGURE 2 - INPUT CLUTCH RETAINER 1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer as shown. If the bump is present, replace the retainer with a new one (P/N 4431609). 2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package. When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the compression of the Orings. 3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is no difference in any of the O-rings. The color was added to facilitate assembly. 4. Inspect and replace any distressed (burned) clutch components as required. Step C 1. Remove and discard the steel separator plate from the valve body. 2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow to the overdrive clutch circuit. Step D Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 4426 1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play to the service preferred setting of .005" to .015". The actual total end play specification is .005" to .025" and is acceptable if the service preferred setting cannot be obtained. Other Recommendations 1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not use other kinds of petroleum based greases such as chassis grease that could plug critical orifices or might be incompatible with transmission fluid. 2. Replace the torque convertor if a clutch failure has occurred. 3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY. Replace it if necessary. 4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has occurred. 5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be used if ATF Plus is not available. POLICY: Reimbursable within the limits of the warranty. TIME ALLOWANCE: Labor Operation No. 21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs. FAILURE CODE: 7H - Reaction shaft/supt. assy. failed Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 4427 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision Technical Service Bulletin # 210889 Date: 890403 A/T Reaction Shaft Support - Revision Models 1989 AC & AS Body Equipped W/Ultradrive Automatic Transaxle Subject Revised Reaction Shaft Support Index TRANSMISSION Date April 3, 1989 No. 21-08-89 P-1408 (C21-16-9) Description BODY CODE LEGEND AC - DYNASTY/NEW YORKER/LANDAU AS - RAM VAN/CARAVAN/VOYAGER SYMPTOM/CONDITION NOTE: THIS BULLETIN APPLIES TO ALL "AC" & "AS" BODIES BUILT WITH THE ULTRADRIVE AUTOMATIC TRANSAXLE, PART NUMBER 4446659. The procedure outlined in this bulletin should be followed if removal and disassembly of the transaxle is required. DIAGNOSIS 1. Use the diagnostic procedures outlined in the Ultradrive Transaxle Powertrain Diagnostic Manual (#81-699-9009), Service Manual, AND TECHNICAL SERVICE BULLETIN 21-001-89 (Revision A) to determine if disassembly is required. Use the following procedure when the transaxle is disassembled for repair. PARTS REQUIRED 1 Repair package P/N 4549248 1 Gasket Package P/N 4504558 1 Controller (AS REQUIRED) P/N 5234678 NOTE: REFER TO THE BULLETIN REPAIR PROCEDURE TO DETERMINE IF A NEW INPUT CLUTCH HUB IS REQUIRED. Input Clutch Retainer P/N 4431609 REPAIR PROCEDURE 1. Disassemble, clean and rebuild the transaxle per the service manual instruction and the following guidelines. 2. If the transmission controller part number is 5234623 or 5234649, replace it with a 5234678 (or subsequent) controller. Always check input shaft end play before disassembling the transaxle. Step A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 4433 FIGURE 1 - FRONT PUMP REACTION SHAFT 1. Inspect the front pump reaction shaft support. If the reaction support has three ring grooves, replace it with the four ring reaction support supplied in the repair package (Figure 1). If the reaction support that is removed from the transaxle has four ring grooves, the repair package is not needed. Step B FIGURE 2 - INPUT CLUTCH RETAINER 1. Compare the input clutch retainer to Figure 2. check for a bump on the rear face of the retainer as shown. If the bump is present, replace the retainer with a new one (P/N 4431609). 2. Replace the input clutch hub (P/N 4431614) with the new hub supplied in the service package. When installing the input shaft into the new hub, use a plastic hammer and tap the shaft lightly on the rear face until the snap ring is bottomed on the hub. This will "seat" the snap ring and prevent input shaft runout. The new input clutch hub has shallower "O" ring grooves to increase the compression of the Orings. 3. The input clutch hub "O" rings may be either black, or orange (front) and green (rear). There is no difference in any of the O-rings. The color was added to facilitate assembly. 4. Inspect and replace any distressed (burned) clutch components as required. Step C 1. Remove and discard the steel separator plate from the valve body. 2. Thoroughly clean all contaminants from the valve body and install the new plate supplied in the package. The new steel plate has a larger overdrive clutch feed orifice to provide increased oil flow to the overdrive clutch circuit. Step D Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 4434 1. During reassembly of the transaxle, select the proper #4 thrust washer to set input shaft end play to the service preferred setting of .005" to .015". The actual total end play specification is .005" to .025" and is acceptable if the service preferred setting cannot be obtained. Other Recommendations 1. Always use Door Ease on all O-rings and mating parts to ease assembly. Use Vaseline or petroleum jelly to temporarily hold parts (such as thrust bearings) in place during assembly. Do not use other kinds of petroleum based greases such as chassis grease that could plug critical orifices or might be incompatible with transmission fluid. 2. Replace the torque convertor if a clutch failure has occurred. 3. The solenoid assembly can be reused unless the transmission experienced a gear train failure or a clutch failure that generated metal debris. NEVER DISASSEMBLE THE SOLENOID ASSEMBLY. Replace it if necessary. 4. Always reverse flush the transmission oil cooler circuit if a clutch failure or gear train failure has occurred. 5. Use Mopar ATF Plus (Type 7176) transmission fluid (P/N 4467721) to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid (P/N 4467723) may be used if ATF Plus is not available. POLICY: Reimbursable within the limits of the warranty. TIME ALLOWANCE: Labor Operation No. 21-34-02-90 . . . . . . . . . . . . . . 9.0 Hrs. FAILURE CODE: 7H - Reaction shaft/supt. assy. failed Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 210889 > Apr > 89 > A/T Reaction Shaft Support Revision > Page 4435 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4438 Control Module: Locations Power Distribution Center Power Distribution Center Fuse Block Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4439 Control Module: Diagrams Part 1 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4440 Part 2 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4441 Part 3 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4442 Part 4 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4443 Part 5 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4444 Part 6 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4445 Part 7 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4446 Part 8 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4447 Part 9 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4448 Part 10 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4449 Part 11 Of 11 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 Control Module: Description and Operation A604 DESCRIPTION This computer is dedicated to the control of the A-604 Transaxle. It has a connector shaped similarly to the one on the Engine Controller. It contains on-board diagnostics and fault code memory which is accessed by the DRBII Diagnostic Tool through Chrysler's C2D Bus. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 > Page 4452 Control Module: Description and Operation 41TE Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > A604 > Page 4453 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 4456 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4460 Back Up Lamp Relay / Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4461 Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4462 Transmission Control System Relay: Description and Operation DESCRIPTION This relay is operated by the A-604 controller. Its purpose is to make operating voltage available to the solenoids and switches located in the Solenoid Pack. When the Controller opens the relay, voltage is taken away from the solenoids and the transmission goes into a limp-in mode. While in this mode, only second gear, reverse and neutral are available. This relay may also be referred to as the Safety Shutdown Relay. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations Transmission Position Relay: Component Locations Back Up Lamp Relay / Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page 4467 Back Up Lamp Relay Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation A604 (41TE) 4 Speed Transaxle DESCRIPTION The PRNDL switch is similar in appearance to the Neutral Safety Switch. Its purpose is to help the transaxle controller sense the shifter position (manual valve), and help operate the reverse lamps. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4481 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4482 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4483 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4489 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4490 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4495 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4496 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4497 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4503 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4504 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4507 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4508 Transmission Position Switch/Sensor: Locations 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4509 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 4512 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 4515 Transmission Position Switch/Sensor: Description and Operation PRNDL The white PRNDL is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. It may have been replaced by a transmission range sensor (TRS). Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 4518 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 4519 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 4520 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 4529 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4534 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4535 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4536 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 4542 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4547 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4548 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4549 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4550 Input / Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Transmission Speed Sensor: Description and Operation Output Speed Sensor DESCRIPTION This is a two wire, magnetic pick-up device used to sense the output speed of the transaxle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor > Page 4553 Transmission Speed Sensor: Description and Operation Turbine Speed Sensor A604 (41TE) 4 Speed Transaxle DESCRIPTION This is a two wire, magnetic pick-up device used to sense the input speed of the transaxle (torque convertor turbine). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 4554 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The Anti-Lock warning light will normally come on for approximately one to two seconds when the ignition switch is first turned to the ON position. Anytime the Controller Anti-Lock Brake (CAB) detects a condition which results in a shutdown of the ABS function other than when the ignition switch is first turned on it will activate the ABS warning lamp. When the light is on only the Anti-Lock function of the brake system is affected. The standard brake system and ability to stop the vehicle will not be affected. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Accumulator > Component Information > Service and Repair > Depressurizing Hydraulic Accumulator Brake Fluid Accumulator: Service and Repair Depressurizing Hydraulic Accumulator NOTE:The ABS pump/motor assembly will keep the hydraulic accumulator charged to a pressure between 1600-2000 psi anytime the ignition is in the ON position. The pump/motor cannot run if the ignition is off or either battery cable is disconnected. WARNING: The hydraulic accumulator should be depressurized before disassembling any portion of the hydraulic system. 1. Turn ignition switch to the OFF position, or disconnect battery ground cable. 2. Pump brake pedal a minimum of 40 times using approximately 50 pounds of pedal force. Pedal feel should change noticeably when accumulator is discharged. 3. After a definite increase in pedal effort is felt, pump pedal a few additional times. This will remove all hydraulic pressure from the system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Accumulator > Component Information > Service and Repair > Depressurizing Hydraulic Accumulator > Page 4567 Brake Fluid Accumulator: Service and Repair Accumulator Replacement 1. Depressurize hydraulic accumulator as outlined under "Hydraulic Assembly/Service and Repair." See: Depressurizing Hydraulic Accumulator WARNING:Failure to de-pressurize the hydraulic accumulator, may result in personal injury, or damage to painted surfaces. 2. Remove accumulator assembly. 3. Reverse procedure to install. Torque accumulator to 30 ft. lbs., then turn ignition On and check for leaks. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Description and Operation Brake Fluid Pump: Description and Operation The Pump/Motor assembly is located under the hydraulic assembly at the rear lefthand side of the engine compartment. This pump is electrically driven and takes low pressure brake fluid from the hydraulic assembly reservoir and pressurizes it for storage in two accumulators for power assist and anti-lock braking. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Description and Operation > Page 4571 Brake Fluid Pump: Service and Repair 1. Depressurize hydraulic accumulator as outlined under "Hydraulic Assembly/Service and Repair." See: Brake Fluid Accumulator/Service and Repair/Depressurizing Hydraulic Accumulator WARNING:Failure to de-pressurize the hydraulic accumulator, may result in personal injury, or damage to painted surfaces. 2. Remove air intake ducts from engine. 3. Loosen low pressure hose clamp at hydraulic unit. 4. Disconnect high pressure fluid line clip from battery tray, then disconnect electrical connectors at pump and near high and low pressure lines. 5. Disconnect high and low pressure lines from hydraulic assembly. 6. Disconnect pump/motor to engine mount electrical connector, then remove pump heat shield bolt from front of pump bracket. 7. Remove front heat shield, then the pump/motor assembly. 8. Reverse procedure to install, noting the following: a. Torque low pressure hose clamp to 10 inch lbs. b. Torque high pressure hose fitting to pump assembly to 145 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Diagnostic Connector - ABS: Locations This ABS system has a self diagnostic connector located under the lefthand side of the instrument panel, left of the steering column. The diagnostic connector is a blue 6-way connector which can be connected to a DRB II readout box. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine compartment. The CAB uses the wheel speed information from the wheel speed sensors to control the ABS system function. The CAB also monitors ABS operation and detects system faults. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4578 Electronic Brake Control Module: Description and Operation The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine compartment. The CAB uses the wheel speed information from the wheel speed sensors to control the ABS system function. The CAB also monitors ABS operation and detects system faults. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4579 Electronic Brake Control Module: Service and Repair 1. Turn ignition Off. 2. Remove speed control servo. 3. Disconnect wiring harness 60-way connector from anti-lock brake controller. 4. Remove controller mounting bolts, then the controller. 5. Reverse procedure to install. 6. Torque controller attaching bolts to 40 in. lbs. and electrical connector screw to 105 in. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations Wheel Speed Sensor: Locations The wheel speed sensors are located at each wheel and transmit wheel speed information to the Controller Anti-Lock Brake. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 4583 Wheel Speed Sensor: Description and Operation The wheel speed sensors are located at each wheel and transmit wheel speed information to the Controller Anti-Lock Brake (CAB). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Fig. 66 Front Speed Sensor Assembly 1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove screw from clip that retains sensor wiring grommet, then pull sensor grommet from fenderwell. 3. Disconnect electrical connector, then remove two screws retaining sensor wiring routing tube. 4. Remove sensor head screw, then the sensor head from steering knuckle. CAUTION: If sensor head is seized, use a punch and gently rock sensor back and forth until free. Do not use pliers on sensor head. 5. Reverse procedure to install. Coat sensor with suitable high temperature E.P. grease and Torque mounting bolt to 60 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4586 Wheel Speed Sensor: Service and Repair Rear 1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove sensor wiring grommet retainer bracket, then pull sensor grommet from underbody. 3. Disconnect electrical connector, then remove wiring to frame rail attaching bracket. 4. Remove rear axle U-bolt nuts, then the sensor assembly mounting bracket. 5. Remove sensor head screw, then the sensor head from steering knuckle. If sensor head is seized, use a punch and gently rock sensor back and forth until free. Do not use pliers on sensor head. 6. Reverse procedure to install. Torque sensor mounting bolt to 60 inch lbs. and U-bolt nuts to 65 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding WHEN BLEEDING BRAKES REMEMBER... - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always flush and bleed the brake hydraulic sys. when servicing the brakes, because: Brake fluid absorbs moisture from the air, after 3-4 years of service the water content of the brake fluid may be as high as 6-7%. This significantly reduces the boiling point of the brake fluid which may result in a soft pedal or brake failure during prolonged or severe braking. Corrosion deposits and other contaminants gradually build up inside of the brake hydraulic sys. Check the bottom of the master-cylinder reservoir for a build up of fine black silt. If any is present the brake fluid should be flushed. - Never reuse brake fluid that has been drained from the brake system. DOT 3,4 or DOT 5 As a general rule DOT 5 brake fluid should not be used in vehicles recommending DOT 3 or 4 type fluid. DOT 5 brake fluid is silicone based. DOT 3 (standard) and DOT 4 (heavy-duty) are glycol-based. DOT 5 can be distinguished from conventional brake fluids by its purple color (which comes from a dye). DOT 5 silicone brake fluid won't mix with glycol-based brake fluid (creating concern over sludging if all old fluid isn't removed when a system is refilled with silicone). Silicone does not absorb moisture. DOT 5 brake fluid does not become contaminated with moisture over time as conventional DOT 3 and 4 brake fluids do. Silicone is also chemically inert, nontoxic and won't damage paint like conventional brake fluid. It also has a higher boiling point. Because of this, it is often marketed as a premium "lifetime" brake fluid. It is often used to preserve brake systems in antique vehicles and those that sit for long periods of time between use. Silicone also has slightly different physical properties and compressibility, making it unsuitable for ABS systems calibrated to work with DOT 3 or 4 brake fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 4591 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures When bleeding ABS systems use only diaphragm type bleed pressure bleeder. 1. Turn ignition switch to Off position, then pump brake pedal a minimum of 40 times to de-pressurize hydraulic accumulator. 2. Attach bleeding equipment to brake reservoir. 3. Connect a suitable transparent hose to bleeder valve on left rear wheel cylinder and submerge other end in a glass container partially filled with clean brake fluid. 4. Turn pressure bleeder On, open brake bleed screw 3/4 to one turn. Allow brake fluid to flow until clear and bubble free. 5. Continue to bleed right rear, left front, then right front brakes in that order. 6. Turn Off pressure bleeder, then slowly bleed off pressure from equipment. 7. Remove pressure bleeder from vehicle, ensure proper fluid level in master cylinder. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations Brake Warning Indicator: Locations Engine Compartment Components. LH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations > Page 4595 Engine Compartment & Transaxle Components. LH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations > Page 4596 Brake Warning Indicator: Description and Operation The brake warning light is designed to light only when either: The parking brake is applied with the ignition key turned "ON". - One of the two service brake systems has failed. Bulb Check The instrument panel bulb can be checked each time the ignition switch is turned to the start position or the parking brake is set. Pressure Differential Warning Light Switch Purpose The function of the Pressure Differential Switch is to alert the driver to a malfunction in the brake system. Operation The hydraulic brake system is split diagonally. The left front and right rear brakes are part of one system and the right front and left rear are part of another. Both systems are routed through, but hydraulically separated by the Pressure Differential Switch. If hydraulic pressure is lost in one system, the warning light switch will activate a red light on the instrument panel, when the brake pedal is depressed. At this point the brakes require service. - However, since the brake systems are split diagonally the vehicle will retain 50% of its stopping capability in the event of a failure in either half. The warning light switch is the latching type. It will automatically recenter itself after the repair is made and the brake pedal Is depressed. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations > Page 4597 Brake Warning Indicator: Testing and Inspection Bulb Check The instrument panel bulb can be checked each time the ignition switch is turned to the start position or the parking brake is set. Pressure Differential Warning Light Switch Circuit Check 1. Raise and support vehicle, then open a wheel cylinder bleeder valve. 2. Press down on brake pedal and observe brake warning lamp. If lamp fails to illuminate, inspect for the following: a. Faulty bulb. b. Disconnected electrical socket. c. A broken or disconnected wire at the switch, located in the brake line "T" fitting, mounted on frame rail in engine compartment below master cylinder. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Bleed Screw 80-170 in.lb Caliper Guide Pins 25-35 ft.lb Caliper Adapter Mounting bolt 130-190 ft.lb Caliper Bearing Retainer Mounting Bolt 200-300 in.lb Brake Hoses to Calipers (Banjo Bolts) 19-29 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Diagrams > Kelsey-Hayes Double Pin Floating Caliper Fig 2 Disc Brake Caliper Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Diagrams > Kelsey-Hayes Double Pin Floating Caliper > Page 4604 Single Pin Disc Brake Caliper Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Diagrams > Page 4605 Brake Caliper: Application and ID Single Pin Disc Brake Caliper Kelsey Hayes Single Pin Caliper Fig 2 Disc Brake Caliper Kelsey Hayes Double Pin Caliper Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Kelsey-Hayes Double Pin Floating Caliper Brake Caliper: Description and Operation Kelsey-Hayes Double Pin Floating Caliper Fig 2 Disc Brake Caliper Fig. 1 Kelsey-Hayes Dual Pin Floating Caliper Disc Brake Assembly The double pin caliper consists of a driving hub, braking disc, caliper, pads and adapter on vehicles without an integral knuckle. The caliper is mounted through two bushings and sleeves. An anti-rattle clip is attached to the outer pad and the inner pad has a retainer clip. The caliper is a one piece casting with the inboard side containing a single piston and bore. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Kelsey-Hayes Double Pin Floating Caliper > Page 4608 Brake Caliper: Description and Operation Kelsey-Hayes Single Piston Sliding Caliper Disc Break Assembly Caliper Mounting Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Kelsey-Hayes Double Pin Floating Caliper > Page 4609 Single Pin Disc Brake Caliper OPERATION The single piston caliper assembly floats through a rubber bushing on a single pin threaded into the adapter. The bushing is inserted into the inboard portion of the caliper. Two machined abutments on the adapter position and align the caliper fore and aft. The guide pin and bushing controls the movement of the caliper and the piston seal to assist in maintaining proper shoe clearance. All of the braking force is taken directly by the adapter. The caliper is a one-piece casting with the inboard side containing a single piston cylinder bore. CONSTRUCTION Caliper Assembly Consists of a rotor, caliper, shoes and linings, and adapter. Piston The phenolic piston is 2.13 inches in diameter. Fig. 2 Piston Seal Function Seal A square cut rubber piston seal is located in a machined groove in the caliper bore and provides a seal between piston and caliper bore. Boot A molded rubber dust boot installed in a groove in the cylinder bore and piston keeps contamination from the caliper bore and piston. The boot mounts in the caliper bore and in a groove in the piston. Anti-Rattle Clips This assembly has three anti-rattle clips. One is on top of the inboard shoe, one clip is on the bottom of the outboard shoe, and one clip is on top of the caliper. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Page 4610 Brake Caliper: Testing and Inspection WITH CALIPER ON VEHICLE Check for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper assembly and install a new seal and boot, (and piston if corroded or scored). Check the mating surfaces of the abutments on the caliper and adapter. If corroded or rusty, clean surfaces with wire brush. Inspect braking surfaces of disc. Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or brittle. WITH CALIPER REMOVED Cleaning Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air. Blow out all drilled passages and bores. NOTE: Whenever a caliper has been disassembled, a new boot and seal must be installed at reassembly. Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). - If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Kelsey-Hayes Double Pin Caliper For additional information see Removal Notes. See: Fundamentals and Basics Fig. 1 Kelsey-Hayes Dual Pin Floating Caliper Disc Brake Assembly Fig 2 Disc Brake Caliper NOTE: If a shoe and lining does not require replacement, reinstall, making sure each shoe is returned to the original position. 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies. 3. Remove caliper to knuckle attaching bolts. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4613 Fig 3 Removing Caliper And Brake Shoes As An Assembly 4. Pull lower end of the caliper out from the machined abutment on the steering knuckle and roll caliper out and away from braking disc. The shoe assemblies will remain with the caliper. Fig 4 Prying Outboard Shoe Assembly Away From Caliper 5. Remove outboard shoe by prying between shoe and caliper. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4614 Fig 5 Removing Or Installing Inboard Shoe Assembly 6. Remove the inboard shoe from the assembly by pulling the shoe and lining assembly away from the piston. Kelsey-Hayes Single Pin Caliper For additional information see Removal Notes. See: Fundamentals and Basics Single Pin Disc Brake Caliper 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4615 Removing Or Installing Guide Pin 3. Remove caliper guide pin. Loosening Caliper 4. After removing caliper guide pin, wedge the caliper away from the braking disc with a screwdriver to break the gasket adhesive seals. Removing Or Installing Caliper 5. Remove caliper from disc by slowly sliding caliper assembly out and away from braking disc. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4616 Hanging Caliper Out Of The Way 6. Support caliper firmly to prevent weight of caliper from damaging the flexible hose. Removing Or Installing Outboard Shoe Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4617 Removing Or Installing Brake Disc Removing Or Installing Inboard Shoe Assembly 7. Remove the outboard shoe assembly. Fig 2 Marking Brake Disc And Wheel Stud For Reassembly 8. Mark disc and stud for assembly. 9. Remove braking disc from drive flange studs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4618 10. Remove the inboard shoe assembly. Kelsey-Hayes Double Pin Caliper For additional information see Installation Notes. See: Fundamentals and Basics Fig 2 Disc Brake Caliper 1. Lubricate both adapter ways with a liberal amount of Mopar Multipurpose Lubricant Part Number 4318063, or equivalent. Fig. 4 Brake Pad Identification 2. The inboard brake shoes are common. The outboard shoes are marked with an "L" or "R" denoting which side of the vehicle they should be installed on. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4619 Fig 5 Removing Or Installing Inboard Shoe Assembly 3. Install new inboard brake pad assembly in caliper, entering retainer into the bore in the piston. Fig 7 Installing Outboard Shoe Assembly Onto Caliper 4. Remove protective paper from the noise suppression gasket and position the properly marked outboard shoe hold-down spring onto caliper. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4620 Fig 3 Removing Caliper And Brake Shoes As An Assembly 5. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment on knuckle assembly. 6. Install attaching bolts and tighten to 24-34 Nm (18-25 ft lb). CAUTION: When installing attaching bolts, use extreme caution not to cross the threads. 6. Install wheel and tire assembly. Tighten stud nuts in the proper sequence until all nuts are torqued to half specification. THIS IS IMPORTANT. Then repeat sequence to full specification. 7. Remove jackstands or lower hoist. CAUTION: Before moving vehicle, be sure it has a firm pedal. 8. Road test vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings. The vehicle may pull to one side or the other if this is not done. Kelsey-Hayes Single Pin Caliper For additional information see Installation Notes. See: Fundamentals and Basics Single Pin Disc Brake Caliper 1. Push piston back into cylinder bore with uniform pressure until it is bottomed. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4621 Removing Or Installing Inboard Shoe Assembly Removing Or Installing Brake Disc 2. Position inboard pad on adapter. Fig 2 Marking Brake Disc And Wheel Stud For Reassembly 3. Slide brake disc assembly on drive flange studs. Pay attention to marks for assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4622 4. Clean both sides of braking disc with alcohol or suitable solvent. Removing Or Installing Outboard Shoe Removing Or Installing Caliper 5. While holding outboard pad in position on adapter, carefully position caliper over disc brake rotor. 6. Lower caliper over rotor and adapter. 7. Install guide pin through bushing caliper and adapter. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4623 Removing Or Installing Guide Pin 8. Press in on guide pin and thread pin into adapter. Torque pin to 25-35 ft lb. 9. Install wheel and tire assembly, then lower vehicle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4624 Brake Caliper: Service and Repair Disassembly and Assembly Cleaning, Inspecting & Honing Caliper Honing Brake Caliper Piston Bore Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, using Tool C-4095, providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). - If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. When using a hone: Coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff nonmetallic rotary brush. Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lintless cloth and then clean a second time. Be sure to install the hone baffle before honing bore. - The baffle is used to protect the hone stones from damage. Use extreme care in cleaning the caliper after honing. Kelsey-Hayes Single Pin Caliper DISASSEMBLING CALIPER 1. Support caliper assembly on upper control arms on shop towels to absorb any hydraulic fluid loss. 2. Place a small piece of wood between the piston and caliper fingers. 3. Carefully depress brake pedal to hydraulically push piston out of bore (brake pedal will fall away when piston has passed bore opening). 4. Prop brake pedal to any position below the first inch of pedal travel -- to prevent loss of brake fluid. If both front caliper pistons are to be removed: 1. Disconnect flexible brake line at frame bracket after removing piston. 2. Plug brake tube and remove piston from opposite caliper. CAUTION: Under no condition should air pressure be used to remove piston from bore! Personal Injury could result from such practice. 3. Disconnect brake flexible hose from the caliper. 4. To disassemble, mount caliper assembly in a vise equipped with protective jaws. CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4625 Fig. 10 Dust Boot Removal 5. Support caliper and remove dust boot and discard. Removing Piston Seal From Caliper 6. Using a plastic trim stick, work piston seal out of its groove in piston bore. Discard old seal. Do not use a screwdriver or other metal tool for this operation, because of possibility of scratching piston bore or burring edges of seal groove. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4626 Fig 11 Removing Bushings 7. Remove bushing from caliper by pressing out of bore, using a suitable tool. Discard bushing. CLEANING AND INSPECTION Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air. Blow out all drilled passages and bores. NOTE: Whenever a caliper has been disassembled, a new boot and seal must be installed at reassembly. Honing Brake Caliper Piston Bore Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). - If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. When using a hone: Coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff nonmetallic rotary brush. Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lintless cloth and then clean a second time. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4627 ASSEMBLING CALIPER 1. Clamp caliper in vise (with protector jaws). CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. Installing New Piston Seal In Caliper 2. Dip new piston seal in clean brake fluid and install in groove in bore. Seal should be positioned at one area in groove and gently worked around the groove, using fingers until properly seated. CAUTION: NEVER USE AN OLD PISTON SEAL. (Be sure that fingers are clean and seal is not twisted or rolled). 3. Coat new piston boot with clean brake fluid leaving a generous amount inside of boot. 4. Position dust boot over piston after coating with brake fluid. Fig. 4 Caliper piston installation 5. Install piston into bore pushing it past the piston seal until it bottoms in the bore. CAUTION: Force must be applied uniformly to avoid cocking the piston. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4628 6. Position dust boot in counterbore. Using a hammer and Tool C4842 with C4171 handle or equivalent, drive boot into counterbore. Fig 16 Installing Bushings 7. Compress flanges of guide pin bushings in with fingers and work into position by pressing IN on bushings, using fingertips or plastic trim stick until seated. 8. Be sure flanges extend over caliper casting evenly on both sides. 9. Before installing caliper assembly on vehicle, inspect braking disc. 10. Install brake hose to caliper using new seal washers. 11. Bleed the brake system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes Brake Caliper: Fundamentals and Basics Removal Notes When Removing the Caliper, Remember... - Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir is only 1/3 full. - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining thickness between wheels on the same axle will result in a strong steering pull when the brakes are applied. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. - When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is forced back into the caliper, these deposits will be forced back through the brake lines and into the master-cylinder. - When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake fluid will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to "shoot" brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose and a glass or plastic jar to catch the expelled fluid. - Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses can be damaged easily by this practice. These hoses are double walled, damage to the interior pressure hose will not be visible. - Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not attempt to insert the piston back into the caliper. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 4631 Brake Caliper: Fundamentals and Basics Installation Notes WHEN INSTALLING CALIPERS AND PADS, REMEMBER... - Clean and lubricate caliper slide joint/pins with high temperature silicone grease: Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted movement of the caliper slide assemblies to release the brakes. If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon the release of the brake pedal. This will result in overheated brakes and premature brake wear. Disc Brake Mechanical Force Diagram NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel forces the inner pad against the rotor, then further travel forces the movable part of the caliper to pull the outer pad against the rotor. High temperature silicone lubricant must be used. Low temperature grease can melt and contaminate the pads and rotors, or can bake into a very hard substance which binds the slides. Petroleum based grease can cause the slide boots to soften and swell. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. Anti-squeal Coating - Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an insulator to dampen high frequency vibrations that are generated during normal braking. These compounds are highly effective in preventing brake squeal. - Many professional repair shops recommend always rebuilding or replacing the calipers when replacing the brake linings, because: When the pistons are forced back into the calipers, the piston seals are dragged across any corrosion or abrasives that may be deposited on the inside of the caliper. Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston is gradually withdrawn from the caliper. This results in the piston seals again being dragged across the layer of corrosion and deposits. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 4632 Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking. - Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck bleeder screw is much easier with the caliper removed from the vehicle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Minimum Combined Thickness Of Lining And Backing 0.313 in Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4636 Brake Pad: Service Precautions Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective shoe and lining is worn or damaged. Inspect and, if necessary, replace rear brake linings also. If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4637 Brake Pad: Application and ID Single Pin Disc Brake Caliper Kelsey Hayes Single Pin Caliper Fig 2 Disc Brake Caliper Kelsey Hayes Double Pin Caliper Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation Brake Pad: Service and Repair Removal and Installation Removal For additional information see Removal Notes. See: Brake Caliper/Fundamentals and Basics Fig. 1 Kelsey-Hayes Dual Pin Floating Caliper Disc Brake Assembly Fig 2 Disc Brake Caliper NOTE: If a shoe and lining does not require replacement, reinstall, making sure each shoe is returned to the original position. 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies. 3. Remove caliper to knuckle attaching bolts. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4640 Fig 3 Removing Caliper And Brake Shoes As An Assembly 4. Pull lower end of the caliper out from the machined abutment on the steering knuckle and roll caliper out and away from braking disc. The shoe assemblies will remain with the caliper. Fig 4 Prying Outboard Shoe Assembly Away From Caliper 5. Remove outboard shoe by prying between shoe and caliper. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4641 Fig 5 Removing Or Installing Inboard Shoe Assembly 6. Remove the inboard shoe from the assembly by pulling the shoe and lining assembly away from the piston. Installation For additional information see Installation Notes. See: Brake Caliper/Fundamentals and Basics Fig 2 Disc Brake Caliper 1. Lubricate both adapter ways with a liberal amount of Mopar Multipurpose Lubricant Part Number 4318063, or equivalent. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4642 Fig. 4 Brake Pad Identification 2. The inboard brake shoes are common. The outboard shoes are marked with an "L" or "R" denoting which side of the vehicle they should be installed on. Fig 5 Removing Or Installing Inboard Shoe Assembly 3. Install new inboard brake pad assembly in caliper, entering retainer into the bore in the piston. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4643 Fig 7 Installing Outboard Shoe Assembly Onto Caliper 4. Remove protective paper from the noise suppression gasket and position the properly marked outboard shoe hold-down spring onto caliper. Fig 3 Removing Caliper And Brake Shoes As An Assembly 5. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment on knuckle assembly. 6. Install attaching bolts and tighten to 24-34 Nm (18-25 ft lb). CAUTION: When installing attaching bolts, use extreme caution not to cross the threads. 6. Install wheel and tire assembly. Tighten stud nuts in the proper sequence until all nuts are torqued to half specification. THIS IS IMPORTANT. Then repeat sequence to full specification. 7. Remove jackstands or lower hoist. CAUTION: Before moving vehicle, be sure it has a firm pedal. 8. Road test vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings. The vehicle may pull to one side or the other if this is not done. Removal For additional information see Removal Notes. See: Brake Caliper/Fundamentals and Basics Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4644 Single Pin Disc Brake Caliper 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies. Removing Or Installing Guide Pin 3. Remove caliper guide pin. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4645 Loosening Caliper 4. After removing caliper guide pin, wedge the caliper away from the braking disc with a screwdriver to break the gasket adhesive seals. Removing Or Installing Caliper 5. Remove caliper from disc by slowly sliding caliper assembly out and away from braking disc. Hanging Caliper Out Of The Way Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4646 6. Support caliper firmly to prevent weight of caliper from damaging the flexible hose. Removing Or Installing Outboard Shoe Removing Or Installing Brake Disc Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4647 Removing Or Installing Inboard Shoe Assembly 7. Remove the outboard shoe assembly. Fig 2 Marking Brake Disc And Wheel Stud For Reassembly 8. Mark disc and stud for assembly. 9. Remove braking disc from drive flange studs. 10. Remove the inboard shoe assembly. Installation For additional information see Installation Notes. See: Brake Caliper/Fundamentals and Basics Single Pin Disc Brake Caliper 1. Push piston back into cylinder bore with uniform pressure until it is bottomed. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4648 Removing Or Installing Inboard Shoe Assembly Removing Or Installing Brake Disc 2. Position inboard pad on adapter. Fig 2 Marking Brake Disc And Wheel Stud For Reassembly 3. Slide brake disc assembly on drive flange studs. Pay attention to marks for assembly. 4. Clean both sides of braking disc with alcohol or suitable solvent. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4649 Removing Or Installing Outboard Shoe Removing Or Installing Caliper 5. While holding outboard pad in position on adapter, carefully position caliper over disc brake rotor. 6. Lower caliper over rotor and adapter. 7. Install guide pin through bushing caliper and adapter. Removing Or Installing Guide Pin Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4650 8. Press in on guide pin and thread pin into adapter. Torque pin to 25-35 ft lb. 9. Install wheel and tire assembly, then lower vehicle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4651 Brake Pad: Service and Repair Cleaning and Inspection Remove one of the front wheels and inspect the brake disc, caliper and linings. If linings are contaminated replace them with fresh linings. If a visual inspection does not adequately determine lining condition, remove the pads and measure the total thickness of lining and backing at the thinnest point. If combined thickness of lining and backing is 7.95 mm (5/16 in) or less replace pads. CAUTION: Do not get any oil or grease on the linings. NOTES: The wheel bearings should be inspected at this time and repacked if necessary. - It is recommended that all front wheel pads -- both sides -- be replaced whenever any front pad is worn or damaged. - Rear brake linings should be inspected when a brake problem is suspected. - Uneven wear of linings on different sides of the caliper or vehicle may indicate a sticking caliper. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Nominal Thickness 0.870-0.861 in Minimum Thickness 0.803 in Total Indicated Runout (TIR) 0.005 in Hub Runout 0.003 in Thickness Variation (Maximum) 0.0005 in Measured in 12 places 1" from edge of disc Finish 15-80 micro-in Fig 1 Checking Total Indicated Runout (TIR) Fig 3 Checking Hub Runout Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4655 Fig 5 Checking Disc Thickness Fig 7 Refacing Brake Disc -- Final Finish Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4656 Brake Rotor/Disc: Service Precautions When machining brake discs it is essential to use precision equipment designed for this purpose to insure proper brake operation. Friction surfaces must have a non-directional, micro-inch finish to prevent brake roughness, avoid pulls and erratic performance and promote long lining life and equal lining wear of both left and right brakes. Do not attempt to refinish brake rubbing surfaces unless equipment, capable of measuring in micro-inches is available. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4657 Brake Rotor/Disc: Testing and Inspection NOTE: If a vehicle has not been driven for a period of time, the discs will rust in the area not covered by the lining and cause noise and chatter. NOTE: Some discoloration or wear of the disc surface is normal and does not require re-surfacing when linings are replaced. CAUTION: Any servicing of the braking disc requires extreme care to maintain the braking disc within service tolerances to ensure proper brake action. BEFORE REFINISHING OR REFACING A BRAKING DISC INSPECT FOR: - Scoring, rust, impregnation of lining material and worn ridges. - Excessive wear and scoring of the disc CAUTION: Excessive wear and scoring of the disc can cause temporary improper lining contact if ridges are not removed before installation of new brake shoe assemblies. - Runout or wobble CAUTION: Excessive runout or wobble in a disc can increase pedal travel due, to piston knockback This will increase guide pin bushing wear due to tendency of caliper to follow disc wobble. - Thickness variation (Parallelism). NOTE: Thickness variation in a disc can also result in pedal pulsation, chatter and surge due to variation in brake output when disc section is uneven. - Dishing or distortion (Flatness). NOTE: Dishing or distortion can be caused by extreme heat and abuse of the brakes. SPECIFICATION - See: Specifications Fig 1 Checking Total Indicated Runout (TIR) MEASURING TOTAL DISC RUNOUT ON VEHICLE: NOTE: On Vehicle, Braking Disc (rotor) Runout is the combination of the individual runout of the hub face and the runout of the disc. The hub and disc are separable. NOTE: Before checking the runout, wheel bearings should be adjusted. 1. Remove the wheel and reinstall the lug nuts to tighten the disc to the hub. 2. Mount dial indicator with adapter on steering arm with plunger contacting disc braking surface approximately one inch from edge of disc. 3. Check lateral runout (both sides of disc). - Runout should not exceed 0.13mm (0.005 inch). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4658 - If total runout is in exceeds specification check the lateral runout of the hub face. Fig 2 Marking Brake Disc And Wheel Stud For Reassembly MEASURING LATERAL RUNOUT OF THE HUB FACE: 1. Before removing disc, make a chalk mark across both the disc and one wheel stud, on the high side of runout, so you'll know exactly how the disc and hub was originally mounted. 2. Remove disc from hub. Fig 3 Checking Hub Runout 3. Install dial indicator with adapter on steering arm with stem contacting hub face near outer diameter (care must be taken to position dial indicator stem outside the stud circle but inside the chamfer on the hub rim. Runout should not exceed 0.05mm (0.002 inch). If runout exceeds this specification, hub must be replaced. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4659 Fig 4 Indexing Disc And Wheel Stud - If hub runout does not exceed this specification, install disc on hub with chalk marks 180 degrees apart. 4. Finally, recheck runout of disc to see if runout is now within specifications. - If runout is in excess of specifications, install a new disc or reface disc, being careful to remove as little as possible from each side of disc. Remove equal amounts from each side of disc. Do not reduce thickness below the recommended minimum thickness. NOTE: Thickness variation measurements of disc should be made in conjunction with runout. Fig 5 Checking Disc Thickness THICKNESS VARIATION MEASUREMENTS Measure thickness of disc at twelve (12) equal points with a micrometer at a radius approximately 25.4 mm (one (1) inch) from edge of disc. If thickness measurements vary by more than 13 mm (0.0005 inch) disc should be removed and resurfaced, or a new disc installed. - If cracks or burned spots are evident in the disc, disc must be replaced. - For additional information on how to use a micrometer, see Fundamentals and Basics.See: Fundamentals and Basics NOTE: Light scoring and/or wear Is acceptable: If heavy scoring or warping is evident, the disc must be refinished or replaced. - If cracks are evident in the disc, replace the disc. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Rotor Removal and Installation Brake Rotor/Disc: Service and Repair Rotor Removal and Installation Removal 1. Raise vehicle on hoist or jackstands. 2. Remove wheel and tire assembly. Hanging Caliper Out Of The Way 3. Remove caliper assembly, but do not disconnect brake line. 4. Suspend caliper from wire hook or loop to avoid strain on flexible hose. Fig 2 Marking Brake Disc And Wheel Stud For Reassembly 5. Mark disc and stud for assembly. 6. Remove braking disc from drive flange studs. Installation Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Rotor Removal and Installation > Page 4662 Fig 2 Marking Brake Disc And Wheel Stud For Reassembly 1. Slide brake disc assembly on drive flange studs. Pay attention to marks for assembly. 2. Clean both sides of braking disc with alcohol or suitable solvent. 3. Install caliper assembly. For additional information see Installation Notes. See: Fundamentals and Basics Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Rotor Removal and Installation > Page 4663 Brake Rotor/Disc: Service and Repair Rotor Refinishing CAUTION: When refacing a disc brake rotor the required 0.10 mm (0.004 inch) TIR (Total Indicator Reading) and 0.013 mm (0.0005 in.) thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required. Resurfacing Notes: This operation can be used when the disc surface is rusty or has lining deposits. A sanding disc attachment will remove surface contamination without removing much material. - It will generally follow variations in thickness which are in the disc. Refacing Braking Disc Notes: Rotors do not have to be refaced whenever a disc brake is relined. - If the rotor surface is deeply scored or warped or there is a complaint of brake roughness the rotor should be refaced. - The collets, shafts and adaptors on the lathe and the bearing cups in the rotor MUST be clean and free from any chips or contamination. - When mounting the disc on the lathe, strict attention to the manufacturer's instructions is required. - If the disc is not mounted properly the run-out will be worse after refacing than before refacing. Fig 6 Refacing Brake Disc Fig 7 Refacing Brake Disc -- Final Finish Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Rotor Removal and Installation > Page 4664 - The use of a double straddle cutter which machines both sides of the disc at the same time is highly recommended. Fig 8 Minimum Disc Thickness Marking Fig 8 Minimum Disc Thickness Marking Measurements and specifications when servicing the braking disc: NOTE: All braking discs (rotors) have markings for minimum allowable thickness cast on an un-machined surface. This marking includes 0.76 mm (0.030 inch) allowable disc wear beyond the recommended 0.76 mm (0.030 inch) of disc refacing. - This surface may be as shown, or on an alternate surface. Do Not Reface Beyond ........................................................................................................................ ....................................... 21.16 mm (0.833 in) Allows for Wear of 0.76mm (0.030 in.) Minimum Allowable Thickness ................................................................................................................................................ 20.4Omm (0.803 in) NOTE: For additional information on how to use a micrometer, see Fundamentals and Basics. See: Fundamentals and Basics Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Fundamentals and Basics > How to Use A Micrometer Brake Rotor/Disc: Fundamentals and Basics How to Use A Micrometer CONSTRUCTION The spindle on a micrometer is moved in or out by rotating the thimble or ratchet. The thread pitch on the spindle is 40 threads per inch. A single full rotation of the thimble extends or retracts the spindle one thread or 1/40 of an inch (0.025, 25 thousands). The thimble is divided into 25 equal divisions. Rotating the thimble one division will extend or retract the spindle 1/25 of a thread. (1/25) x (1/40)inch = 1/1000 inch (0.001), one division on the thimble is equal to 0.001 inches. HOW TO READ As the thimble is rotated out it uncovers a scale on the sleeve. Each major division on the scale is 1/10 of an inch (0.100) Each major division is separated into 4 minor divisions, each equal to 25/1000 of an inch (0.025). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Fundamentals and Basics > How to Use A Micrometer > Page 4667 A full rotation will move the thimble exactly one minor division on the sleeve. To read the micrometer you must add the measurement which is visible on the sleeve to the measurement which is showing on the thimble In the example the sleeve measurement is 0.250 inches and the thimble measurement is 0.017 inches. The total measurement is then equal to the two measurements combined, 0.267 inches. NOTES The accuracy and calibration of a micrometer can be altered easily by applying too much pressure to the spindle. Use the thimble to quickly rotate the spindle in until it is near the rotor. - Use the ratchet to rotate the spindle into contact with the rotor. - The ratchet has a built in slip which prevents excessive stress or pressure from developing. Calibrate the micrometer regularly. Most micrometers come with a precision dowel which allows for easy and accurate adjustments. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Fundamentals and Basics > How to Use A Micrometer > Page 4668 Brake Rotor/Disc: Fundamentals and Basics Installation Notes WHEN INSTALLING A ROTOR/DISC, REMEMBER... Thoroughly clean the rotors with brake cleaner. - Any grease or brake fluid which comes in contact with the rotor should be thoroughly cleaned prior to installing the new pads/linings. - Grease and other contaminants become lodged in the microscopic pores of the rotor's surface. This prolongs the brake-in time of the new linings and contaminates the friction material. - Commercially produced aerosol brake cleaners should be used to clean the rotor. Unlike carburetor cleaner or other petroleum based solvents, brake cleaner does not leave a residue on the rotor's surface. Recheck the wheel bearings once the tires are installed. - With the vehicle raised and properly supported, grasp the tire at the top and bottom and attempt to rock them back and forth. There should be no detectable lateral (wobble) movement. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Fundamentals and Basics > How to Use A Micrometer > Page 4669 Brake Rotor/Disc: Fundamentals and Basics Tightening Notes WHEN TIGHTENING LUG NUTS, REMEMBER... Always tighten the lug nuts to the correct torque specification. Lightly lubricate the studs with an anti-seize compound to ensure proper torque and prevent damage to the threads. Tighten in an alternating pattern around the wheel until the wheel is centered on the studs. Do your final tightening with a torque wrench. When servicing disc brakes it is very important to properly torque the wheel assembly. Lug nuts which are installed with an air impact tool are often over-torqued. This may distort the rotor and result in excessive lateral runout (rotor wobble) and a pedal pulsation upon braking. Recheck the wheel bearings once the tires are installed. With the vehicle raised and properly supported, grasp the tire at the top and bottom and attempt to rock them back and forth. There should be no detectable lateral (wobble) movement. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Brake support plate to rear axle bolts ............................................................................................................................................... 88-129 Nm (65-95 ft lb) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4674 Backing Plate: Testing and Inspection Inspect backing plate shoe contact surface for grooves that may restrict shoe movement and cannot be removed by lightly sanding with emery cloth or other suitable abrasive. If backing plate exhibits above condition, it should be replaced. Also inspect for signs of cracks, warpage and excessive rust, indicating need for replacement. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4675 Backing Plate: Service and Repair Fig 9 Removing Brake Cable From Backing Plate REMOVAL 1. With wheel and brake drum removed, remove brake shoe assemblies and disconnect brake cable from parking brake lever. 2. Using a suitable tool such as an aircraft type hose clamp compress the flared legs of cable retainer and pull brake cable out of support plate. 3. Disconnect hydraulic brake tube from wheel cylinder. 4. Remove support to wheel cylinder attaching nuts and washers. 5. Remove brake support and spindle mounting screws. 6. Remove brake support, spindle and gasket from rear axle. Fig 1 Rear Wheel Brake INSTALLATION 1. Install support plate, spindle and gasket to rear axle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4676 Brake Shoe Contact Pads On Backing (Support) Plate 2. Apply RTV sealant around wheel cylinder mounting surface. 3. Install wheel cylinder and attach hydraulic brake tube. 4. Insert parking brake cable into support plate and attach cable to parking brake lever. 5. Install brake shoes on support plate. 6. Install brake drum and wheel. Adjust and bleed brakes. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection Brake Drum: Testing and Inspection Fig 5 Drum Maximum Diameter Specification NOTE: Any brake drum sufficiently out of round to cause vehicle vibration or noise while braking, or showing taper should also be machined, removing only enough stock to true up the brake drum. If the braking surface diameter is within specifications: Drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. - Minor scores should be removed with sandpaper. - Grooves and large scores can only be removed by machining with special equipment, as long as the braking surface is within specifications stamped on brake drum outer surface. Measuring Drum Runout and Diameter NOTE: Measure the drum runout and diameter with an accurate gauge. Maximum Variation There should be no variation in the drum diameter greater than 0.O5mm (0.002 in.). Maximum Runout Drum runout should not exceed 0.15mm (0.006 in.) out of round. - If the drum runout or diameter variation exceed these values the drum should be refaced. Maximum Single Cut For best results in eliminating the irregularities that cause brake roughness and surge, the amount of material removed during a single cut should be limited to 0.13mm (0.005 in.). Final Cut When the entire braking surface has been cleaned a final cut of 0.0254mm (0.001 in.) will assure a good drum surface providing the equipment used is capable of giving the precision required for resurfacing brake drums. Deeper cuts are permissible for the sole purpose of removing deep score marks. CAUTION: Do not reface more than 1.52mm (0.60 in.) over the standard drum diameter. NOTE: If one brake drum is machined, the other should also be machined to the same diameter to maintain equal braking forces. After a brake drum is machined: Wipe the braking surface diameter with a cloth soaked in denatured alcohol. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal Brake Drum: Service and Repair Brake Drum Removal For additional information see Notes, Warnings, and Hints. Fig. 9 Release Brake Adjuster Fig. 6 Release type brake adjuster 1. Remove the tire and wheel assembly. 2. Remove rear plug from brake adjusting access hole. 3. Insert a thin screwdriver into brake adjusting hole and hold adjusting lever away from notches of adjusting screw. 4. Insert Tool C-3784 or equivalent, into brake adjusting hole and engage notches of brake adjusting screw. Release brake by prying down with adjusting tool. NOTE: The rear hubs are held on by the axle nut which should be covered by a dust cap. Fig. 3 Wheel bearing assembly 5. Remove rear hub and drum assembly. 6. Inspect brake lining for wear, shoe alignment, or contamination from grease or brake fluid. Inspect wheel bearings for rust or signs of wear. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal > Page 4682 Brake Drum: Service and Repair Brake Drum Installation For additional information see Notes, Warnings, and Hints. NOTE: Reinstallation of retaining clips is not necessary. Fig. 3 Wheel bearing assembly 1. Install hub and drum assembly. - Torque adjusting nut to 270 inch lbs. while rotating wheel. - Stop wheel and loosen adjusting nut. Tighten adjusting nut finger tight. End play should be 0.0001---0.0020 inch. - Install castle lock with slots aligned with cotter pin hole. - Install cotter pin and grease cap. 2. Install wheel and tire assembly. - When tightening wheel stud nuts, using a criss-cross tightening sequence as shown. - Tighten all stud nuts to one-half specified torque. Repeat, fully tightening to specified torque. Fig 6 Wheel Stud Tightening Sequence - Wheel stud lug nut torque 110 - 135 Nm (85 - 115 ft lb) 3. Adjust rear brakes. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal > Page 4683 Brake Drum: Service and Repair Brake Drum Refinishing Fig 5 Drum Maximum Diameter Specification CAUTION: Do not reface more than 1.52mm (0.60 in.) over the standard drum diameter. NOTE: If one brake drum is machined, the other should also be machined to the same diameter to maintain equal braking forces. NOTE: All drums will show markings of maximum allowable diameter. For example, a drum will have a marking of MAX. Dia. 231.0mm (9.09 in.). This marking includes 0.76mm (0.030 in.) for allowable drum wear beyond the recommended 1.52mm (0.060 in.) of drum refacing. Measuring Drum Runout and Diameter NOTE: Measure the drum runout and diameter with an accurate gauge. Maximum Variation There should be no variation in the drum diameter greater than 0.O5mm (0.002 in.). Maximum Runout Drum runout should not exceed 0.15mm (0.006 in.) out of round. If the drum runout or diameter variation exceed these values the drum should be refaced. Maximum Single Cut For best results in eliminating the irregularities that cause brake roughness and surge, the amount of material removed during a single cut should be limited to 0.13mm (0.005 in.). Final Cut When the entire braking surface has been cleaned a final cut of 0.0254mm (0.001 in.) will assure a good drum surface providing the equipment used is capable of giving the precision required for resurfacing brake drums. Deeper cuts are permissible for the sole purpose of removing deep score marks. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments Brake Shoe: Adjustments Fig. 9 Release Brake Adjuster Fig. 6 Release type brake adjuster NOTE: Normally self adjusting drum brakes will not require manual adjustment but in the event of a brake reline it is advisable to make the initial adjustment manually to speed up the adjusting time. 1. Jack up vehicle so all wheels are free to turn. 2. Remove rear adjusting hole cover from brake supports of vehicle. 3. Be sure parking brake lever is fully released, then back off parking brake cable adjustment so there is slack In cable. 4. Insert adjusting tool C-3784 or equivalent, into star wheel of adjusting screw. Move handle of tool upward until a slight drag is felt when road wheel is rotated. 5. Insert a thin screwdriver or piece of welding rod into brake adjusting hole and push adjusting lever out of engagement with star wheel. CAUTION: Care should be taken so as not to bend adjusting lever or distort lever spring. 6. While holding adjusting lever out of engagement, back off star wheel to insure a free wheel with no brake shoe drag. 7. Repeat above adjustment at the other rear wheel. Install adjusting hole covers in brake supports. 8. Adjust parking brake after wheel brake adjustment. CAUTION: It is important to follow the above sequence to avoid the possibility of the parking brake system causing brake drag, if the parking brakes are adjusted before the service brakes. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation Brake Shoe: Service and Repair Brake Shoe Removal and Installation Removal For additional information see Notes, Warnings, and Hints. Fig 1 Rear Wheel Brake Fig 2 Removing And Installing Shoe Return Springs TIP: Unless you are very familiar with this rear brake system you should consider servicing one side at a time. This will leave you an example of how the pieces go back together. 1. Remove rear wheel, and hub and drum assembly. 2. Using tool C-3785 or equivalent, remove brake shoe return springs. NOTE: For additional information see Brake Spring Removal and Installation Notes. NOTE: The secondary shoe return spring overlaps the primary shoe return spring. 3. Slide the eye of automatic adjuster cable off anchor and then unhook from adjusting lever. 4. Remove cable, overload spring, cable guide and anchor plate. 5. Disengage adjusting lever from spring by sliding forward to clear pivot, then working out from under spring. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4689 6. Remove spring from pivot. 7. Remove shoe to shoe spring from secondary shoe web and disengage form primary shoe web. 8. Remove spring. 9. Disengage primary and secondary shoes and remove adjusting star wheel assembly from shoes. Fig 3 Removing And Installing Shoe Retainers, Springs And Nails 10. Remove brake shoe retainers, springs and nails using Tool C-4070 or equivalent and remove from support. 11. Remove parking brake lever from secondary shoe. 12. Remove shoes. 13. Disengage parking brake lever from the parking brake cable. Installation For additional information see Notes, Warnings, and Hints. Fig 1 Rear Wheel Brake Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4690 Brake Shoe Contact Pads On Backing (Support) Plate NOTE: Lubricate the six shoe tab contact pads on support plate with a thin film of MOPAR MultiPurpose Lubricant, Part number 2932524 or equivalent. Fig 3 Removing And Installing Shoe Retainers, Springs And Nails 1. Slide primary shoe against support plate, at the same time engage shoe web with wheel cylinder piston and against anchor. Using tool C-4070 or equivalent install shoe retaining nail, retainer, and spring. NOTE: For additional information see Brake Spring Removal and Installation Notes. Fig 7 Removing Of Installing Parking Brake Strut And Spring Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4691 2. Install anchor plate over anchor, then install eye of adjuster cable over anchor. Fig 2 Removing And Installing Shoe Return Springs 3. Engage primary shoe return spring in web of shoe and install free end over anchor. 4. Slide parking brake strut into slot in parking brake lever. Slide anti-rattle spring over free end of strut. 5. Engage parking brake lever with cable. Install parking brake lever into rectangular hole of secondary brake shoe. Installing Brake Shoes 6. Slide secondary shoe into position and engage with wheel cylinder piston and free end of strut. Install shoe retaining nail, retainer, and spring. 7. Insert protruding hole rim of cable guide into hole in secondary shoe web. Holding guide in position, engage secondary shoe return spring through both, hole in guide, and hole in web. Using Tool C-3785, install spring over anchor. Be sure cable guide remains flat against shoe web and that secondary spring overlaps primary). - Using pliers, squeeze ends of spring loops (around anchor) until parallel. 8. Install adjusting star wheel assembly between primary and secondary shoes, with star wheel next to secondary shoe. - The left star wheel adjusting stud end is stamped "L" (indicating its position on the vehicle) and the star wheel is cadmium plated. - The right star wheel is black and the adjusting stud end is stamped "R". Install shoe to shoe spring between shoes. - Engage primary shoe first. 9. Install adjusting lever spring over pivot pin on shoe web. Install adjusting lever under spring and over pivot pin. Slide lever slightly rearward to lock in position. 10. Thread adjuster cable over guide and hook end of overload spring in lever. - Be sure eye of cable is pulled tight against anchor and in a straight line with guide. 11. Check operation of automatic application adjuster by pulling adjuster cable rearward. Star wheel should rotate upwards. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4692 Brake Shoe: Service and Repair Cleaning and Inspection Inspect brake linings for excessive wear, damage, oil, grease or brake fluid contamination. If any of the above conditions exists, brake linings should be replaced. Do not attempt to replace only one set of brake shoes; they should be replaced as an axle set only to maintain equal braking forces. Examine brake shoe webbing, hold-down and return springs for signs of overheating indicated by a slight blue color. If any component exhibits signs of overheating, replace hold-down and return springs with new ones. Overheated springs lose their pull and could cause brake linings to wear out prematurely. Inspect all springs for sags, bends and external damage, and replace as necessary. Inspect hold-down retainers and pins for bends, rust and corrosion. If any of the above conditions exist, replace retainers and pins. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Bore Diameter Wheel Cylinder: Specifications Rear Wheel Cylinder Bore Diameter 0.75 in Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Bore Diameter > Page 4697 Wheel Cylinder: Specifications Hydraulic Brake Tubes To All Fittings (if Not Specified) 115-170 in.lb Wheel Cylinder To Rear Brake Support Plate 75 in.lb Wheel Cylinder Bleed Screw 60-100 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 4698 Fig 3 Wheel Cylinder Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal Wheel Cylinder: Service and Repair Wheel Cylinder Removal Fig 1 Brake Tube Disconnected 1. In case of a leak, remove brake shoes, (replace if soaked with grease or brake fluid). 2. Disconnect brake tube from wheel cylinder. Fig 2 Removing Or Installing Wheel Cylinder 3. Remove wheel cylinder attaching bolts, then pull wheel cylinder assembly out of support. For additional information see Notes, Warnings, and Hints. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 4701 Wheel Cylinder: Service and Repair Wheel Cylinder Installation For additional information see Notes, Warinings, and Hints. Brake Shoe Contact Pads On Backing (Support) Plate 1. Apply RTV sealant around wheel cylinder mounting surface. Fig 2 Removing Or Installing Wheel Cylinder Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 4702 Fig 1 Brake Tube Disconnected 2. Slide wheel cylinder into position on support. Install mounting screws and tighten as specified. 3. Connect brake tube to wheel cylinder. 4. Insert parking brake cable into support plate and attach cable to parking brake lever. 5. Install brake shoes on support plate. 6. Install brake drum and wheel. 7. Adjust and bleed brakes. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 4703 Wheel Cylinder: Service and Repair Cleaning and Inspection Fig 3 Wheel Cylinder 1. With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. 2. Block brake pedal in stroke position, visually check the boots for cuts, tears, or heat cracks. If any of the above conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. NOTE: A slight amount of fluid on the boot may be preservative fluid used at assembly and should not automatically be considered a leak. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 4704 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul For additional information see Notes, Warinings, and Hints. Fig 3 Wheel Cylinder NOTE: To perform service operations or inspections of the wheel cylinders, it will be necessary to remove the cylinders from the support plate and disassemble on the bench. CAUTION: Wheel cylinders with cup expanders must have cup expanders after any service procedures (reconditioning or replacement). DISASSEMBLING WHEEL CYLINDERS 1. Pry boots away from cylinders and remove. 2. Press In on one piston to force out other piston, cup, spring -- with cup expanders -- cup and piston. 3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol. - Clean thoroughly and blow dry with compressed air. CAUTION: Do not use a rag as lint from the rag will adhere to bore surfaces. 4. Inspect cylinder bore and piston for scoring and pitting. - Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. - Cylinder walls that have light scratches, or show signs of corrosion, can usually be cleaned with crocus cloth, using a circular motion. - Black stains on the cylinder walls are caused by piston cups and will not impair operation of cylinder. ASSEMBLING WHEEL CYLINDERS Assembly Notes: Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. - If the boots are deteriorated, cracked or do not fit tightly on the push rods or the cylinder casting, install new boots. 1. Coat cylinder bore with clean brake fluid. 2. Install expansion spring with cup expanders in cylinder. Install cups in each end of cylinder with open end of cups facing each other. 3. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup, already installed. 4. Install a boot over each end of cylinder. Use care not to damage boot. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding WHEN BLEEDING BRAKES REMEMBER... - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always flush and bleed the brake hydraulic sys. when servicing the brakes, because: Brake fluid absorbs moisture from the air, after 3-4 years of service the water content of the brake fluid may be as high as 6-7%. This significantly reduces the boiling point of the brake fluid which may result in a soft pedal or brake failure during prolonged or severe braking. Corrosion deposits and other contaminants gradually build up inside of the brake hydraulic sys. Check the bottom of the master-cylinder reservoir for a build up of fine black silt. If any is present the brake fluid should be flushed. - Never reuse brake fluid that has been drained from the brake system. DOT 3,4 or DOT 5 As a general rule DOT 5 brake fluid should not be used in vehicles recommending DOT 3 or 4 type fluid. DOT 5 brake fluid is silicone based. DOT 3 (standard) and DOT 4 (heavy-duty) are glycol-based. DOT 5 can be distinguished from conventional brake fluids by its purple color (which comes from a dye). DOT 5 silicone brake fluid won't mix with glycol-based brake fluid (creating concern over sludging if all old fluid isn't removed when a system is refilled with silicone). Silicone does not absorb moisture. DOT 5 brake fluid does not become contaminated with moisture over time as conventional DOT 3 and 4 brake fluids do. Silicone is also chemically inert, nontoxic and won't damage paint like conventional brake fluid. It also has a higher boiling point. Because of this, it is often marketed as a premium "lifetime" brake fluid. It is often used to preserve brake systems in antique vehicles and those that sit for long periods of time between use. Silicone also has slightly different physical properties and compressibility, making it unsuitable for ABS systems calibrated to work with DOT 3 or 4 brake fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 4710 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures When bleeding ABS systems use only diaphragm type bleed pressure bleeder. 1. Turn ignition switch to Off position, then pump brake pedal a minimum of 40 times to de-pressurize hydraulic accumulator. 2. Attach bleeding equipment to brake reservoir. 3. Connect a suitable transparent hose to bleeder valve on left rear wheel cylinder and submerge other end in a glass container partially filled with clean brake fluid. 4. Turn pressure bleeder On, open brake bleed screw 3/4 to one turn. Allow brake fluid to flow until clear and bubble free. 5. Continue to bleed right rear, left front, then right front brakes in that order. 6. Turn Off pressure bleeder, then slowly bleed off pressure from equipment. 7. Remove pressure bleeder from vehicle, ensure proper fluid level in master cylinder. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Bleed Screw 80-170 in.lb Caliper Guide Pins 25-35 ft.lb Caliper Adapter Mounting bolt 130-190 ft.lb Caliper Bearing Retainer Mounting Bolt 200-300 in.lb Brake Hoses to Calipers (Banjo Bolts) 19-29 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Diagrams > Kelsey-Hayes Double Pin Floating Caliper Fig 2 Disc Brake Caliper Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Diagrams > Kelsey-Hayes Double Pin Floating Caliper > Page 4716 Single Pin Disc Brake Caliper Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Diagrams > Page 4717 Brake Caliper: Application and ID Single Pin Disc Brake Caliper Kelsey Hayes Single Pin Caliper Fig 2 Disc Brake Caliper Kelsey Hayes Double Pin Caliper Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Kelsey-Hayes Double Pin Floating Caliper Brake Caliper: Description and Operation Kelsey-Hayes Double Pin Floating Caliper Fig 2 Disc Brake Caliper Fig. 1 Kelsey-Hayes Dual Pin Floating Caliper Disc Brake Assembly The double pin caliper consists of a driving hub, braking disc, caliper, pads and adapter on vehicles without an integral knuckle. The caliper is mounted through two bushings and sleeves. An anti-rattle clip is attached to the outer pad and the inner pad has a retainer clip. The caliper is a one piece casting with the inboard side containing a single piston and bore. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Kelsey-Hayes Double Pin Floating Caliper > Page 4720 Brake Caliper: Description and Operation Kelsey-Hayes Single Piston Sliding Caliper Disc Break Assembly Caliper Mounting Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Kelsey-Hayes Double Pin Floating Caliper > Page 4721 Single Pin Disc Brake Caliper OPERATION The single piston caliper assembly floats through a rubber bushing on a single pin threaded into the adapter. The bushing is inserted into the inboard portion of the caliper. Two machined abutments on the adapter position and align the caliper fore and aft. The guide pin and bushing controls the movement of the caliper and the piston seal to assist in maintaining proper shoe clearance. All of the braking force is taken directly by the adapter. The caliper is a one-piece casting with the inboard side containing a single piston cylinder bore. CONSTRUCTION Caliper Assembly Consists of a rotor, caliper, shoes and linings, and adapter. Piston The phenolic piston is 2.13 inches in diameter. Fig. 2 Piston Seal Function Seal A square cut rubber piston seal is located in a machined groove in the caliper bore and provides a seal between piston and caliper bore. Boot A molded rubber dust boot installed in a groove in the cylinder bore and piston keeps contamination from the caliper bore and piston. The boot mounts in the caliper bore and in a groove in the piston. Anti-Rattle Clips This assembly has three anti-rattle clips. One is on top of the inboard shoe, one clip is on the bottom of the outboard shoe, and one clip is on top of the caliper. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Page 4722 Brake Caliper: Testing and Inspection WITH CALIPER ON VEHICLE Check for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper assembly and install a new seal and boot, (and piston if corroded or scored). Check the mating surfaces of the abutments on the caliper and adapter. If corroded or rusty, clean surfaces with wire brush. Inspect braking surfaces of disc. Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or brittle. WITH CALIPER REMOVED Cleaning Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air. Blow out all drilled passages and bores. NOTE: Whenever a caliper has been disassembled, a new boot and seal must be installed at reassembly. Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). - If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Kelsey-Hayes Double Pin Caliper For additional information see Removal Notes. See: Fundamentals and Basics Fig. 1 Kelsey-Hayes Dual Pin Floating Caliper Disc Brake Assembly Fig 2 Disc Brake Caliper NOTE: If a shoe and lining does not require replacement, reinstall, making sure each shoe is returned to the original position. 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies. 3. Remove caliper to knuckle attaching bolts. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4725 Fig 3 Removing Caliper And Brake Shoes As An Assembly 4. Pull lower end of the caliper out from the machined abutment on the steering knuckle and roll caliper out and away from braking disc. The shoe assemblies will remain with the caliper. Fig 4 Prying Outboard Shoe Assembly Away From Caliper 5. Remove outboard shoe by prying between shoe and caliper. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4726 Fig 5 Removing Or Installing Inboard Shoe Assembly 6. Remove the inboard shoe from the assembly by pulling the shoe and lining assembly away from the piston. Kelsey-Hayes Single Pin Caliper For additional information see Removal Notes. See: Fundamentals and Basics Single Pin Disc Brake Caliper 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4727 Removing Or Installing Guide Pin 3. Remove caliper guide pin. Loosening Caliper 4. After removing caliper guide pin, wedge the caliper away from the braking disc with a screwdriver to break the gasket adhesive seals. Removing Or Installing Caliper 5. Remove caliper from disc by slowly sliding caliper assembly out and away from braking disc. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4728 Hanging Caliper Out Of The Way 6. Support caliper firmly to prevent weight of caliper from damaging the flexible hose. Removing Or Installing Outboard Shoe Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4729 Removing Or Installing Brake Disc Removing Or Installing Inboard Shoe Assembly 7. Remove the outboard shoe assembly. Fig 2 Marking Brake Disc And Wheel Stud For Reassembly 8. Mark disc and stud for assembly. 9. Remove braking disc from drive flange studs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4730 10. Remove the inboard shoe assembly. Kelsey-Hayes Double Pin Caliper For additional information see Installation Notes. See: Fundamentals and Basics Fig 2 Disc Brake Caliper 1. Lubricate both adapter ways with a liberal amount of Mopar Multipurpose Lubricant Part Number 4318063, or equivalent. Fig. 4 Brake Pad Identification 2. The inboard brake shoes are common. The outboard shoes are marked with an "L" or "R" denoting which side of the vehicle they should be installed on. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4731 Fig 5 Removing Or Installing Inboard Shoe Assembly 3. Install new inboard brake pad assembly in caliper, entering retainer into the bore in the piston. Fig 7 Installing Outboard Shoe Assembly Onto Caliper 4. Remove protective paper from the noise suppression gasket and position the properly marked outboard shoe hold-down spring onto caliper. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4732 Fig 3 Removing Caliper And Brake Shoes As An Assembly 5. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment on knuckle assembly. 6. Install attaching bolts and tighten to 24-34 Nm (18-25 ft lb). CAUTION: When installing attaching bolts, use extreme caution not to cross the threads. 6. Install wheel and tire assembly. Tighten stud nuts in the proper sequence until all nuts are torqued to half specification. THIS IS IMPORTANT. Then repeat sequence to full specification. 7. Remove jackstands or lower hoist. CAUTION: Before moving vehicle, be sure it has a firm pedal. 8. Road test vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings. The vehicle may pull to one side or the other if this is not done. Kelsey-Hayes Single Pin Caliper For additional information see Installation Notes. See: Fundamentals and Basics Single Pin Disc Brake Caliper 1. Push piston back into cylinder bore with uniform pressure until it is bottomed. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4733 Removing Or Installing Inboard Shoe Assembly Removing Or Installing Brake Disc 2. Position inboard pad on adapter. Fig 2 Marking Brake Disc And Wheel Stud For Reassembly 3. Slide brake disc assembly on drive flange studs. Pay attention to marks for assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4734 4. Clean both sides of braking disc with alcohol or suitable solvent. Removing Or Installing Outboard Shoe Removing Or Installing Caliper 5. While holding outboard pad in position on adapter, carefully position caliper over disc brake rotor. 6. Lower caliper over rotor and adapter. 7. Install guide pin through bushing caliper and adapter. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4735 Removing Or Installing Guide Pin 8. Press in on guide pin and thread pin into adapter. Torque pin to 25-35 ft lb. 9. Install wheel and tire assembly, then lower vehicle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4736 Brake Caliper: Service and Repair Disassembly and Assembly Cleaning, Inspecting & Honing Caliper Honing Brake Caliper Piston Bore Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, using Tool C-4095, providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). - If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. When using a hone: Coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff nonmetallic rotary brush. Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lintless cloth and then clean a second time. Be sure to install the hone baffle before honing bore. - The baffle is used to protect the hone stones from damage. Use extreme care in cleaning the caliper after honing. Kelsey-Hayes Single Pin Caliper DISASSEMBLING CALIPER 1. Support caliper assembly on upper control arms on shop towels to absorb any hydraulic fluid loss. 2. Place a small piece of wood between the piston and caliper fingers. 3. Carefully depress brake pedal to hydraulically push piston out of bore (brake pedal will fall away when piston has passed bore opening). 4. Prop brake pedal to any position below the first inch of pedal travel -- to prevent loss of brake fluid. If both front caliper pistons are to be removed: 1. Disconnect flexible brake line at frame bracket after removing piston. 2. Plug brake tube and remove piston from opposite caliper. CAUTION: Under no condition should air pressure be used to remove piston from bore! Personal Injury could result from such practice. 3. Disconnect brake flexible hose from the caliper. 4. To disassemble, mount caliper assembly in a vise equipped with protective jaws. CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4737 Fig. 10 Dust Boot Removal 5. Support caliper and remove dust boot and discard. Removing Piston Seal From Caliper 6. Using a plastic trim stick, work piston seal out of its groove in piston bore. Discard old seal. Do not use a screwdriver or other metal tool for this operation, because of possibility of scratching piston bore or burring edges of seal groove. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4738 Fig 11 Removing Bushings 7. Remove bushing from caliper by pressing out of bore, using a suitable tool. Discard bushing. CLEANING AND INSPECTION Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air. Blow out all drilled passages and bores. NOTE: Whenever a caliper has been disassembled, a new boot and seal must be installed at reassembly. Honing Brake Caliper Piston Bore Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). - If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. When using a hone: Coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff nonmetallic rotary brush. Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lintless cloth and then clean a second time. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4739 ASSEMBLING CALIPER 1. Clamp caliper in vise (with protector jaws). CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. Installing New Piston Seal In Caliper 2. Dip new piston seal in clean brake fluid and install in groove in bore. Seal should be positioned at one area in groove and gently worked around the groove, using fingers until properly seated. CAUTION: NEVER USE AN OLD PISTON SEAL. (Be sure that fingers are clean and seal is not twisted or rolled). 3. Coat new piston boot with clean brake fluid leaving a generous amount inside of boot. 4. Position dust boot over piston after coating with brake fluid. Fig. 4 Caliper piston installation 5. Install piston into bore pushing it past the piston seal until it bottoms in the bore. CAUTION: Force must be applied uniformly to avoid cocking the piston. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4740 6. Position dust boot in counterbore. Using a hammer and Tool C4842 with C4171 handle or equivalent, drive boot into counterbore. Fig 16 Installing Bushings 7. Compress flanges of guide pin bushings in with fingers and work into position by pressing IN on bushings, using fingertips or plastic trim stick until seated. 8. Be sure flanges extend over caliper casting evenly on both sides. 9. Before installing caliper assembly on vehicle, inspect braking disc. 10. Install brake hose to caliper using new seal washers. 11. Bleed the brake system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes Brake Caliper: Fundamentals and Basics Removal Notes When Removing the Caliper, Remember... - Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir is only 1/3 full. - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining thickness between wheels on the same axle will result in a strong steering pull when the brakes are applied. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. - When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is forced back into the caliper, these deposits will be forced back through the brake lines and into the master-cylinder. - When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake fluid will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to "shoot" brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose and a glass or plastic jar to catch the expelled fluid. - Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses can be damaged easily by this practice. These hoses are double walled, damage to the interior pressure hose will not be visible. - Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not attempt to insert the piston back into the caliper. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 4743 Brake Caliper: Fundamentals and Basics Installation Notes WHEN INSTALLING CALIPERS AND PADS, REMEMBER... - Clean and lubricate caliper slide joint/pins with high temperature silicone grease: Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted movement of the caliper slide assemblies to release the brakes. If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon the release of the brake pedal. This will result in overheated brakes and premature brake wear. Disc Brake Mechanical Force Diagram NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel forces the inner pad against the rotor, then further travel forces the movable part of the caliper to pull the outer pad against the rotor. High temperature silicone lubricant must be used. Low temperature grease can melt and contaminate the pads and rotors, or can bake into a very hard substance which binds the slides. Petroleum based grease can cause the slide boots to soften and swell. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. Anti-squeal Coating - Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an insulator to dampen high frequency vibrations that are generated during normal braking. These compounds are highly effective in preventing brake squeal. - Many professional repair shops recommend always rebuilding or replacing the calipers when replacing the brake linings, because: When the pistons are forced back into the calipers, the piston seals are dragged across any corrosion or abrasives that may be deposited on the inside of the caliper. Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston is gradually withdrawn from the caliper. This results in the piston seals again being dragged across the layer of corrosion and deposits. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 4744 Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking. - Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck bleeder screw is much easier with the caliper removed from the vehicle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Use new brake fluid only, to top off the master cylinder or refill system. Never use reclaimed fluid, unmarked or unspecified fluid, fluid not meeting SAE/DOT standards, fluid marked 70R1, or fluid from a container that has been left open. Brake Fluid Type DOT 3 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4748 Brake Fluid: Testing and Inspection Indications of fluid contamination: Swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination: Put small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil contamination. If contaminated: Drain and thoroughly flush system, and replace all rubber parts. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4749 Brake Fluid: Service and Repair Aluminum Master Cylinder NOTES: - Check master cylinder fluid level twice annually. - Master cylinder reservoirs are marked with the words "fill to bottom of rings". - Add DOT 3 fluid to bring the level to the bottom of the primary split ring. CAUTION: Use of brake fluid with a lower boiling point than DOT 3 fluid could result in brake failure during long, hard braking. CAUTION: Do not use fluid which has been stored in an unsealed container. Brake fluid stored in this manner will absorb moisture which could result in brake failure during long, hard braking. CAUTION: Use of petroleum based fluids will result in seal damage. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Accumulator > Component Information > Service and Repair > Depressurizing Hydraulic Accumulator Brake Fluid Accumulator: Service and Repair Depressurizing Hydraulic Accumulator NOTE:The ABS pump/motor assembly will keep the hydraulic accumulator charged to a pressure between 1600-2000 psi anytime the ignition is in the ON position. The pump/motor cannot run if the ignition is off or either battery cable is disconnected. WARNING: The hydraulic accumulator should be depressurized before disassembling any portion of the hydraulic system. 1. Turn ignition switch to the OFF position, or disconnect battery ground cable. 2. Pump brake pedal a minimum of 40 times using approximately 50 pounds of pedal force. Pedal feel should change noticeably when accumulator is discharged. 3. After a definite increase in pedal effort is felt, pump pedal a few additional times. This will remove all hydraulic pressure from the system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Accumulator > Component Information > Service and Repair > Depressurizing Hydraulic Accumulator > Page 4754 Brake Fluid Accumulator: Service and Repair Accumulator Replacement 1. Depressurize hydraulic accumulator as outlined under "Hydraulic Assembly/Service and Repair." See: Depressurizing Hydraulic Accumulator WARNING:Failure to de-pressurize the hydraulic accumulator, may result in personal injury, or damage to painted surfaces. 2. Remove accumulator assembly. 3. Reverse procedure to install. Torque accumulator to 30 ft. lbs., then turn ignition On and check for leaks. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Brake Fluid Pressure Sensor/Switch: Locations Engine Compartment Components. LH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 4758 Engine Compartment & Transaxle Components. LH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 4759 Brake Fluid Pressure Sensor/Switch: Description and Operation The switch activates a light on the dash panel to indicate that one of the hydraulic systems has failed. There are two basic types of switches. In some earlier models, as pressure falls in one system, the normal pressure of the other system forces the piston to the inoperative side where it contacts the switch terminal, causing the warning lights to illuminate. On most models, the brake warning switch is of the latching type. If a pressure loss occurs in one side of the system, the piston in the valve is forced toward the failed side where it latches in position and illuminates the warning light. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Hydraulic brake tubes to all fittings (if not specified) .................................................................................................................... 13-20 Nm (115-170 in lb) Brake hoses to calipers (banjo bolts) .................................................................................................................................................. 26-40 Nm (19-29 ft lb) Front Brake hose intermediate bracket .............................................................................................................................................. 8-13 Nm (75-115 in lb) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 4763 Brake Hose/Line: Service and Repair - Always use factory recommended brake hose to insure quality, correct length and superior fatigue life. - Care should be taken to make sure that the tube and hose mating surfaces are clean and free from nicks and burrs. Right and left hoses are not interchangeable. - Use new copper seal washers on all "banjo" bolts and tighten all fittings to specified torque. Connections should be tight and properly made. - The flexible hydraulic brake hose should always be installed on the vehicle by first attaching the "Banjo" connector to the caliper assembly. Then bolt the intermediate hose bracket to the strut assembly allowing the bracket to position the hose to prevent twisting. Attach the hose to the body bracket and steel brake tubing. Tighten all fittings to specified torque. - The body bracket and hose end are "keyed" so that they will only fit one way. - Install rear brake hoses first to the trailing arm cross member tubes and then to the floor pan tubes. Minimize hose twisting. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation Brake Proportioning/Combination Valve: Description and Operation Some vehicles incorporate a hold-off valve, usually in combination with the brake warning switch. This valve holds off hydraulic pressure to the front disc brakes to a given psi range to allow the rear drum brake shoes to overcome the return springs and begin to contact drums. This action helps prevent locking of the front brakes on icy surfaces under light braking conditions. This valve has no effect on front brake pressure during hard stopping. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 4767 Brake Proportioning/Combination Valve: Service and Repair The proportioning valves should never be disassembled. 1. Remove fresh air intake ducts and air cleaner assembly. 2. Remove pressure and return hose from hydraulic unit. 3. Remove brake tube and fitting from proportioning valve. 4. Remove proportioning valve from hydraulic assembly. 5. Reverse procedure to install, noting the following: a. Torque proportioning valve bolts to 30 ft. lbs. b. Torque brake tube to 11 ft. lbs. c. Bleed brake system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Diagrams Height Sensing Proportioning Valve Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Diagrams > Page 4771 Load Compensator: Description and Operation Height Sensing Proportioning Valve CAUTION: The use of aftermarket load leveling or capacity increasing devices is prohibited. Use of air shock absorbers or helper springs will cause the valve to inappropriately reduce the rear brake power potentially resulting in increased stopping distance. PURPOSE Proportioning valves balance front to rear braking by controlling at a given ratio, the increase in rear system hydraulic pressure above a preset level. Under light pedal application, the valve allows full hydraulic pressure to the rear brakes. OPERATION These vehicles use a height sensing dual proportioning valve in addition to the regular differential warning switch. This valve is located under the load bed just forward of the rear axle. The height sensing rear brake proportioning valve automatically provides optimum brake balance front-to-rear regardless of the vehicle load condition. The valve modulates the pressure to the rear brakes sensing vehicle load condition through relative movement between the rear axle and the load floor. The valve is mounted to a load floor cross member. A large external spring is connected between a lever mounted on the valve and an adjustable bracket mounted on the rear axle. In conditions of light load the line pressure to the rear brakes is minimized. As the load increases (resulting in decreasing vehicle height) higher brake line pressure is allowed. The proportioning valve section operates by transmitting full input pressure to the rear brakes up to a certain point, called the split point, and beyond that point it reduces the amount of pressure increase to the rear brakes according to a certain ratio. Thus, on light pedal applications, approximately equal brake pressure will be transmitted to the front and rear brakes, while at higher pressures, the pressure transmitted to the rear brakes will be lower than to the front brakes to prevent premature rear wheel lock-up and skid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Diagrams > Page 4772 Load Compensator: Testing and Inspection Rear Brakes Locking On Application Height Sensing Proportioning Valve Fig. 3 Master cylinder & brake warning switch. Symptom When a premature rear wheel slide is obtained on brake application, it could be an indication that the fluid pressure to the rear brakes is above the reduction ratio for the rear line pressure and that a malfunction has occurred within the proportioning valve unit which should be tested. To test the proportioning valve, proceed as follows: 1. Disconnect the external spring at the valve end. 2. Install one gauge and "T" of set C4007-A or equivalent in the line from either master cylinder port to the brake valve assembly. 3. Install the second gauge to either rear brake outlet port between proportioning valve assembly and the rear brake line. 4. Bleed both hydraulic circuits and the gauges. 5. Have a helper exert pressure on the brake pedal (holding pressure) to get a reading on the valve inlet gauge and check the reading on the outlet gauge. The inlet pressure should be 500 psi and the outlet pressure should be 100-200 psi. - If not, replace the valve torque mounting bolts to 250 inch lbs. - If the valve tests OK re-adjust external spring and road test vehicle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Diagrams > Page 4773 Load Compensator: Adjustments Height Sensing Proportioning Valve NOTE: After installing a new height sensing dual proportioning valve, bleed both hydraulic circuits at rear brakes. CAUTION: The rubber stone/snow shield must be installed when ever the valve is serviced. The shield protects the valve and hydraulic lines from stone impact and the packing of snow and slush. 1. Lift vehicle with a frame contact hoist or other means so that rear suspension is hanging free with shock absorbers disconnected from the axle. 2. Remove tire and wheels from rear axle. 3. Loosen both front spring hanger pivot bolts. NOTE: Ensure rear springs do not contact hoist, or the adjustment will not be correct. 4. Loosen adjustment nut on the actuator assembly. 5. Verify actuator assembly hook is properly seated on valve lever. 6. Pull actuator assembly toward spring hanger until valve lever bottoms on valve body. Hold in position and torque adjustment nut to 25 inch lbs (5 Nm). 7. Install shocks and tire and wheel assemblies, then lower vehicle. 8. With full weight on vehicles wheels, torque both front spring hanger pivot bolts to 95 ft lb (129 Nm). 9. Road test vehicle. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Hydraulic brake tubes to all fittings (if not specified) .................................................................................................................... 13-20 Nm (115-170 in lb) Master cylinder to brake booster mounting nuts ......................................................................................................................... 22.6-34 Nm (200-300 in lb) Brake booster assembly to dash panel ........................................................................................................................................ 22.6-34 Nm (200-300 in lb) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4777 Brake Master Cylinder: Service Precautions CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes Brake Master Cylinder: Description and Operation With Antilock Brakes This Anti-lock Brake System (ABS) uses an integral hydraulic assembly which contains the wheel circuit valves used for brake pressure modulation. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes > Page 4780 Brake Master Cylinder: Description and Operation Without Antilock Brakes Aluminum Master Cylinder CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface. OPERATION The brake system is a diagonally split system. This system operates on the same principles as conventional front and rear split systems using primary and secondary master cylinders moving simultaneously to exert hydraulic pressure on their respective systems. The hydraulic brake lines on this system, however, have been diagonally split front to rear (left front to right rear and right front to left rear) in place of separate lines to the front and rear wheels. System Failure In the event of a system failure this would cause the remaining good system to do all the braking on one front wheel and the opposite rear wheel, thus maintaining 50% of the total braking force. The hydraulic pressure loss would result in a pressure differential in the system and cause a warning light on the dashboard to glow as in front and rear split systems. CONSTRUCTION The tandem master cylinder has a glass reinforced nylon reservoir and an anodized aluminum body. The secondary outlet tube from the master cylinder is connected to the valve mounted under the master cylinder. The front part of this block supplies the right rear and left front brakes. - The rear portion of the block connects to the primary outlet tube and supplies the right front and left rear brakes. The reservoir is indexed to prevent installation in the wrong direction. The cap diaphragms are slit to allow pressure to equalize. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 4781 Brake Master Cylinder: Testing and Inspection INSPECTION Inspect for Leakage NOTE: The master-cylinder should be cleaned thoroughly prior to inspection (several days preferably). Spilled brake fluid can be easily confused with leakage. Piston Seals Leakage around the piston seals will seep out from the end of the cylinder and leak down the outside of the brake booster. - Inspect for signs of seepage or bubbled paint on the brake booster. - If any leakage is detected the master-cylinder should be replaced or overhauled Brake Line Fittings While someone is applying pressure to the brake pedal, inspect the brake line fittings on the master-cylinder for leakage. - If the fittings are leaking they should be disassembled and inspected. Reservoir to Cylinder Gasket Inspect the gasket for signs of leakage or hardening and cracking. Overhaul or replace the master-cylinder if any leakage is indicated. Inspect for Oil Contamination. - Inspect the rubber gasket on the inside of the master-cylinder lid. If the gasket is swollen or bloated, the brake fluid is contaminated with oil. - Siphon or scoop a small amount of brake fluid out of the master-cylinder and place into a styrofoam cup filled 2/3 of the way with water. Brake fluid will mix with the water while oil contaminants will float on the surface and dissolve the styrofoam. NOTE: If any oil contamination is present ALL brake components containing rubber seals will need to be replaced or overhauled. This includes the master-cylinder, both front calipers, both rear wheel cylinders, and all flexible brake hoses. Verify Hold-Down Bolts Are Tight - While someone is applying and releasing pressure to the brake pedal, verify the the master-cylinder is tightly secured to the brake booster. Retighten hold-down bolts if necessary. Functional Checks WARNING: Always bleed the entire brake system and verify the rear brakes are properly adjusted prior to diagnosing a master-cylinder as defective. For additional information on master-cylinder / brake pedal relationship see Fundamentals and Basics. See: Fundamentals and Basics Check Related Systems Check for proper brake booster operation 1. With the engine "OFF", depress and release the brake pedal 4-5 times (this bleeds off the vacuum reserve in the booster). 2. Depress the brake pedal firmly and start the engine. If the pedal goes down slightly the brake booster is assisting in brake operation. If the pedal does not go down slightly the brake booster is not assisting in brake operation and should be diagnosed for problems. - Check and adjust rear brakes. - Check all brake lines and brake assemblies for leakage. Repair all deficiencies with related systems prior to diagnosing the master-cylinder as defective. Check Brake Pedal Travel (Non-Antilock Brake Systems Only) Fully depress the brake pedal and check for the following: The pedal should have a 75% reserve. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 4782 Pedal Reserve Checks - The pedal should be firm and not leak down. Prior to replacing a master-cylinder for poor pedal travel or feel verify the following: There were no problems with any of the related systems. - The entire brake system has been bled. - Rear brakes are properly adjusted. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 4783 Brake Master Cylinder: Adjustments Not adjustable Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Bench Bleeding Bleeding Master Cylinder NOTE: It is not necessary to bleed the entire hydraulic system after replacing the master cylinder if the master cylinder has been bench bled and refilled prior to installation. 1. Clamp master cylinder in vise and attach bleeding tubes. 2. Use residual valve on outlet of each bleeder tube. 3. Fill both reservoirs with approved brake fluid. 4. Depress push rod slowly and then allow pistons to return. 5. Repeat several times until all air bubbles are expelled. 6. Remove bleeding tubes from cylinder, plug outlets and install caps. 7. Remove from vise and install master cylinder. For additional information see Bench Bleeding Notes. See: Fundamentals and Basics Pressure Bleeding Air Trapped In Brake System NOTE: When bleeding the brake system some air may be trapped in the brake line or valving far upstream, sometimes as much as ten feet from the bleeder screw. Therefore it is absolutely essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure the system is purged of all air bubbles. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4786 Bleeding Brake System Caliper Bleeding Screw CAUTION: Pressure bleed system using equipment designed for this purpose and vehicle only. 1. Wipe master cylinder caps and top with a clean rag. 2. Connect pressure bleeder following manufacturer's instructions for use of bleeder. 3. Attach a clear plastic hose to the bleeder screw at one wheel and insert the other end of the tube into a clear jar containing fresh brake fluid. 4. Open the bleeder screw at least one full turn. CAUTION: "Cracking" the bleeder screw often allows only a slow weak fluid flow. This may not be sufficient to remove all air from the system. 5. After a good volume of fluid has been forced through the brake system, an "air free flow" in the plastic hose and clear jar indicates a thorough bleed. 6. Repeat this procedure at all other bleeder screws. 7. Check brake pedal travel. If pedal travel is excessive repeat the procedure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4787 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Removal Master Cylinder 1. Disconnect primary and secondary brake tubes from master cylinder and install plugs at outlets. 2. Remove nuts attaching master cylinder to power brake booster. 3. Slide master cylinder straight out, away from power brake booster. For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Installation Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4788 Master Cylinder 1. Position master cylinder over studs of power brake booster. 2. Align push rod with master cylinder piston. 3. Install attaching nuts and tighten to specification 22.6-34 Nm (200-300 in lb). 4. Connect brake tubes and have a helper apply force to the brake pedal while tube nuts are cracked to release any air, then tighten to specification 13-20 Nm (115-170 in lb). For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4789 Brake Master Cylinder: Service and Repair Master Cylinder Overhaul Aluminum Master Cylinder CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface. If the cylinder is scored, replace the master cylinder as an assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4790 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement Removing Reservoir 1. Clean housing and reservoir. 2. Remove caps and empty brake fluid. 3. Position master cylinder in vise. 4. Rock reservoir from side to side and remove from master cylinder housing. CAUTION: Do not pry off with tool as this may damage reservoir. Removing Grommets 5. Remove housing to reservoir grommets. 6. Install new housing to reservoir grommets in master cylinder housing. 7. Lubricate reservoir mounting area with brake fluid. 8. Place reservoir in position over grommets and seat reservoir with a rocking motion onto master cylinder housing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4791 Brake Master Cylinder: Service and Repair Hydraulic Assembly Replacement 1. Depressurize hydraulic accumulator as outlined under "Hydraulic Assembly/Service and Repair." See: Brake Fluid Accumulator/Service and Repair/Depressurizing Hydraulic Accumulator WARNING:Failure to de-pressurize the hydraulic accumulator, may result in personal injury, or damage to painted surfaces. 2. Remove fresh air intake and air cleaner assembly from engine. 3. Remove windshield washer fluid reservoir, then disconnect electrical connectors from hydraulic assembly. 4. Drain as much fluid from hydraulic reservoir as possible. 5. Disconnect pump high pressure line from hydraulic unit. 6. Disconnect pump return hose from steel tube, then cap the end of the steel tube. 7. Disconnect all brakes tubes from hydraulic assembly. 8. Remove retainer clip from brake pedal pin. 9. Remove four hydraulic mounting unit nuts, then the hydraulic unit. 10. Reverse procedure to install, noting the following: a. Torque mounting bolts to 250 inch lbs. b. Lubricate bearing surface of pedal pin with lubriplate. c. Install new retainer clip on pedal pin. d. Torque brake tubes to hydraulic unit to 30 ft. lbs. e. Torque return hose clamp to 10 inch lbs. f. Torque high pressure hose to 145 inch lbs. g. Bleed brake system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Page 4792 Brake Master Cylinder: Tools and Equipment BASIC SERVICE (Removal and Installation) - Fender cover (servicing and bleeding a master-cylinder can be a messy process) WARNING: DOT 3 or 4 brake fluid is very corrosive to the vehicles finish and electrical connections. - Drip pan. - Complete set of combination wrenches or sockets. - Bleeding device: - Pressure bleeder or - Vacuum bleeder or - One-man brake bleeder kit or - Length of clear plastic hose (3/16 inch ID) and a glass jar. Brake Bleeding Setup - Brake adjusting tool (rear brake adjustment should be checked) - Clean shop towels. OPTIONAL - Master Cylinder bleeding kit (contains plastic fittings and hoses used for bleeding master cylinders) - Suction bulb (for removing brake fluid from reservoir) IF MASTER-CYLINDER IS OVERHAULED - Snap-ring pliers - Small pry bar (for separating the reservoir from the cylinder) - Feeler gauges (for checking piston to cylinder clearance). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints Brake Master Cylinder: Fundamentals and Basics Notes, Warnings, and Hints REMOVAL WARNING: DOT 3 or DOT 4 brake fluid is very corrosive to your vehicles finish. Removing master cylinders can be a messy process. To prevent or minimize any possible damage perform the following: Siphon all brake fluid from the master-cylinder reservoir prior to removal. - Use a fender cover to protect the vehicles finish. - Use a drip pan to catch all fluid that leaks from the master-cylinder during removal. - Any brake fluid which contacts the vehicles finish should be washed off immediately. - Any brake fluid which drips onto electrical connections should be immediately removed (aerosol brake cleaner works well for this). After the brake lines have been disconnected from the master-cylinder place vacuum caps over ends of the lines to prevent further leakage or contamination. Once the master-cylinder has been removed place it in a drip pan. Although the reservoir is empty, brake fluid trapped within the cylinder bore will continue to slowly leak out. OVERHAUL WARNING: Never hone aluminum cylinders, if deposits cannot be removed with crocus cloth the cylinder should be replaced. Check the cylinder bore for excessive clearance. With the piston installed you should not be able to install a 0.006 inch feeler gauge between piston and cylinder. If the clearance is greater than 0.006 inches the cylinder should be replaced. When installing the piston and seals into the cylinder always use clean brake fluid or assembly lubricant to lubricate the components. INSTALLATION Prior to installation the master-cylinder should be bench bled (this can be done on the vehicle but it is much easier on a workbench. NOTE: Normal brake bleeding procedures will not remove air which is trapped in the cylinder bore area of a master-cylinder. Attach the brake line fittings prior to snugging down the master-cylinder retaining bolts. The fittings are much easier to start turning when the master-cylinder is still loose. WARNING: Remember to tighten the retaining bolts after the brake lines are installed and tightened. When snugging down the retaining bolts, alternately tighten them in small increments. This prevents the master-cylinder or push rod from becoming cocked. Upon installing the master-cylinder the entire brake system (front and rear) will need to be bled. Air enters the brake system as soon as the brake lines are removed. It only requires a very small amount of air in the system to create a soft brake pedal. WARNING: Never test drive a vehicle after a master-cylinder replacement until a firm brake pedal with a 75% reserve is established. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 4795 Brake Master Cylinder: Fundamentals and Basics Parts Reminder List RECOMMENDED PARTS Basic Service, Replacement New or rebuilt master-cylinder - Fresh/New brake fluid If Overhaul is Required Master cylinder overhaul kit - Brake assembly lubricant Optional Aerosol brake cleaner. New or Rebuilt Master Cylinder Always closely compare the new master-cylinder with the old master-cylinder. Minor variations in the size and depth of the primary piston can result in significant reductions in braking performance. Examine the end of the master-cylinder where the pushrod contacts the piston. The depth and diameters of the pistons should match. Brake Fluid - Proper bench bleeding the master-cylinder and flushing the brake system will require a minimum of 16 oz of brake fluid. - Never Mix DOT 3 (light amber in color) with DOT 5 (purple in color). There have been reports of damage to brake system seals when DOT 3 and DOT 5 fluids are mixed - Always store brake fluid in a sealed container. When left open brake fluid will absorb moisture from the air. This reduces the boiling point of the brake fluid and could lead to a soft pedal or brake system failure during prolonged or emergency braking. - Never add automatic transmission fluid, engine oil, or power steering fluid to the master-cylinder. Petroleum based fluids will cause the rubber seals and gaskets in the brake system to swell and leak. Master Cylinder Overhaul Kit Overhaul kits will often come with a variety cup and seal sizes. Closely match the old cups and seals with the new ones. Brake Assembly Lubricant Assembly lubricant can greatly simply the master-cylinder overhaul process and prolong the life of the new seals. - Clean brake fluid can be used to lubricate the master-cylinder bore during assembly but assembly lube is much slicker and prevents any sticking or binding and possible damage to the new cups and seals. Aerosol Brake Cleaner - Commercially produced aerosol brake cleaners are designed to effectively clean brake systems while not leaving an oily residue. - Do not use carburetor cleaner or solvent based products to clean brake system components. These products will leave a residue which could contaminate the brake fluid or cause a reduction in braking performance. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 4796 Brake Master Cylinder: Fundamentals and Basics Master Cylinder / Brake Pedal Relationship MASTER CYLINDER / BRAKE PEDAL RELATIONSHIP WARNING: Master Cylinders can be easily misdiagnosed for problems related to excessive brake pedal travel. Excessive brake pedal travel is often associated with a defective master-cylinder, however total pedal travel is affected by a wide variety of components and issues. Issues Affecting Pedal Travel Brake Fluid Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 4797 - Brake fluid which is contaminated with air or water will significantly add to the amount of pedal travel. - Pure DOT 3 (or 4) brake fluid is incompressible (allowing for a solid, firm pedal). A small amount of air trapped in the brake fluid will require extra effort from the master-cylinder to compress it, resulting in a soft and spongy pedal. - During prolonged or severe braking the brake fluid temperature can rapidly rise above 212 degrees F. When this occurs any water in the brake fluid will boil into steam (which is compressable) and create a soft and spongy pedal. Rear Brake Shoe Adjustment Drum brake system utilize return springs to pull the shoes away from the drums when not in use. The amount of distance the shoes have to extend to meet the drums greatly affects the amount of pedal travel. - Shoes/Linings which are badly out of adjustment can by themselves result in a brake pedal sinking all the way to the floor NOTE: Improperly adjusted rear shoes/linings also affect the parking brake. Calipers Excessive rotor wobble caused by a warped rotor or loose/worn wheel bearings can knock the caliper piston further inward from its normal resting position. This results in additional pedal travel required to extend the piston and apply the brakes. Drum Expansion Drums which are worn past their "Discard" thickness are prone to expanding outwards into an oval shape during heavy braking. This drum expansion results in additional brake pedal travel. Brake Fade During prolonged or severe braking, the amount of pedal effort/travel required to slow the vehicle increases as the ability of the brakes to dissipate heat decreases. - As the brake linings heat up, their "coefficient of friction" is reduced (they become slicker). As the coefficient of friction is reduced, more hydraulic pressure is required to stop the vehicle. More hydraulic pressure results in more heat which then results in more pedal fade. - As the brake linings, rotors, and drums begin to wear, their ability to absorb and release heat is reduced significantly. This makes worn brakes more prone to "pedal fade". NOTE: Prior to replacing a master-cylinder, verify the entire brake system is functioning properly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 4798 Brake Master Cylinder: Fundamentals and Basics Bench Bleeding Notes BENCH BLEEDING Why A master-cylinder will develop little or no pressure if air is trapped in cylinder bore. Normal brake bleeding will not remove air trapped within the master-cylinder. How Clamp the master-cylinder securely in a vice. It is usually best to clamp the side of the vice onto the flat surface that is used to secure the master-cylinder to the brake booster. There are two basic methods for bleeding master-cylinder, one utilizes stroking the master-cylinder to expel air from the cylinder bore while the other utilizes a large syringe to backflush fluid from the outlet ports to the reservoir. Stroking Fill the master-cylinder with clean brake fluid. - The brake line fittings on the master-cylinder should be capped or plugged. NOTE: Special "bench bleeding" plastic fittings are available which allow for recirculating the brake fluid back into the reservoir. - Using a dull object, slowly stroke the master-cylinder piston, air and brake fluid will be expelled from the brake line fittings. Prior to releasing the piston plug or cap the outlet ports. - Repeat this procedure 8-10 times or until no air is emitted from the outlet ports. - When finished, cap the outlet ports and install the master-cylinder. Syringe Fill the syringe (one especially designed for brake bleeding) with clean brake fluid. - Insert the end of the syringe into one of the outlet ports on the master-cylinder. - Slowly compress the syringe and back flush the brake fluid through the master-cylinder. - A combination of air and brake fluid will be emitted from the inlet port in the fluid reservoir. - Repeat this procedure until only brake fluid is emitted into the reservoir. - Cap the outlet ports and install the master-cylinder. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Bore Diameter Wheel Cylinder: Specifications Rear Wheel Cylinder Bore Diameter 0.75 in Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Bore Diameter > Page 4803 Wheel Cylinder: Specifications Hydraulic Brake Tubes To All Fittings (if Not Specified) 115-170 in.lb Wheel Cylinder To Rear Brake Support Plate 75 in.lb Wheel Cylinder Bleed Screw 60-100 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 4804 Fig 3 Wheel Cylinder Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal Wheel Cylinder: Service and Repair Wheel Cylinder Removal Fig 1 Brake Tube Disconnected 1. In case of a leak, remove brake shoes, (replace if soaked with grease or brake fluid). 2. Disconnect brake tube from wheel cylinder. Fig 2 Removing Or Installing Wheel Cylinder 3. Remove wheel cylinder attaching bolts, then pull wheel cylinder assembly out of support. For additional information see Notes, Warnings, and Hints. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 4807 Wheel Cylinder: Service and Repair Wheel Cylinder Installation For additional information see Notes, Warinings, and Hints. Brake Shoe Contact Pads On Backing (Support) Plate 1. Apply RTV sealant around wheel cylinder mounting surface. Fig 2 Removing Or Installing Wheel Cylinder Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 4808 Fig 1 Brake Tube Disconnected 2. Slide wheel cylinder into position on support. Install mounting screws and tighten as specified. 3. Connect brake tube to wheel cylinder. 4. Insert parking brake cable into support plate and attach cable to parking brake lever. 5. Install brake shoes on support plate. 6. Install brake drum and wheel. 7. Adjust and bleed brakes. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 4809 Wheel Cylinder: Service and Repair Cleaning and Inspection Fig 3 Wheel Cylinder 1. With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. 2. Block brake pedal in stroke position, visually check the boots for cuts, tears, or heat cracks. If any of the above conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. NOTE: A slight amount of fluid on the boot may be preservative fluid used at assembly and should not automatically be considered a leak. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 4810 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul For additional information see Notes, Warinings, and Hints. Fig 3 Wheel Cylinder NOTE: To perform service operations or inspections of the wheel cylinders, it will be necessary to remove the cylinders from the support plate and disassemble on the bench. CAUTION: Wheel cylinders with cup expanders must have cup expanders after any service procedures (reconditioning or replacement). DISASSEMBLING WHEEL CYLINDERS 1. Pry boots away from cylinders and remove. 2. Press In on one piston to force out other piston, cup, spring -- with cup expanders -- cup and piston. 3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol. - Clean thoroughly and blow dry with compressed air. CAUTION: Do not use a rag as lint from the rag will adhere to bore surfaces. 4. Inspect cylinder bore and piston for scoring and pitting. - Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. - Cylinder walls that have light scratches, or show signs of corrosion, can usually be cleaned with crocus cloth, using a circular motion. - Black stains on the cylinder walls are caused by piston cups and will not impair operation of cylinder. ASSEMBLING WHEEL CYLINDERS Assembly Notes: Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. - If the boots are deteriorated, cracked or do not fit tightly on the push rods or the cylinder casting, install new boots. 1. Coat cylinder bore with clean brake fluid. 2. Install expansion spring with cup expanders in cylinder. Install cups in each end of cylinder with open end of cups facing each other. 3. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup, already installed. 4. Install a boot over each end of cylinder. Use care not to damage boot. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams Parking Brake Cable Routing Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams > Page 4815 Parking Brake Cable: Testing and Inspection Inspect parking brake cable ends, inspect cables for kinks, fraying and elongation, and replace as necessary. TIP: Use a small hose clamp to compress clamp where it enters backing plate to remove. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement Parking Brake Cable: Service and Repair Front Cable Replacement REMOVING PARKING BRAKE FRONT CABLE Parking Brake Cable Routing 1. Loosen cable adjusting nut under car and disengage front cable from connector. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 4818 2. Loosen cable housing retainers at the rail bracket and parking brake pedal assembly. 3. Lift floor mat for access to floor pan and force seal out of hole. 4. Pull cable end forward and disconnect from clevis. 5. Pull cable assembly through hole. INSTALLING PARKING BRAKE FRONT CABLE Parking Brake Pedal 1. Feed cable assembly through hole in floor and attach to brake pedal assembly. 2. Engage cable end in lever clevis. 3. Install floor pan seal and floor mat. 4. Feed cable assembly through rail bracket and fasten with retainer. 5. Engage cable end into connector on intermediate cable assembly. 6. Adjust service and parking brakes. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 4819 Parking Brake Cable: Service and Repair Rear Cable Replacement REMOVING PARKING BRAKE REAR CABLE Parking Brake Cable Routing 1. The independent rear brake cables are attached to rear connectors. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 4820 2. Should it become necessary to remove either parking brake cable for installation of a new cable, proceed as follows: 3. With vehicle jacked up on a suitable hoist, remove wheel and tire. Removing Brake Cable From Support Plate 4. Back off cable adjusting nut to provide slack and disconnect rear brake cable from connector. Remove retaining clip from brake cable bracket. Remove brake drum from spindle. Disconnect cable from parking brake lever. Using an aircraft type hose clamp and screwdriver, compress retainers on end of cable housing and start housing out of support plate. Remove clamp when retainer is free. 5. Pull out brake cable assembly from support plate and disconnect from bracket under spring. INSTALLING PARKING BRAKE REAR CABLE 1. Insert brake cable and housing into brake support plate making certain that housing retainers lock the housing firmly into place. 2. Attach brake cable to parking lever. 3. Install brake drum and wheel. 4. Attach cable assembly to bracket under spring seat. 5. Insert brake cable and housing through cable bracket and install retaining clip. 6. Insert brake cable into connector. 7. Adjust service brakes and then parking brakes. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations I/P, Cowl & Steering Column Components LH Kickpanel On Park Brake Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Master cylinder to brake booster mounting nuts ......................................................................................................................... 22.6-34 Nm (200-300 in lb) Brake booster assembly to dash panel ........................................................................................................................................ 22.6-34 Nm (200-300 in lb) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4828 Vacuum Brake Booster: Description and Operation These units are self contained vacuum hydraulic power braking units. They are the vacuum suspended type which use engine intake manifold vacuum and atmospheric pressure for their power, eliminating the need for a vacuum reservoir. A mechanically operated control valve, integral with the vacuum power diaphragms, controls degree of brake application or release depending on amount of foot pressure applied to valve operating rod through the brake pedal linkage. The control valve is a single poppet type valve with the atmospheric port and a vacuum port. The vacuum port seal is a part of the valve body attached to the diaphragm assembly. The atmospheric port is a part of the valve plunger which moves within the valve housing and vacuum power diaphragm assembly. These units require no maintenance and must be replaced as a complete assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4829 Vacuum Brake Booster: Service and Repair 1. Remove master cylinder attaching nuts, slide master cylinder from mounting studs and support on fender shield. Do not disconnect brake tubes from master cylinder. 2. Disconnect vacuum hose from power brake unit. Do not remove check valve from booster. 3. Install suitable screwdriver between center tang on retainer clip and brake pedal pin located under instrument panel. Rotate screwdriver so retainer clip center tang will pass over brake pedal pin. 4. Pull retainer clip from pin and discard clip. 5. Remove brackets from steel heater water line at dash panel and left frame rail, if equipped. 6. On models equipped with manual transaxle, remove clutch cable bracket at shock tower and position aside. 7. On all models, remove power brake unit attaching nuts, then the power brake unit from vehicle. 8. Reverse procedure to install, ensuring to use retainer new clip. Do not attempt to service booster, it can only be serviced by replacing assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine compartment. The CAB uses the wheel speed information from the wheel speed sensors to control the ABS system function. The CAB also monitors ABS operation and detects system faults. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4834 Electronic Brake Control Module: Description and Operation The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine compartment. The CAB uses the wheel speed information from the wheel speed sensors to control the ABS system function. The CAB also monitors ABS operation and detects system faults. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4835 Electronic Brake Control Module: Service and Repair 1. Turn ignition Off. 2. Remove speed control servo. 3. Disconnect wiring harness 60-way connector from anti-lock brake controller. 4. Remove controller mounting bolts, then the controller. 5. Reverse procedure to install. 6. Torque controller attaching bolts to 40 in. lbs. and electrical connector screw to 105 in. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Brake Fluid Pressure Sensor/Switch: Locations Engine Compartment Components. LH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 4840 Engine Compartment & Transaxle Components. LH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 4841 Brake Fluid Pressure Sensor/Switch: Description and Operation The switch activates a light on the dash panel to indicate that one of the hydraulic systems has failed. There are two basic types of switches. In some earlier models, as pressure falls in one system, the normal pressure of the other system forces the piston to the inoperative side where it contacts the switch terminal, causing the warning lights to illuminate. On most models, the brake warning switch is of the latching type. If a pressure loss occurs in one side of the system, the piston in the valve is forced toward the failed side where it latches in position and illuminates the warning light. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations I/P, Cowl & Steering Column Components LH Kickpanel On Park Brake Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations Wheel Speed Sensor: Locations The wheel speed sensors are located at each wheel and transmit wheel speed information to the Controller Anti-Lock Brake. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4848 Wheel Speed Sensor: Description and Operation The wheel speed sensors are located at each wheel and transmit wheel speed information to the Controller Anti-Lock Brake (CAB). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Fig. 66 Front Speed Sensor Assembly 1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove screw from clip that retains sensor wiring grommet, then pull sensor grommet from fenderwell. 3. Disconnect electrical connector, then remove two screws retaining sensor wiring routing tube. 4. Remove sensor head screw, then the sensor head from steering knuckle. CAUTION: If sensor head is seized, use a punch and gently rock sensor back and forth until free. Do not use pliers on sensor head. 5. Reverse procedure to install. Coat sensor with suitable high temperature E.P. grease and Torque mounting bolt to 60 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4851 Wheel Speed Sensor: Service and Repair Rear 1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove sensor wiring grommet retainer bracket, then pull sensor grommet from underbody. 3. Disconnect electrical connector, then remove wiring to frame rail attaching bracket. 4. Remove rear axle U-bolt nuts, then the sensor assembly mounting bracket. 5. Remove sensor head screw, then the sensor head from steering knuckle. If sensor head is seized, use a punch and gently rock sensor back and forth until free. Do not use pliers on sensor head. 6. Reverse procedure to install. Torque sensor mounting bolt to 60 inch lbs. and U-bolt nuts to 65 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Clutch (Inhibitor) Switch Test 1. Disconnect double connector at switch pigtail, then connect a 12 volt power source to either end of switch terminal. 2. Connect a test light to remaining terminal end and ground. 3. Test light should be on when pedal is in normal position and off when pedal is depressed. 4. If above step is not as specified, replace clutch switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Locations Ignition Switch: Locations I/P, Cowl & Steering Column Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Locations > Page 4860 Steering Column Components Top Of Steering Column Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Locations > Page 4861 Ignition Switch: Service and Repair Fig. 10 Ignition switch replacement 1. If equipped, disarm airbag system, refer to MAINTENANCE PROCEDURES. 2. Remove left lower instrument panel cover. 3. Position gear selector to D and disconnect indicator cable, if equipped with automatic transaxle. 4. Remove lower panel reinforcement, then five steering column to support bracket attaching nuts. 5. Lower column and disconnect ignition switch electrical connector. 6. Position ignition lock cylinder in Lock position. 7. Tape ignition switch rod to steering column to prevent rod from falling out of lock cylinder assembly. 8. Remove two ignition switch attaching screws, then the switch. 9. Reverse procedure to install. Rearm airbag system, refer to MAINTENANCE PROCEDURES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > 3 Speed A/T Neutral Safety Switch: Locations 3 Speed A/T Neutral/Park Safety Switch Neutral Starting And Back-Up Lamp Switch The neutral starting switch is the center terminal of the 3 terminal switch. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > 3 Speed A/T > Page 4866 Neutral Safety Switch: Locations 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > 3 Speed A/T > Page 4867 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4870 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 Neutral Safety Switch: Electrical Diagrams 3 Speed A/T Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at the vehicle level. See: Diagrams/Electrical Diagrams 4 Speed A/T The Neutral Safety Switch wiring is part of the starting system circuit. See: Starting System/Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Description and Operation > 3 Speed A/T Neutral Safety Switch: Description and Operation 3 Speed A/T Neutral Starting And Back-Up Lamp Switch The neutral starting switch is the center terminal of the 3 terminal switch. - It provides ground for the starter solenoid circuit through the selector lever in only Park and Neutral positions. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Description and Operation > 3 Speed A/T > Page 4874 Neutral Safety Switch: Description and Operation 4 Speed A/T The Neutral Safety Switch sends a signal to the EATX control module and the engine control module, controlling starter relay operation when the transaxle is in any gear other than Park or Neutral. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Testing and Inspection > 3 Speed A/T Neutral Safety Switch: Testing and Inspection 3 Speed A/T Neutral Starting And Back-Up Lamp Switch Replacement And Test 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in Park or Neutral. 2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to Park and then to Neutral positions, and inspect to see that the switch operating lever fingers are centered in switch opening in the case. 4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 8. Continuity should exist only with transaxle in Reverse position. 9. No continuity should exist from either pin to the case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Testing and Inspection > 3 Speed A/T > Page 4877 Neutral Safety Switch: Testing and Inspection 4 Speed A/T The 4 speed Automatic Transaxle is computer controlled, if troubleshooting this system, extract codes. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair > 3 Speed A/T Neutral Safety Switch: Service and Repair 3 Speed A/T Neutral Starting And Back-Up Lamp Switch Replacement And Test 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in Park or Neutral. 2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to Park and then to Neutral positions, and inspect to see that the switch operating lever fingers are centered in switch opening in the case. 4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 8. Continuity should exist only with transaxle in Reverse position. 9. No continuity should exist from either pin to the case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair > 3 Speed A/T > Page 4880 Neutral Safety Switch: Service and Repair 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair > 3 Speed A/T > Page 4881 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Engine Compartment & Front End Components. On Left Fenderwell Applicable to: 4-153/2.5L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4886 Engine Compartment Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4887 Engine Compartment & Transaxle Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Electrical Specifications Battery: Electrical Specifications Standard Battery Standard Battery BCI Group Number 34 Cranking Performance 500 A Optional Battery Optional Battery BCI Group Number 34 Cranking Performance 625 A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Electrical Specifications > Page 4892 Battery: Mechanical Specifications Optional Battery Optional Battery BCI Group Number 34 Cranking Performance 625 A Standard Battery Standard Battery BCI Group Number 34 Cranking Performance 500 A Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Chrysler Alternator: Specifications Chrysler, Rated Output Chrysler, Rated Output Identification Number- 5233508 Minimum Output 98 A at 1250 rpm Note: At 15 Volts Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Chrysler > Page 4898 Alternator: Specifications Nippondenso, Rated Output Nippondenso, Rated Output Identification Number- 5227349 Minimum Output 87 A at 1250 rpm Note: At 15 Volts Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Preliminary Check Alternator: Testing and Inspection Preliminary Check Prior to testing system, ensure battery is fully charged and all connections are good. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Preliminary Check > Page 4901 Alternator: Testing and Inspection Alternator Output Wire Resistance Test On models equipped with airbags, before attempting to diagnose or service components, disconnect and isolate battery ground cable, then wait at least 10 minutes prior to beginning service. Failure to do so may result in accidental deployment or possible personal injury. TESTING 1. Disconnect battery ground cable. 2. Disconnect "B+" lead at alternator output terminal. Fig. 1 Alternator output wire resistance test. Except front wheel drive 3. Connect a 0-150 amp D.C. ammeter in series between alternator "B+" terminal and disconnected "B+" lead wire. 4. Connect positive lead wire of a suitable voltmeter to disconnected "B+" lead wire, then connect negative lead to battery positive post. 5. Remove air hose between Engine Controller and air cleaner. 6. On 1988-91 models except 1991 Front Wheel Drive vans and wagons and Jeep Cherokee, Comanche and Wrangler, ground one end of a suitable jumper wire and probe green R3 wire. This may generate a fault code. Use caution not to ground J2 wire. Both R3 and J2 wires are green on alternator side of wire connector. On dash side of connector, R3 wire is green, while J2 wire is blue. Fig. 2 Alternator output wire resistance test. Front wheel drive 7. On 1991 Front Wheel Drive vans and wagons, connect suitable jumper wire to ground and K20 (green) terminal, at rear of alternator. This may generate a fault code. Do not connect A21 (blue) circuit to ground, as fusible link will burn. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Preliminary Check > Page 4902 Fig. 3 Alternator output wire resistance test 8. On 1991-92 Jeep Cherokee, Comanche and Wrangler, connect suitable jumper wire to ground and K20 (green) lead wire at rear of alternator. This will generate a fault code. Do not connect A142 (green/orange) lead wire to ground. 9. On all 1992 models except Jeep Cherokee, Comanche and Wrangler, connect suitable jumper wire to ground and K20 (green) lead wire at rear of alternator. This will generate a fault code. Do not connect A142 (blue) lead wire to ground. 10. On all models, connect a suitable engine tachometer, then reconnect battery ground cable. 11. Ensure carbon pile is in OPEN or OFF position, then connect a variable carbon pile rheostat to battery terminals. 12. Start engine and operate at idle speed, then adjust carbon pile and engine speed to maintain a 20 amp circuit flow. Note voltmeter reading. Voltmeter reading should not exceed .5 volt. TESTING RESULTS 1. If a higher than specified voltage drop is indicated, clean and tighten all connectors in charging circuit. A voltage drop test may be performed at each connector to locate point of excessive resistance. 2. If charging circuit resistance test was satisfactory, disconnect battery ground cable, then the ammeter, voltmeter, carbon pile and tachometer. 3. Remove jumper wire. 4. Connect battery ground cable, then the hose between Engine Controller and air cleaner. 5. On models quipped with on board diagnostics, erase codes using DRBII test tool or equivalent. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Preliminary Check > Page 4903 Alternator: Testing and Inspection Current Output Test On models equipped with airbags, before attempting to diagnose or service components, disconnect and isolate battery ground cable, then wait at least 10 minutes prior to beginning service. Failure to do so may result in accidental deployment or possible personal injury. TESTING 1. Disconnect battery ground cable. 2. Disconnect "B+" lead at alternator output terminal. Fig. 4 Alternator current output test. Except front wheel drive 3. Connect a 0-150 amp D.C. ammeter in series between alternator "B+" terminal and disconnected "B+" lead wire. 4. Connect positive lead of a suitable voltmeter to "B+" terminal of alternator, then connect negative lead to suitable ground. 5. Connect a suitable engine tachometer, then reconnect battery ground cable. 6. Connect a variable carbon pile rheostat between battery terminals, ensuring carbon piles are in Open or Off position. 7. Remove air hose between Engine Controller and air cleaner. 8. On 1988-91 models except 1991 Front Wheel Drive vans and wagons and Jeep Cherokee, Comanche and Wrangler, ground one end of a suitable jumper wire and probe green R3 wire. This may generate a fault code. Use caution not to ground J2 wire. Both R3 and J2 wires are green on alternator side of wire connector. On dash side of connector, R3 wire is green, while J2 wire is blue. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Preliminary Check > Page 4904 Fig. 5 Alternator current output test. Front wheel drive 9. On 1991 Front Wheel Drive vans and wagons, connect suitable jumper wire to ground and K20 (green) terminal, at rear of alternator. This may generate a fault code. Do not connect A21 (blue) circuit to ground, as fusible link will burn. Fig. 6 Alternator current output test Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Preliminary Check > Page 4905 10. On 1991-92 Jeep Cherokee, Comanche and Wrangler, connect suitable jumper wire to ground and K20 (green) lead wire at rear of alternator. This will generate a fault code. Do not connect A142 (green/orange) lead wire to ground. Fig. 3 Alternator output wire resistance test 11. On all 1992 models except Jeep Cherokee, Comanche and Wrangler, connect suitable jumper wire to ground and K20 (green) lead wire at rear of alternator. This will generate a fault code. Do not connect A142 (blue) lead wire to ground. 12. On all models, start engine and operate at idle speed, then adjust carbon pile and engine speed in increments until a speed of 1250 RPM at 15 volts is obtained. Do not allow voltmeter range to exceed 16 volts during testing. TEST RESULTS 1. Note ammeter reading. Ammeter reading should be within specified limits noted in specification charts in individual truck chapters. 2. If reading is less than specified and alternator wire resistance is not excessive, alternator is defective. 3. After completion of current output test, turn off carbon pile and ignition switch, then disconnect battery ground cable. 4. Remove ammeter, voltmeter, tachometer and carbon pile, then reconnect "B+" lead to alternator output terminal. 5. Disconnect jumper wire, then connect air hose from Engine Controller to air cleaner. 6. Connect battery ground cable. 7. On models quipped with on board diagnostics, erase codes using DRBII test tool or equivalent. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Page 4906 Alternator: Service and Repair 1. Disconnect battery ground cable. 2. Remove alternator drive belt, then the alternator mounting bolts. 3. Separate alternator from mounting bracket and remove electrical connectors. 4. Remove alternator from vehicle. 5. Reverse procedure to install. Torque mounting bolts to 250 inch lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Testing and Inspection Voltage Regulator: Testing and Inspection Voltage regulator is internal to the PCM. For testing see Charging System/Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Clutch (Inhibitor) Switch Test 1. Disconnect double connector at switch pigtail, then connect a 12 volt power source to either end of switch terminal. 2. Connect a test light to remaining terminal end and ground. 3. Test light should be on when pedal is in normal position and off when pedal is depressed. 4. If above step is not as specified, replace clutch switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Standard Column Ignition Lock: Service and Repair Standard Column 1. If equipped, disarm airbag system as described under MAINTENANCE PROCEDURES. 2. Remove steering wheel. Steering column cover, silencer & reinforcement removal 3. Remove steering column cover and silencer. 4. Remove shift indicator operating cable from slot in shift housing. 5. Pry off wiring trough from steering column, then disconnect control lever electrical connectors. 6. Remove screws attaching turn signal lever cover to lock housing, then lever cover. 7. Remove washer/wiper switch assembly. 8. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching screws. 9. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch. 10. Remove turn signal/hazard switch attaching screws. Turn signal switch replacement 11. On all models, remove turn signal/hazard warning switch assembly by gently pulling switch up from column while straightening and guiding wires up through column opening. 12. Remove key lamp assembly retaining screw, then key lamp assembly. 13. Remove retaining screws holding bearing housing to lock housing. 14. Remove snap ring from upper end of steering shaft, then bearing housing from shaft. 15. Remove lock plate spring and lock plate from steering shaft. 16. Remove ignition key. 17. Remove buzzer/chime switch attaching screws, then remove switch. 18. Remove two screws attaching ignition switch to steering column, then remove switch by rotating it 90° and sliding from rod. 19. Remove two screws attaching dimmer switch, then disengage dimmer switch from actuator rod. 20. Remove two bell crank attaching screws, then slide bell crank up into lock housing until it can be disconnected from ignition switch actuator rod. Fig. 7 Ignition lock removal. W/standard column Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Standard Column > Page 4918 21. With lock cylinder in Lock position, insert a small diameter screwdriver into lock cylinder release holes and push inward until spring loaded lock cylinder retainers release. 22. Remove lock cylinder from lock housing bore. 23. Reverse procedure to install. Rearm airbag system. Lock cylinder and ignition switch must be in Lock position. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Standard Column > Page 4919 Ignition Lock: Service and Repair Tilt Column Tilt Column 1. If equipped, disarm airbag system as described under MAINTENANCE PROCEDURES. 2. Remove steering wheel. Steering column cover, silencer & reinforcement removal 3. Remove steering column cover and silencer. 4. Remove shift indicator operating cable from slot in shift housing. 5. Pry off wiring trough from steering column, then disconnect control lever electrical connectors. a. Remove tilt lever, then hazard warning knob. Push knob in and unscrew to remove. b. Remove ignition key lamp assembly, then remove knob off washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch. Lock plate removal. Models w/tilt column e. Depress lock plate using lock plate compressor No. C-4156 or equivalent and pry retaining ring out of groove with a suitable screwdriver. The full load of upper bearing spring should not be relieved. If full load is relieved, retaining ring will turn too easily and make removal difficult. f. Remove lock plate, cancelling cam and upper bearing spring. g. Remove turn signal/hazard switch actuator screws and arm. h. Remove turn signal/hazard switch attaching screws, Place shift bowl in Low position. Turn signal switch replacement 6. Remove turn signal/hazard warning switch assembly by gently pulling switch up from column while straightening and guiding wires up through column opening. 7. Remove ignition key lamp. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Standard Column > Page 4920 Fig. 2 Ignition lock removal. Models w/tilt column 8. Position ignition lock cylinder in Lock position, then insert a small diameter screwdriver into lock cylinder release holes and push inward until spring loaded lock cylinder retainers release. 9. Reverse procedure to install. Rearm airbag system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Locations Ignition Switch: Locations I/P, Cowl & Steering Column Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Locations > Page 4924 Steering Column Components Top Of Steering Column Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Locations > Page 4925 Ignition Switch: Service and Repair Fig. 10 Ignition switch replacement 1. If equipped, disarm airbag system, refer to MAINTENANCE PROCEDURES. 2. Remove left lower instrument panel cover. 3. Position gear selector to D and disconnect indicator cable, if equipped with automatic transaxle. 4. Remove lower panel reinforcement, then five steering column to support bracket attaching nuts. 5. Lower column and disconnect ignition switch electrical connector. 6. Position ignition lock cylinder in Lock position. 7. Tape ignition switch rod to steering column to prevent rod from falling out of lock cylinder assembly. 8. Remove two ignition switch attaching screws, then the switch. 9. Reverse procedure to install. Rearm airbag system, refer to MAINTENANCE PROCEDURES. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > 3 Speed A/T Neutral Safety Switch: Locations 3 Speed A/T Neutral/Park Safety Switch Neutral Starting And Back-Up Lamp Switch The neutral starting switch is the center terminal of the 3 terminal switch. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > 3 Speed A/T > Page 4930 Neutral Safety Switch: Locations 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > 3 Speed A/T > Page 4931 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 Neutral Safety Switch: Electrical Diagrams 3 Speed A/T Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at the vehicle level. See: Diagrams/Electrical Diagrams 4 Speed A/T The Neutral Safety Switch wiring is part of the starting system circuit. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Description and Operation > 3 Speed A/T Neutral Safety Switch: Description and Operation 3 Speed A/T Neutral Starting And Back-Up Lamp Switch The neutral starting switch is the center terminal of the 3 terminal switch. - It provides ground for the starter solenoid circuit through the selector lever in only Park and Neutral positions. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Description and Operation > 3 Speed A/T > Page 4938 Neutral Safety Switch: Description and Operation 4 Speed A/T The Neutral Safety Switch sends a signal to the EATX control module and the engine control module, controlling starter relay operation when the transaxle is in any gear other than Park or Neutral. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Testing and Inspection > 3 Speed A/T Neutral Safety Switch: Testing and Inspection 3 Speed A/T Neutral Starting And Back-Up Lamp Switch Replacement And Test 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in Park or Neutral. 2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to Park and then to Neutral positions, and inspect to see that the switch operating lever fingers are centered in switch opening in the case. 4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 8. Continuity should exist only with transaxle in Reverse position. 9. No continuity should exist from either pin to the case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Testing and Inspection > 3 Speed A/T > Page 4941 Neutral Safety Switch: Testing and Inspection 4 Speed A/T The 4 speed Automatic Transaxle is computer controlled, if troubleshooting this system, extract codes. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Service and Repair > 3 Speed A/T Neutral Safety Switch: Service and Repair 3 Speed A/T Neutral Starting And Back-Up Lamp Switch Replacement And Test 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in Park or Neutral. 2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to Park and then to Neutral positions, and inspect to see that the switch operating lever fingers are centered in switch opening in the case. 4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 8. Continuity should exist only with transaxle in Reverse position. 9. No continuity should exist from either pin to the case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Service and Repair > 3 Speed A/T > Page 4944 Neutral Safety Switch: Service and Repair 4 Speed A/T Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Service and Repair > 3 Speed A/T > Page 4945 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Starter Replacement - Information Only Starter Motor: Technical Service Bulletins Starter Replacement - Information Only NO.: 08-12-93 GROUP: Electrical DATE: Mar. 19, 1993 SUBJECT: 3.0L Engine Starter Replacement MODELS: 1989 - 1993 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country If the starter motor on subject vehicles requires replacement, use only P/N 4557284. It may be necessary to adjust the wiring harness at the points where it is secured to the body in order to obtain an appropriate wiring length for connection to the replacement starter motor. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications Starter Motor Specifications Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 4952 Starter Motor: Mechanical Specifications Starter Motor Specifications Starter To Transaxle Bellhousing Bolt 40 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4953 Starter Motor: Locations View Of Engine & Transmission Components. Front Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4954 Starter Motor: Description and Operation Two types of starters are used. The first type is a direct drive starter motor with an overrunning clutch type starter drive. A solenoid switch is mounted on the starter motor. The second type is a permanent magnet reduction gear starter. A planetary gear train transmits power between starter motor and pinion shaft. The structure is different on both type starters, but electrical wiring is the same. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4955 Fig. 1 Starter motor diagnosis Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4956 Starter Motor: Service and Repair 1. Disconnect battery ground cable. 2. On 3.0L/V6-181 models, loosen air pump tube at exhaust manifold, then swivel tube away from starter. 3. On all models, disconnect all electrical connectors from starter motor. 4. Remove starter motor attaching bolts. 5. Remove starter. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Engine Compartment & Front End Components. On Left Fenderwell Applicable to: 4-153/2.5L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4960 Engine Compartment Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4961 Engine Compartment & Transaxle Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing and Inspection Starter Solenoid: Testing and Inspection Bench Testing Starter Solenoid Fig. 4 Bosch starter solenoid terminal identification Fig. 5 Nippondenso starter solenoid terminal identification 1. Remove starter assembly from vehicle. 2. Disconnect field coil wire from field coil terminal. 3. Check for continuity between solenoid terminal and field coil terminal. Continuity should exist. 4. Check for continuity between solenoid terminal and solenoid housing. Continuity should exist. 5. If there is no continuity in either step 3 or 4, solenoid has an open circuit and must be replaced. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Circuit Location Amp Power Window Motors......................Fuse Block...........30 Power Door Locks, Seats & Mirror.........Fuse Block...........30 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 Circuit Breaker: Electrical Diagrams Circuit Location Amp Power Window Motors......................Fuse Block...........30 Power Door Locks, Seats & Mirror.........Fuse Block...........30 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Page 4973 Circuit Breaker: Testing and Inspection NOTE: Perform SWITCH VOLTAGE TEST, and verify that the battery is fully charged before starting this test. 1. Locate the circuit breaker (in the fuse box) and connect the positive lead of a voltmeter to the light green terminal. Connect the other lead of the voltmeter to a good ground and check that there is battery voltage. 2. If battery voltage is not present, connect the voltmeter to the other (battery) side of the circuit breaker and check for battery voltage. 3. If battery voltage is present, the circuit breaker is defective and needs to be replaced. If battery voltage is not present, check for an open wire in the harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Lower I/P Components RH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 Fuse Block: Connector Views Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 Fuse Panel Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4983 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4984 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4985 Fuse Block: Electrical Diagrams Fuse Panel Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4986 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 Fuse Panel Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4990 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > A604 EATX - Wiring Repair Package Multiple Junction Connector: Technical Service Bulletins A604 EATX - Wiring Repair Package NO.: 08-16-90 GROUP: ELECTRICAL DATE: Sept. 24, 1990 SUBJECT: A604 EATX Wiring Harness/ Electronic Connector Repair Package MODEL YEARS/BODY CODES: 1989-90 AC - DYNASTY/NEW YORKER/NEW YORKER LANDAU AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY 1990 AA - ACCLAIM/SPIRIT AG - DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AY - IMPERIAL/FIFTH AVENUE DISCUSSION When inspecting wiring and connectors, look for cut wiring or worn through insulation, terminal push-out, and spreading of terminals. These problems have led to intermittent setting of fault codes 12, 39, and 41 among others. Wiring must be properly routed and secure to avoid sharp or moving parts. Connector seals, covers, and shields must be present and in good shape. Terminals must be clean and fully engaged with a tight fit. The 60-way, 8-way and other sealer connectors for the A604 EATX should contain Mopar Lubriplate grease PN 4549615 in the female terminals. When wiring, connectors or terminals need repair on an A604 EATX the following service parts are now available. REQUIRED PARTS FOR REPAIRS Repair Package - 8-Way Solenoid Connector 4419476 (Connector Assembly on Wire w/Heat Shrink) Repair Package - 2-Way Connector (For 4419478 Output and Turbine Speed Sensors) Repair Package - 60-Way Connector 4419479 (14 Two Terminal Leads) Repair Package - 60-Way Insulator 4419491 60-Way Connector Outer Shield 4400980 REQUIRED PARTS FOR MAKING A GAUGE 0.045 in. Male Pin Terminal - 2-Way 4400110 0.090 in. Male Pin Terminal - 8-Way 4368163 Heat Shrink Tubing - 0.25 in. Diameter 4419644 PROCEDURE FOR MAKING A GAUGE To properly check a terminal for spreading, a gauge is required. To make a gauge, select the correct male pins from the parts list above (pins for gauging the 60-way connector are included in Repair Package PN 4419479). Two pins are required to make each gauge. Insert the base of a pin into each end of a single piece of heat shrink tubing PN 4419644. Heat evenly until the tubing shrinks tightly onto the base of both pins. The shrink tubing will now serve as a handle while gauging terminals. INSPECTING CONNECTORS Inspect connectors for pushed out terminals by removing from the A604 EATX and looking at the face of the connectors. If terminals are pushed out, carefully remove the locking wedge and push in the terminals until they snap into position. Carefully install the wedge until it is flush with the outer surface. Make sure that all of the terminals remain fully seated. If the wedge does not go in all of the way, clear the wedge cavity and reinstall the wedge. To inspect the connector for spread terminals, take the appropriate size gauge and insert it into each of the female connector pins. The terminals should mate snugly with the gauge. Verify proper transaxle operation after service. NOTE: WHEN REPLACING EITHER THE SPEED SENSOR OR SOLENOID PACK, MAKE SURE THAT ALL TERMINALS HAVE AN INTERFERENCE FIT. 60-WAY CONNECTOR REPAIRS If the 60-way insulator is damaged or the locking fingers are broken, replace the insulator using repair package PN 4419491. If terminals are damaged or Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > A604 EATX - Wiring Repair Package > Page 4995 spread, replace them using Repair Package 4419479 and the following procedure. 1. Remove the shield, wedge, and tape as needed. Remove the bad terminal while flexing the plastic locking finger. 2. Cut the wire with the bad terminal from the wiring harness. Strip one half inch of insulation from the remaining wire and slide on a piece of heat shrink tubing included in the Repair Package. 3. Select from the Repair Package a wire of the same base color as the wire just cut from the harness. Cut the wire to the proper length and remove one half inch of insulation from the wire and twist the two bare ends around each other. 4. Solder the joint together using a ROSIN CORE SOLDER. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of heat shrink tubing. 5. Insert the new terminal and fully seat. Install the wedge, retape the harness and snap on the shield. If the shield is damaged, replace with PN 4400980. 6. Connect the 60-way connector and torque to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE. 8-WAY CONNECTOR If the 8-way insulator is damaged, the locking fingers are broken or terminals are spread replace the connector using Repair Package PN 4419476 and the following procedure. 1. With the vehicle raised disconnect the wiring from the solenoid pack and transmission switches and drop the wiring for access. 2. Remove the wire covering, cut the leads to the damaged 8-way at staggered even lengths and place a piece of heat shrink tubing on each wire. 3. Cut the matching wires on the new 8-way to staggered even lengths (allowing extra lengths for solder connections) so that the length of the new wiring is the same as the original wiring. 4. Strip one half inch of insulation from each wire and twist each pair of matching wires together. Solder each joint using a ROSIN CORE SOLDER. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of heat shrink tubing. 5. Install the covering and connect the wiring to the solenoid and switches following the original routing. 6. Torque the 8-way connector bolt to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE. 2-WAY CONNECTOR REPAIRS If the 2-way insulator is damaged, the locking fingers are broken or terminals are spread replace the connector using Repair Package PN 4419478 and the following procedure. 1. With the vehicle raised, disconnect the wiring from the solenoid pack and transmission switches and drop the wiring for access. 2. Cut the leads to the damaged 2-way at staggered even lengths and place a piece of heat shrink tubing on each wire. 3. Cut the matching wires on the new 2-way to staggered even lengths (allowing extra length for solder connections) so that the length of the new wiring is the same as the original wiring. 4. Strip one half inch of insulation from each wire and twist each pair of matching wires together. Solder each joint using a ROSIN CORE SOLDER. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tube. 5. Install the wiring in its original routing. 6. Torque the 8-way connector bolt to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 4996 Multiple Junction Connector: Locations LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Circuit Location Amp Power Window Motors......................Fuse Block...........30 Power Door Locks, Seats & Mirror.........Fuse Block...........30 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5003 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5004 Circuit Breaker: Electrical Diagrams Circuit Location Amp Power Window Motors......................Fuse Block...........30 Power Door Locks, Seats & Mirror.........Fuse Block...........30 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Page 5005 Circuit Breaker: Testing and Inspection NOTE: Perform SWITCH VOLTAGE TEST, and verify that the battery is fully charged before starting this test. 1. Locate the circuit breaker (in the fuse box) and connect the positive lead of a voltmeter to the light green terminal. Connect the other lead of the voltmeter to a good ground and check that there is battery voltage. 2. If battery voltage is not present, connect the voltmeter to the other (battery) side of the circuit breaker and check for battery voltage. 3. If battery voltage is present, the circuit breaker is defective and needs to be replaced. If battery voltage is not present, check for an open wire in the harness. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Lower I/P Components RH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5011 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 Fuse Block: Connector Views Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 Fuse Panel Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5016 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5017 Fuse Block: Electrical Diagrams Fuse Panel Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5018 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5019 Fuse Panel Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5020 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5021 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5022 Fuse Application Chart Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > A604 EATX - Wiring Repair Package Multiple Junction Connector: Technical Service Bulletins A604 EATX - Wiring Repair Package NO.: 08-16-90 GROUP: ELECTRICAL DATE: Sept. 24, 1990 SUBJECT: A604 EATX Wiring Harness/ Electronic Connector Repair Package MODEL YEARS/BODY CODES: 1989-90 AC - DYNASTY/NEW YORKER/NEW YORKER LANDAU AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY 1990 AA - ACCLAIM/SPIRIT AG - DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AY - IMPERIAL/FIFTH AVENUE DISCUSSION When inspecting wiring and connectors, look for cut wiring or worn through insulation, terminal push-out, and spreading of terminals. These problems have led to intermittent setting of fault codes 12, 39, and 41 among others. Wiring must be properly routed and secure to avoid sharp or moving parts. Connector seals, covers, and shields must be present and in good shape. Terminals must be clean and fully engaged with a tight fit. The 60-way, 8-way and other sealer connectors for the A604 EATX should contain Mopar Lubriplate grease PN 4549615 in the female terminals. When wiring, connectors or terminals need repair on an A604 EATX the following service parts are now available. REQUIRED PARTS FOR REPAIRS Repair Package - 8-Way Solenoid Connector 4419476 (Connector Assembly on Wire w/Heat Shrink) Repair Package - 2-Way Connector (For 4419478 Output and Turbine Speed Sensors) Repair Package - 60-Way Connector 4419479 (14 Two Terminal Leads) Repair Package - 60-Way Insulator 4419491 60-Way Connector Outer Shield 4400980 REQUIRED PARTS FOR MAKING A GAUGE 0.045 in. Male Pin Terminal - 2-Way 4400110 0.090 in. Male Pin Terminal - 8-Way 4368163 Heat Shrink Tubing - 0.25 in. Diameter 4419644 PROCEDURE FOR MAKING A GAUGE To properly check a terminal for spreading, a gauge is required. To make a gauge, select the correct male pins from the parts list above (pins for gauging the 60-way connector are included in Repair Package PN 4419479). Two pins are required to make each gauge. Insert the base of a pin into each end of a single piece of heat shrink tubing PN 4419644. Heat evenly until the tubing shrinks tightly onto the base of both pins. The shrink tubing will now serve as a handle while gauging terminals. INSPECTING CONNECTORS Inspect connectors for pushed out terminals by removing from the A604 EATX and looking at the face of the connectors. If terminals are pushed out, carefully remove the locking wedge and push in the terminals until they snap into position. Carefully install the wedge until it is flush with the outer surface. Make sure that all of the terminals remain fully seated. If the wedge does not go in all of the way, clear the wedge cavity and reinstall the wedge. To inspect the connector for spread terminals, take the appropriate size gauge and insert it into each of the female connector pins. The terminals should mate snugly with the gauge. Verify proper transaxle operation after service. NOTE: WHEN REPLACING EITHER THE SPEED SENSOR OR SOLENOID PACK, MAKE SURE THAT ALL TERMINALS HAVE AN INTERFERENCE FIT. 60-WAY CONNECTOR REPAIRS If the 60-way insulator is damaged or the locking fingers are broken, replace the insulator using repair package PN 4419491. If terminals are damaged or Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > A604 EATX - Wiring Repair Package > Page 5027 spread, replace them using Repair Package 4419479 and the following procedure. 1. Remove the shield, wedge, and tape as needed. Remove the bad terminal while flexing the plastic locking finger. 2. Cut the wire with the bad terminal from the wiring harness. Strip one half inch of insulation from the remaining wire and slide on a piece of heat shrink tubing included in the Repair Package. 3. Select from the Repair Package a wire of the same base color as the wire just cut from the harness. Cut the wire to the proper length and remove one half inch of insulation from the wire and twist the two bare ends around each other. 4. Solder the joint together using a ROSIN CORE SOLDER. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of heat shrink tubing. 5. Insert the new terminal and fully seat. Install the wedge, retape the harness and snap on the shield. If the shield is damaged, replace with PN 4400980. 6. Connect the 60-way connector and torque to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE. 8-WAY CONNECTOR If the 8-way insulator is damaged, the locking fingers are broken or terminals are spread replace the connector using Repair Package PN 4419476 and the following procedure. 1. With the vehicle raised disconnect the wiring from the solenoid pack and transmission switches and drop the wiring for access. 2. Remove the wire covering, cut the leads to the damaged 8-way at staggered even lengths and place a piece of heat shrink tubing on each wire. 3. Cut the matching wires on the new 8-way to staggered even lengths (allowing extra lengths for solder connections) so that the length of the new wiring is the same as the original wiring. 4. Strip one half inch of insulation from each wire and twist each pair of matching wires together. Solder each joint using a ROSIN CORE SOLDER. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of heat shrink tubing. 5. Install the covering and connect the wiring to the solenoid and switches following the original routing. 6. Torque the 8-way connector bolt to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE. 2-WAY CONNECTOR REPAIRS If the 2-way insulator is damaged, the locking fingers are broken or terminals are spread replace the connector using Repair Package PN 4419478 and the following procedure. 1. With the vehicle raised, disconnect the wiring from the solenoid pack and transmission switches and drop the wiring for access. 2. Cut the leads to the damaged 2-way at staggered even lengths and place a piece of heat shrink tubing on each wire. 3. Cut the matching wires on the new 2-way to staggered even lengths (allowing extra length for solder connections) so that the length of the new wiring is the same as the original wiring. 4. Strip one half inch of insulation from each wire and twist each pair of matching wires together. Solder each joint using a ROSIN CORE SOLDER. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tube. 5. Install the wiring in its original routing. 6. Torque the 8-way connector bolt to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 5028 Multiple Junction Connector: Locations LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear Alignment: Customer Interest Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Fig. 1-Shim Installation for Toe-Out Fig. 2-Shim Installation for Toe-in Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 5038 Fig. 3-Shim Installation for Positive Camber Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 5039 completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear Alignment: All Technical Service Bulletins Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Fig. 1-Shim Installation for Toe-Out Fig. 2-Shim Installation for Toe-in Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 5045 Fig. 3-Shim Installation for Positive Camber Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 5046 completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5047 Alignment: By Symptom Technical Service Bulletin # 020790 Date: 901105 Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Fig. 1-Shim Installation for Toe-Out Fig. 2-Shim Installation for Toe-in Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5048 Fig. 3-Shim Installation for Positive Camber Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5049 completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Technical Service Bulletin # 020790 Date: 901105 Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5050 Fig. 1-Shim Installation for Toe-Out Fig. 2-Shim Installation for Toe-in Fig. 3-Shim Installation for Positive Camber Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5051 Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5052 The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Technical Service Bulletin # 020790 Date: 901105 Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Fig. 1-Shim Installation for Toe-Out Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5053 Fig. 2-Shim Installation for Toe-in Fig. 3-Shim Installation for Positive Camber Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5054 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Technical Service Bulletin # 020790 Date: 901105 Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5055 reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Fig. 1-Shim Installation for Toe-Out Fig. 2-Shim Installation for Toe-in Fig. 3-Shim Installation for Positive Camber Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5056 Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5057 The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Alignment Specifications Front Wheel Alignment Specifications Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Alignment Specifications > Page 5060 Rear Wheel Alignment Specifications Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment Alignment: Service and Repair Front Alignment Camber Fig. 1 Camber adjustment To adjust camber, loosen cam and through bolts. Rotate upper cam bolt to move top of wheel in or out to achieve specified camber angle. Torque cam bolt nut to 75 ft. lbs. plus an additional 1/4 turn. Caster The caster angle on these vehicles cannot be adjusted. Preliminary Inspection Prior to wheel alignment, ensure tires are at recommended pressure, are of equal size and have approximately the same wear pattern. Check front wheel and tire assembly for radial runout and inspect lower ball joints and steering linkage for looseness. Check front and rear springs for sagging or damage. Front suspension inspections should be performed on a level floor or alignment rack with fuel tank at capacity and vehicle free of luggage and passenger compartment load. Before each alignment reading, the vehicle should be bounced an equal number of times from the center of the bumper alternating first from the rear, then the front, and releasing at bottom of down cycle. Toe Adjustment Fig. 2 Toe-in adjustment To adjust toe-in, center steering wheel and hold in position with a suitable tool. Loosen tie rod locknuts and rotate rod, to adjust toe-in to specifications. Use care not to twist steering gear rubber boots. Torque tie rod locknuts to 55 ft. lbs. Adjust position of steering gear rubber boots. Remove steering wheel holding tool. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment > Page 5063 Alignment: Service and Repair Rear Alignment Rear wheel alignment is not adjustable. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Fig. 9 Steering knuckle assembly Fig. 10 Steering knuckle assembly REMOVAL 1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut. Ensure splined driveshaft is free to separate from spline in hub during knuckle removal. A pulling force on shaft can separate inner C/V joint. Tap lightly with brass drift, if required. 5. Disconnect tie rod end from steering arm with a suitable puller. 6. Disconnect brake hose retainer from strut damper. 7. Remove clamp bolt securing ball joint stud into steering knuckle, then the brake caliper adapter screw and washer assemblies. 8. Support caliper with a piece of wire. Do not hang by brake hose. 9. Remove rotor, then separate ball joint stud from knuckle assembly. 10. Remove knuckle assembly from vehicle. Support driveshaft during knuckle removal. Do not permit driveshaft to hang after separating steering knuckle from vehicle. INSTALLATION 1. Place steering knuckle on lower ball joint stud and the driveshaft through hub. 2. Install and tighten ball joint to steering knuckle clamp bolt to specifications. 3. Install tie rod end into steering arm and tighten nut to specifications. Install cotter pin. 4. Install rotor. 5. Install caliper over rotor and position adapter to steering knuckle. Install adapter to knuckle attaching bolts and tighten to specifications. 6. Attach brake hose retainer to strut damper and tighten attaching screw to specifications. 7. Install hub nut assembly as follows: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 5068 a. With brakes applied, install hub nut and tighten to specifications. b. Install spring washer, locknut and new cotter pin. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair 1. With fluid at room temperature, ensure reservoir is at correct level. 2. Allow fluid to settle for a minimum of two minutes. 3. Start and run engine for a few minutes. 4. Add fluid as necessary, then repeat above steps until fluid level is constant. 5. Raise front wheels off ground. 6. Start engine, then slowly turn steering wheel left and right. Lightly contacting stops. 7. Stop engine and check fluid level, fill as necessary. 8. If fluid is extremely foamy, let stand for a few minutes, then repeat procedure. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications Power Steering Pressure Specifications Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5076 Power Steering Pump: Service and Repair 1. Disconnect vapor separator hose and wires from air conditioning clutch cycling switch. 2. Remove drive belt adjustment locking screw, then pump end hose bracket nut. 3. Raise and support vehicle. 4. Disconnect return hose from gear tube, then drain oil from pump. 5. Remove right side splash shield. 6. Disconnect both hoses from pump. Cap all open hose ends and ports. 7. Remove lower stud nut and pivot screw from pump. 8. Lower vehicle and remove belt from pulley. 9. Move pump rearward to clear mounting bracket and remove adjustment bracket. 10. Rotate pump clockwise so pump pulley faces rear of vehicle, remove pump from vehicle. 11. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming 1. Place ignition switch in lock position. 2. Disconnect and tape battery ground cable connector. 3. Wait at least 1 minute after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy airbag for a short time even after battery has been disconnected. 4. After repairs are performed, connect battery ground cable. 5. From passenger side of vehicle, turn ignition switch to On position. 6. SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate if SRS system is functioning correctly. 7. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Application and ID Steering Gear: Application and ID 88-92 Ram Van, Varavan & Voyager TRW Rack & Pinion Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Application and ID > Page 5084 Steering Gear: Description and Operation Fig. 1 Rack & pinion steering gear The steering gear assembly used on Chrysler Corp. front wheel drive trucks and vans and Dodge Dakota, consists of a housing which contains a toothed rack, a pinion, rack slipper and rack slipper spring. The steering gear rack and pinion assembly converts rotational movement of the pinion assembly into transverse movement of the rack. Tie rods and tie rod ends transmit this movement to the steering arms and wheels while accommodating suspension movement at the same time. The tie rods are coupled to the ends of the rack. This connection is protected by a bellows type oil seal which retains steering gear lubricant. The pinion runs on straddle mounted ball bearings. The lower bearing is incorporated in the pinion housing. The upper bearing is swagged to the pinion shaft. Lock to lock stops are built into the steering gear. The 1991-92 Dakota rack and pinion gears have a larger diameter stud than previous years, so these are not interchangeable. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Hard Steering Steering Gear: Testing and Inspection Hard Steering 1. Tires improperly inflated. 2. Low fluid level. 3. Loose belt. 4. Lack of ball joint lubrication. 5. Low pump pressure. 6. High internal gear leak. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Hard Steering > Page 5087 Steering Gear: Testing and Inspection Poor Return to Center 1. Tires improperly inflated. 2. Improper front wheel alignment. 3. Lack of lubrication in ball joint. 4. Steering column U-joints misaligned. 5. Improperly positioned dash cover. 6. Steering wheel rubbing. 7. Tight steering shaft bearings. 8. Excessive friction coupling universal joint. 9. High friction in steering gear. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Hard Steering > Page 5088 Steering Gear: Testing and Inspection Steering Wheel Binds 1. Low fluid level. 2. Tires improperly inflated. 3. Lack of lube in ball joints or outer tie rod ends. 4. Loose pump belt. 5. Faulty pump flow. 6. Excessive friction in steering column or intermediate shaft. 7. Steering column coupling binding. 8. Excessive friction in gear. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Hard Steering > Page 5089 Steering Gear: Testing and Inspection Steering Wheel Shudder 1. Air in power steering system. 2. Tires improperly inflated. 3. Excessive engine vibration. 4. Faulty accessory drive belt tensioner. 5. Overcharged air conditioning system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 5090 Steering Gear: Adjustments 1. With rack placed in center position, attach rack support cover to gear housing, then tighten cover to specifications using torque wrench socket MB990607-A or equivalent. Back off cover approximately 10°, then install and tighten locking nut to specifications. 2. Rotate pinion gear at a rate of one revolution every 4 to 6 seconds using preload socket CT-1108 and a suitable torque wrench. Total pinion preload should be 5-11 lb-in. NOTE: Measure starting torque through whole stroke of rack. 3. If measured values are not within specifications, readjust rack support cover, then recheck. 4. If still not within specifications, check rack support cover, rack support spring and rack support and replace parts as necessary. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement Steering Gear: Service and Repair Steering Gear Replacement FWD MODELS 1. Raise and support vehicle, then remove front wheels. 2. Remove tie rod ends using a suitable puller. 3. On all models, remove splash shields and boot seal shields, then the fluid lines to pump on power steering gear only. 4. Disconnect tie rod ends from steering knuckles. 5. Remove crossmember to steering gear attaching bolts, then the steering gear from left side of vehicle. 6. Reverse procedure to install noting the following: a. For manual gear, make sure master serrations are in line. b. The right rear crossmember bolt is a pilot bolt that correctly locates the crossmember. Tighten this bolt first. Tighten all four crossmember bolts to specifications. Proper torque is very important. c. Tighten four bolts attaching steering gear to crossmember to specifications. AWD MODELS Fig. 19 Bridge assembly. AWD models Fig. 20 Steering gear assembly. AWD models 1. Remove steering column as described in STEERING WHEEL. 2. Remove tie rod ends from steering knuckle using suitable puller. 3. Remove two bolts and two nuts attaching bridge assembly to crossmember. Gain access to bolts through holes in top of bridge assembly. 4. Remove crossmember to frame rail attaching bolts. Using a suitable jack, lower and suspend crossmember from lower control arm. Do not remove crossmember from vehicle. 5. Disconnect power steering pump, pressure and return lines from steering gear. 6. Remove power steering hose to crossmember bracket. 7. Remove four bolts attaching steering gear to crossover bridge. Note length during removal. 8. Remove lower steering column coupling from steering gear. Drive roll pin from coupler using suitable drift. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5093 9. Remove steering gear from vehicle by pulling out from driver's side wheelwell. 10. Reverse procedure to install. Tighten to specifications. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5094 Steering Gear: Service and Repair Rack and Pinion Disassembly On 1989-92 models, gear is not repairable. If a problem is indicated, unit must be replaced. 1. Disarm airbag system, refer to Air Bags and Seat Belts/Air Bags (Supplemental Restraint Systems)/Service and Repair. 2. Mark location of tie rod end on tie rod, loosen jam nut and remove tie rod end. Fig. 1 Exploded view of TRW power rack & pinion steering gear 3. Remove jam nuts and bellow clamps. 4. Mark breather tube location on bellows and remove from steering gear. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5095 Fig. 2 Removing inner tie rod from rack 5. using a wrench to prevent rack from rotating, position a wrench on inner tie rod pivot housing flats. Turn housing counterclockwise until tie rod assembly separates from rack. Fig. 3 Exploded view of rack bearing 6. Loosen adjuster plug locknut then, remove adjuster plug, spring and rack bearing. Fig. 4 Removing rack bulkhead retaining wire 7. Using a punch, rotate the right side rack bulkhead retaining wire clockwise to expose end of retaining wire. Pull retaining wire out of cylinder slot. 8. Turn stub shaft, moving rack to the right forcing the bulkhead out of the housing. Use drain pan to catch excess fluid. Remove rack. 9. Remove input shaft retaining ring, followed by pinion plug. Fig. 5 Removing pinion locknut from pinion shaft 10. While holding stub shaft in place with holding fixture No. SP-3616, remove pinion locknut from pinion shaft. If stub shaft is not held in place while removing locknut, damage to the pinion teeth may result. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5096 Fig. 6 Removing valve & pinion assembly 11. If only stub shaft seals are to be replaced, position tool No. L-4594-1-2-3 over stub shaft and pull valve and pinion assembly out of valve housing until flush with ball bearing assembly. Complete removal of valve and pinion assembly is not necessary to replace stub shaft seals. 12. To remove valve and pinion assembly, rotate stub shaft until rack is centered in housing, with pinion fully engaged. Mark position of stub shaft flat on housing for reassembly. Using tool No. L-4594-1-2-3 pull valve and pinion assembly out of valve housing. If necessary, remove valve body seal rings. Fig. 7 Removing pinion shaft lower seal 13. Remove pinion shaft lower seal using seal remover No. C4694. 14. Remove pinion bearing using a drift or punch, gently tap on bearing until bearing is removed. Fig. 8 Removing inner rack oil seal 15. Remove inner rack seal from rack housing and dispose using tool No. C-4665. 16. Remove and dispose of rack piston ring, inner rack seal, bulkhead seal and bulkhead O-ring. 17. Mark breather tube to housing location and remove tube. Assembly 1. Align breather tube with previously made marks on housing, then install grommet so tabs lock. 2. Install new piston ring on rack, position seal protector No. C-4666 over rack teeth and slide seal with lip facing piston onto rack. 3. Remove seal protector and bottom the seal on rack piston, slide plastic retaining ring on rack onto seal. Slide rack, seal and piston ring into housing, using caution not to rip or deform ring or seal. Tap rack with a rubber hammer to seat seal. Do not attempt to remove upper pinion bushing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5097 Fig. 9 Bulkhead oil seal installation 4. Coat all seals with automatic transmission fluid then, assemble new O-ring onto bulkhead followed by new oil seal using tool No. C-4669. 5. Lubricate and install seat protector No. C-4670 or equivalent over rack threads, slide bulkhead assembly and end lock ring over seal protector, O-ring end first and insert in rack tube, using caution not to rip or distort the O-ring. Fig. 10 Installing bulkhead assembly into rack tube 6. Using tool No. C-4675, seat bulkhead in the rack tube. Install retaining wire by rotating bulkhead assembly counterclockwise. Remove protective tool. Fig. 11 Pinion shaft seal installation 7. Install pinion shaft lower seal using tool No. C-4883. Then using a suitable socket, press in on race of bearing, using caution not to cock bearing. 8. Install seal rings on valve body, if removed. 9. Center rack in housing, then install pinion shaft and valve assembly so that flat on stub shaft will be aligned with mark on housing when assembly is fully seated. Fig. 12 Stub shaft seal installation 10. Install stub shaft bearing then, position seal protector tool No. C-4668 or equivalent, slide shaft seal over protector into valve housing. Seat seal with seal installer No. C-4667 or equivalent and install retaining snap ring. 11. Install rack bearing, spring and adjuster plug. Turn adjuster plug until it bottoms, then back plug off 40 to 60°. Install locknut and torque to 50 ft. lbs. while holding adjuster plug in position. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5098 Fig. 13 Torquing inner tie rod pivot 12. Install tie rod assembly on rack. While holding rack in position with a wrench torque inner tie rod pivot housing to 60 ft. lbs.. If rack is not held in position while tightening tie rod housing, damage to the pinion teeth will result. 13. lubricate inner surfaces of bellows with silicone or other suitable lubricant. Align bellows marks made previously with breather tube and install bellows with boot seal over housing lip with hole in boot aligned with breather tube. Secure inner clamp. 14. Position bellows outer clamp and jam nut on tie rod. Install tie rod end in the position as removed. Torque jam nut to 55 ft. lbs., then install outer bellows clamp. Ensure bellows is not twisted. 15. Rearm airbag system, refer to Air Bags and Seat Belts/Air Bags (Supplemental Restraint Systems)/Service and Repair. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft Coupler: > 190289 > Apr > 89 > Power Steering Gear `Hissing' Noise Steering Shaft Coupler: Customer Interest Power Steering Gear - `Hissing' Noise Models 1988-1989 A/AC, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, & S/AS Body Equipped With Power Steering Subject Power Steering Gear "Hissing" Noise Index STEERING Date April 24, 1989 No. 19-02-89 (C19-03) BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU E CARAVELLE/600/NEW YORKER TURBO G/AG - DAYTONA H/AH - LANCER/LeBARON GTS J/AJ - LeBARON (2-DOOR COUPE/CONVERTIBLE) K/AK - ARIES/RELIANT/LeBARON (4-DOOR) TOWN & COUNTRY P/AP - SHADOW/SUNDANCE S/AS - CARAVAN/VOYAGER/CARAVAN C/V SYMPTOM/CONDITION Power steering gear "hissing" noise evident inside the passenger compartment. The hissing noise can be heard during quiet times in the vehicle while it is at rest with the engine running or while negotiating low speed turns. DIAGNOSIS Operate the vehicle under the above conditions to verify the noise and that other components of the steering gear system are operating properly. If all system components are OK then it will be necessary to replace the steering column lower coupling to isolate the noise. PARTS REQUIRED 1 Coupling Assembly PN 4470921 (A/AC, C/AC, E, G/AG, H/AH, J/AJ, K/AK, & P/AP Body) 1 Coupling Assembly (S/AS Body) PN 4470915 REPAIR PROCEDURE 1. Remove the lower steering column coupling per the instructions in the appropriate Front-Wheel-Drive Service Manual. 2. Replace the lower steering column coupling with the new one listed in the chart above. 3. Road test the vehicle to assure that the steering gear hissing noise is corrected. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 19-20-12-90 . . . . . . . . . . . 1.0 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft Coupler: > 190289 > Apr > 89 > Power Steering Gear - `Hissing' Noise Steering Shaft Coupler: All Technical Service Bulletins Power Steering Gear - `Hissing' Noise Models 1988-1989 A/AC, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, & S/AS Body Equipped With Power Steering Subject Power Steering Gear "Hissing" Noise Index STEERING Date April 24, 1989 No. 19-02-89 (C19-03) BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU E CARAVELLE/600/NEW YORKER TURBO G/AG - DAYTONA H/AH - LANCER/LeBARON GTS J/AJ - LeBARON (2-DOOR COUPE/CONVERTIBLE) K/AK - ARIES/RELIANT/LeBARON (4-DOOR) TOWN & COUNTRY P/AP - SHADOW/SUNDANCE S/AS - CARAVAN/VOYAGER/CARAVAN C/V SYMPTOM/CONDITION Power steering gear "hissing" noise evident inside the passenger compartment. The hissing noise can be heard during quiet times in the vehicle while it is at rest with the engine running or while negotiating low speed turns. DIAGNOSIS Operate the vehicle under the above conditions to verify the noise and that other components of the steering gear system are operating properly. If all system components are OK then it will be necessary to replace the steering column lower coupling to isolate the noise. PARTS REQUIRED 1 Coupling Assembly PN 4470921 (A/AC, C/AC, E, G/AG, H/AH, J/AJ, K/AK, & P/AP Body) 1 Coupling Assembly (S/AS Body) PN 4470915 REPAIR PROCEDURE 1. Remove the lower steering column coupling per the instructions in the appropriate Front-Wheel-Drive Service Manual. 2. Replace the lower steering column coupling with the new one listed in the chart above. 3. Road test the vehicle to assure that the steering gear hissing noise is corrected. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 19-20-12-90 . . . . . . . . . . . 1.0 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair Steering Wheel: Service and Repair 1. If equipped, disarm airbag system as described under MAINTENANCE PROCEDURES. 2. Disconnect battery ground cable. 3. On column shift models, disconnect gearshift cable rod from grommet in shift lever, then remove gearshift cable clip and cable from lower bracket. 4. On all models, disconnect wiring connectors at steering column jacket. 5. Remove steering wheel center pad assembly, then disconnect horn wire(s) and horn switch. 6. Remove steering wheel nut. 7. On automatic transaxle models, remove damper assembly. 8. On all models, remove steering wheel using puller No. C-3428B or equivalent. 9. Reverse procedure to install. Torque steering wheel attaching nut to 45 ft. lbs. and rearm airbag system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement Ball Joint: Service and Repair Lower Ball Joint Replacement Fig. 6 Ball joint wear inspection INSPECTION With weight of vehicle resting on wheel and tire assembly, attempt to move grease fitting with fingers. Do not use tool or added force to attempt to move grease fitting. If grease fitting moves freely, ball joint is worn and should be replaced. REPLACEMENT The ball joint is pressed into the lower control arm. On these models, the ball joint may be pressed from lower control arm using a 1-1/16 inch deep socket and ball joint installer tool No. C-4699-2 or equivalent. When pressing ball joint into lower control arm, use ball joint installer tool Nos. C-4699-1 and C-4699-2 or equivalents. Install ball joint seal using a 11* inch socket and ball joint installer tool No. C-4699-2 or equivalent. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement > Page 5120 Ball Joint: Service and Repair Upper Ball Joint Replacement Fig. 6 Ball joint wear inspection INSPECTION With weight of vehicle resting on wheel and tire assembly, attempt to move grease fitting with fingers. Do not use tool or added force to attempt to move grease fitting. If grease fitting moves freely, ball joint is worn and should be replaced. REPLACEMENT The ball joint is pressed into the lower control arm. On these models, the ball joint may be pressed from lower control arm using a 1-1/16 inch deep socket and ball joint installer tool No. C-4699-2 or equivalent. When pressing ball joint into lower control arm, use ball joint installer tool Nos. C-4699-1 and C-4699-2 or equivalents. Install ball joint seal using a 11* inch socket and ball joint installer tool No. C-4699-2 or equivalent. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair Control Arm: Service and Repair Fig. 7 Lower control arm assembly REMOVAL 1. Raise and support vehicle. 2. Remove front inner pivot through bolt, rear stub strut nut, retainer and bushing, then the ball joint to steering knuckle clamp bolt. 3. Separate ball joint from steering knuckle by prying between ball stud retainer and lower control arm. Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C/V joint. 4. Remove sway bar to control arm nut, then rotate control arm over sway bar. 5. Remove rear stub strut bushing, sleeve and retainer. On AWD models, pivot bushings are not serviceable and must be replaced as a unit. INSTALLATION 1. Install retainer, bushing and sleeve on stub strut. 2. Position control arm over sway bar and install rear stub strut and front pivot into crossmember. 3. Install front pivot bolt and loosely assemble nut. 4. Install stub strut bushing and retainer and loosely assemble nut. 5. Install ball joint stud into steering knuckle, then the clamp bolt. Tighten clamp bolt to specifications. 6. Place sway bar end bushing retainer to control arm, then install retainer bolts. Tighten retainer bolts to specifications. 7. Lower vehicle so suspension fully supports vehicle, then tighten front pivot bolt and stub strut nut to specifications. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55 MPH Cross-Member: Customer Interest Exhaust System - Drone At 40-55 MPH Models 1987-90 S/AS Bodies With 2.5L & 3.0L Engines Subject Exhaust Drone At 40-55 MPH Index EXHAUST Date September 18, 1989 No. 11-02-89 (C11-01-9) P-3455 BODY CODE LEGEND S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH). DIAGNOSIS Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from under the floor pan area in front of the first bench seat. The vibration will also be present if the engine is run through the 2350-2450 RPM range with the transmission in neutral. PARTS REQUIRED 1 Crossmember Assembly PN 4427322 1 Muffler Support Bracket PN 4427295 1 Heat Shield PN 4401855 4 Screw & Washer Assembly PN 6501305 4 U-Nut PN 6101283 REPAIR PROCEDURE 1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the exhaust insulators to remain on the muffler. 2. Remove the muffler support bracket, crossmember, and heat shield. 3. Install new heat shield, using the fasteners just removed. 4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250 +/- 50 in. lbs., washer should bottom out on sleeve. 5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN 6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs. 6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs. 7. Road test vehicle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55 MPH > Page 5132 TIME ALLOWANCE: Labor Operation No. 11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 110289 > Sep > 89 > Exhaust System Drone At 40-55 MPH Cross-Member: All Technical Service Bulletins Exhaust System - Drone At 40-55 MPH Models 1987-90 S/AS Bodies With 2.5L & 3.0L Engines Subject Exhaust Drone At 40-55 MPH Index EXHAUST Date September 18, 1989 No. 11-02-89 (C11-01-9) P-3455 BODY CODE LEGEND S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH). DIAGNOSIS Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from under the floor pan area in front of the first bench seat. The vibration will also be present if the engine is run through the 2350-2450 RPM range with the transmission in neutral. PARTS REQUIRED 1 Crossmember Assembly PN 4427322 1 Muffler Support Bracket PN 4427295 1 Heat Shield PN 4401855 4 Screw & Washer Assembly PN 6501305 4 U-Nut PN 6101283 REPAIR PROCEDURE 1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the exhaust insulators to remain on the muffler. 2. Remove the muffler support bracket, crossmember, and heat shield. 3. Install new heat shield, using the fasteners just removed. 4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250 +/- 50 in. lbs., washer should bottom out on sleeve. 5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN 6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs. 6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs. 7. Road test vehicle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 110289 > Sep > 89 > Exhaust System Drone At 40-55 MPH > Page 5138 TIME ALLOWANCE: Labor Operation No. 11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Fig. 9 Steering knuckle assembly Fig. 10 Steering knuckle assembly REMOVAL 1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut. Ensure splined driveshaft is free to separate from spline in hub during knuckle removal. A pulling force on shaft can separate inner C/V joint. Tap lightly with brass drift, if required. 5. Disconnect tie rod end from steering arm with a suitable puller. 6. Disconnect brake hose retainer from strut damper. 7. Remove clamp bolt securing ball joint stud into steering knuckle, then the brake caliper adapter screw and washer assemblies. 8. Support caliper with a piece of wire. Do not hang by brake hose. 9. Remove rotor, then separate ball joint stud from knuckle assembly. 10. Remove knuckle assembly from vehicle. Support driveshaft during knuckle removal. Do not permit driveshaft to hang after separating steering knuckle from vehicle. INSTALLATION 1. Place steering knuckle on lower ball joint stud and the driveshaft through hub. 2. Install and tighten ball joint to steering knuckle clamp bolt to specifications. 3. Install tie rod end into steering arm and tighten nut to specifications. Install cotter pin. 4. Install rotor. 5. Install caliper over rotor and position adapter to steering knuckle. Install adapter to knuckle attaching bolts and tighten to specifications. 6. Attach brake hose retainer to strut damper and tighten attaching screw to specifications. 7. Install hub nut assembly as follows: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 5142 a. With brakes applied, install hub nut and tighten to specifications. b. Install spring washer, locknut and new cotter pin. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar: Service and Repair Front Fig. 17 Sway bar assembly REMOVAL 1. Raise and support vehicle. 2. Remove nuts, bolts and retainers at control armsshown, 3. Remove crossmember clamp attaching bolts, then the crossmember clamps. 4. Remove sway bar from vehicle. INSTALLATION 1. Position crossmember bushings on sway bar with curved surface up and split to front of vehicle. 2. Position bar assembly onto crossmember, then install clamps and attaching boltsshown, 3. Position retainers at control arms, then install bolts and attaching nuts. 4. Raise lower control arm to correct position, then tighten attaching bolts to specifications. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 5147 Stabilizer Bar: Service and Repair Rear Fig. 4 Rear sway bar assembly REMOVAL 1. Raise and support vehicle. 2. Remove lower two sway bar to link arm retaining bolts on both sides of vehicle. 3. Loosen, but do not remove four sway bar to bushing retainers to rear axle tube brackets. 4. Hold sway bar in place, then remove four loose bolts and remove sway bar. Remove link arms if needed. INSTALLATION 1. If link arms were removed, install retaining nuts but do not tighten. 2. Position axle to sway bar bushings on sway bar with slit in bushing facing up. 3. Install sway bar assembly onto rear axle but do not tighten bolts. 4. Install two lower link arm bolts to sway bar but do nut tighten bolts. 5. Lower vehicle, then tighten to specifications. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Front Shock Tower - Metal Screws/Bolts Precautions Strut / Shock Tower: Technical Service Bulletins Front Shock Tower - Metal Screws/Bolts Precautions NO.: 02-08-92 GROUP: Suspension DATE: Dec. 14, 1992 SUBJECT: Installation Of Sheet Metal Screws Or Bolts Into The Front Shock Towers MODELS: 1989 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 (AH) Lanced LeBaron GTS 1989 - 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1990 (AQ) Horizon/Omni 1989 - 1993 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler's TC (Maserati Coupe) 1989 - 1993 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 (C) Dynasty/New Yorker 1984 - 1988 (E) Caravelle/600/New Yorker Turbo 1984 - 1988 (G) Daytona/Laser 1985 - 1988 (H) Lancer/LeBaron GTS 1987 - 1988 (J) LeBaron Coupe/LeBaron Convertible 1984 - 1988 (K) Reliant/Aries/LeBaron 4-Door/Town & Country 1984 - 1988 (L) Horizon/Omni 1987 - 1988 (P) Shadow/Sundance 1984 - 1988 (S) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country DISCUSSION: It is very important that no sheet metal screws, bolts or other metal fasteners be installed in the shock towers in place of plastic clips. Also, no holes should be drilled in the shock tower for installation of any metal fasteners (see illustration, area "A"). Because of the minimum clearance in this area, installation of metal fasteners could damage the coil spring coating. If a plastic clip is lost or broken, replace the clip with the equivalent part called out in the appropriate Mopar Parts Catalog. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Front Shock Tower - Metal Screws/Bolts Precautions > Page 5152 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications Suspension Spring ( Coil / Leaf ): Specifications Leaf Spring to Hanger Mounting Nut 105 ft.lb Shackle Nuts 35 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 5156 Suspension Spring ( Coil / Leaf ): Service and Repair Fig. 5 Strut damper mount assembly 1. Remove strut damper assembly as previously described. 2. Compress coil spring using suitable tool. 3. Remove strut rod nut while holding strut rod to prevent rotation. 4. Remove the mount assembly. 5. Remove coil spring from strut damper. 6. Inspect mount assembly for deterioration of rubber isolator, retainers for cracks and distortion, and bearings for blinding. 7. Install dust shield, jounce bumper, spacer and seat to top of spring. Mount assembly to rod, then install retainer and rod nut. 8. Position spring retainer alignment notch parallel to damper lower attaching bracket. 9. Tighten strut rod nut to specifications, using suitable tool, then release spring compressor. 10. With weight of vehicle off front wheels, turn both strut rod and strut rod nut in same direction until upper spring seat is properly positioned, then recheck torque of strut rod nut. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications Shock Absorber Mounting Bolts Lower 80 ft.lb Upper 85 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 5160 Suspension Strut / Shock Absorber: Service and Repair REMOVAL Fig. 3 Strut damper assembly removal 1. Raise and support vehicle, then remove front wheels. 2. Mark position of camber adjusting cam, then remove camber adjusting bolt, through bolt and brake hose to damper bracket retaining screw. 3. Remove strut damper to fender shield mounting nut and washer assemblies. 4. Remove strut damper from vehicle. INSTALLATION Fig. 4 Strut damper assembly installation 1. Position strut assembly into fender reinforcement, then install retaining nut and washer assemblies. Tighten retaining nut to specifications. 2. Position steering knuckle into strut, then install washer plate, cam bolts and knuckle bolts. 3. Attach brake hose retainers to damper. Tighten to specifications. 4. Index cam bolt to alignment mark made during removal. 5. Position a 4 inch or larger C-clamp on steering knuckle and strut, then tighten clamp just enough to eliminate any looseness between strut and knuckle. Tighten cam bolts to specifications. 6. Remove C-clamp, then install wheel and tire assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Nut Torque Nut Torque Front Axle Nut Torque 180 ft.lb Rear Bearing Nut Torque 270 in.lb +/- 30 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5164 Wheel Bearing: Adjustments Fig. 3 Wheel bearing assembly 1. Raise and support rear of vehicle. 2. Tighten adjusting nut to 27 to 34nm (240 to 300 in. lbs.) while rotating wheel. 3. Stop wheel and loosen adjusting nut. 4. Tighten adjusting nut finger tight. End play should be 0.0001-0.0020 inch. 5. Install castle lock with slots aligned with cotter pin hole. 6. Install cotter pin and grease cap. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Permanent Bearings REMOVAL Fig. 15 Removing hub & bearing assembly 1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub and drive shaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6. Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor, then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV joint during this procedure. Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported. 9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as shown. 10. Remove hub and bearing assembly. INSTALLATION Fig. 16 Seal installation 1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve using a suitable lubricant. 4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install rotor, then position caliper over rotor and guide hold-down spring below machined guides on knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut, then with brakes applied, tighten nut to specifications. 10. Install spring washer, locknut and cotter pin. Replaceable Bearings REMOVAL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5167 Fig. 14 Hub removal Fig. 12 Removing bearing from knuckle 1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer. 4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle using tool No. C-4811-2 or equivalent. INSTALLATION Fig. 13 Installing bearing into knuckle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5168 Fig. 14 Installing hub into knuckle 1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer. Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No. C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No. C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5169 Wheel Bearing: Service and Repair Rear REMOVAL 1. Raise and support vehicle, then remove rear wheel and brake drum. 2. Remove cotter pin, nut lock, spring washer and hub nut. 3. Remove half shaft flange retaining bolts. 4. Half shaft is spring loaded, compress inner half shaft joint slightly pulling down to clear rear carrier output shaft. 5. Remove half shaft by pulling half shaft assembly inboard. 6. Remove wheel bearing mounting bolts, then wheel bearing and hub assembly. 7. Replace grease seal if needed. INSTALLATION 1. If grease seal was removed, install a new seal using installer tool No. 6536-A or equivalent. Lubricate circumference of seal before installation. 2. Install washer and hub nut. With brakes applied, torque to 180 ft. lbs. 3. Install spring washer, nut lock and cotter pin. 4. Install hub and bearing assembly. Torque bolts in a crossing pattern to 96 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Permanent Bearings Wheel Hub: Service and Repair Permanent Bearings REMOVAL Fig. 15 Removing hub & bearing assembly 1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub and drive shaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6. Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor, then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV joint during this procedure. Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported. 9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as shown. 10. Remove hub and bearing assembly. INSTALLATION Fig. 16 Seal installation 1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve using a suitable lubricant. 4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install rotor, then position caliper over rotor and guide hold-down spring below machined guides on knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut, then with brakes applied, tighten nut to specifications. 10. Install spring washer, locknut and cotter pin. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Permanent Bearings > Page 5174 Wheel Hub: Service and Repair Replaceable Bearings REMOVAL Fig. 14 Hub removal Fig. 12 Removing bearing from knuckle 1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer. 4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle using tool No. C-4811-2 or equivalent. INSTALLATION Fig. 13 Installing bearing into knuckle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Permanent Bearings > Page 5175 Fig. 14 Installing hub into knuckle 1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer. Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No. C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No. C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear Tires: All Technical Service Bulletins Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Fig. 1-Shim Installation for Toe-Out Fig. 2-Shim Installation for Toe-in Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 5185 Fig. 3-Shim Installation for Positive Camber Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 5186 completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear Tires: Customer Interest Rear Wheel Alignment - Uneven Tire Wear NO.: 02-07-90 GROUP: SUSPENSION DATE: Nov. 5, 1990 SUBJECT: Rear Tire Noise And Wear/Rear Wheel Aligriment MODELS: 1989-1991 All Domestic FWD Vehicles (Excluding BB - Monaco) SYMPTOM/CONDITION: Rear camber and/or toe alignment causing uneven tire wear or excessive tread noise. DIAGNOSIS: If rear alignment is required, place vehicle on alignment rack and check alignrnent specifications. Two or four wheel alignment racks are acceptable, following manufacturers instructions. Re-(2 wheel alignment rack) when recording rear toe-in (vehicle backed onto alignment rack) REMEMBER to reverse sign convention; a total toein on direct reading charts is actually toe-out while driving. Maintain rear alignment within Chrysler Corporation recommendations/specifications. PARTS REQUIRED: 1 or 2 Shims PN 5205114 (except AC, AY and AS Bodies) 1 or 2 Shims PN 4626165 (all carlines) Fig. 1-Shim Installation for Toe-Out Fig. 2-Shim Installation for Toe-in Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 5192 Fig. 3-Shim Installation for Positive Camber Fig. 4-Shim Installation for Negative Camber REPAIR PROCEDURES: Installation of Rear Alignment Shims 1. Block front tires so vehicle will not move. 2. Release parking brake. 3. Hoist vehicle so that rear suspension is in full rebound and tires are off the ground. 4. Remove wheel and tire assembly. 5. Pry off grease cap. 6. Remove cotter pin and castle lock. 7. Remove brake drum/disc retaining nut. 8. Remove brake drum/disc. 9. Loosen four (4) brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 10. Using a maximum of two (2) shims per spindle, install the shim(s) (as shown in Figures 1, 2, 3, and 4) to bring the alignment as close as possible to the preferred camber and toe specifications. Each shim changes alignment (camber or toe depending on shim installation position) by .3~. 11. Tighten four (4) brake assembly and spindle mounting bolts. For AC, AY, and AS Body tighten to 88 N-m (65 ft.lbs.) All other carlines tighten to 60 N-m (45 ft.lbs.) 12. Install brake drum/disc. 13. Install washer and nut. Tighten retaining nut to 27-34 N-m (240-300 in.lbs.) while rotating wheel. Back off adjusting nut with wrench to Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 020790 > Nov > 90 > Rear Wheel Alignment - Uneven Tire Wear > Page 5193 completely release bearing preload. Finger tighten adjusting nut. 14. Position nut lock with one pair of slots in line with cotter pin hole. Install cotter pin. The end play should be .025-mm. (.001-.003 in.). Clean and install grease cap. 15. Install wheel and tire assembly. Tighten wheel nut to 129 N-m (95 ft.lbs.) torque. 16. Lower vehicle. 17. Recheck alignment specifications. The Chrysler Corporation recommended rear wheel specifications are: (FOR PRIOR MODELS REFER TO APPLICABLE SERVICE MANUALS FOR SPECIFICATIONS) POLICY: Information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Nut Torque Nut Torque Front Axle Nut Torque 180 ft.lb Rear Bearing Nut Torque 270 in.lb +/- 30 in.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5197 Wheel Bearing: Adjustments Fig. 3 Wheel bearing assembly 1. Raise and support rear of vehicle. 2. Tighten adjusting nut to 27 to 34nm (240 to 300 in. lbs.) while rotating wheel. 3. Stop wheel and loosen adjusting nut. 4. Tighten adjusting nut finger tight. End play should be 0.0001-0.0020 inch. 5. Install castle lock with slots aligned with cotter pin hole. 6. Install cotter pin and grease cap. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Permanent Bearings REMOVAL Fig. 15 Removing hub & bearing assembly 1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub and drive shaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6. Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor, then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV joint during this procedure. Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported. 9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as shown. 10. Remove hub and bearing assembly. INSTALLATION Fig. 16 Seal installation 1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve using a suitable lubricant. 4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install rotor, then position caliper over rotor and guide hold-down spring below machined guides on knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut, then with brakes applied, tighten nut to specifications. 10. Install spring washer, locknut and cotter pin. Replaceable Bearings REMOVAL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5200 Fig. 14 Hub removal Fig. 12 Removing bearing from knuckle 1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer. 4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle using tool No. C-4811-2 or equivalent. INSTALLATION Fig. 13 Installing bearing into knuckle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5201 Fig. 14 Installing hub into knuckle 1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer. Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No. C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No. C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5202 Wheel Bearing: Service and Repair Rear REMOVAL 1. Raise and support vehicle, then remove rear wheel and brake drum. 2. Remove cotter pin, nut lock, spring washer and hub nut. 3. Remove half shaft flange retaining bolts. 4. Half shaft is spring loaded, compress inner half shaft joint slightly pulling down to clear rear carrier output shaft. 5. Remove half shaft by pulling half shaft assembly inboard. 6. Remove wheel bearing mounting bolts, then wheel bearing and hub assembly. 7. Replace grease seal if needed. INSTALLATION 1. If grease seal was removed, install a new seal using installer tool No. 6536-A or equivalent. Lubricate circumference of seal before installation. 2. Install washer and hub nut. With brakes applied, torque to 180 ft. lbs. 3. Install spring washer, nut lock and cotter pin. 4. Install hub and bearing assembly. Torque bolts in a crossing pattern to 96 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Permanent Bearings Wheel Hub: Service and Repair Permanent Bearings REMOVAL Fig. 15 Removing hub & bearing assembly 1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. The hub and drive shaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut and washer. 5. Using puller tool No. C-3894-A or equivalent, disconnect tie rod end steering arm. 6. Remove bolt attaching ball joint stud to steering knuckle. 7. Remove caliper guide pins, then the caliper. Support caliper with wire and position aside. Do not hang by brake hose. 8. Remove rotor, then separate ball joint stud from knuckle assembly. Care must be taken not to separate inner CV joint during this procedure. Do not allow driveshaft to hang by inner CV joint, driveshafts must be supported. 9. Remove four hub and bearing assembly attaching screws from front of steering knuckle as shown. 10. Remove hub and bearing assembly. INSTALLATION Fig. 16 Seal installation 1. Install hub and bearing assembly. Tighten bolts in a crossing pattern to specifications. 2. Using oil seal installer tool No. C-4698 or equivalent, install seal into knuckle. Lubricate circumference of seal using a suitable lubricant. 3. Using oil seal installer tool No. C-4698 or equivalent, reverse driving head of tool and install wear sleeve. Lubricate circumference of wear sleeve using a suitable lubricant. 4. Install driveshaft through hub, then steering knuckle assembly on lower control arm ball joint stud. 5. Install ball joint to steering knuckle clamp bolt, and tighten bolt to specifications. 6. Install tie rod end into steering arm, then tighten bolt to specifications, then install cotter pin. 7. Install rotor, then position caliper over rotor and guide hold-down spring below machined guides on knuckle assembly. 8. Install guide pins and tighten to specifications. 9. Install washer and hub nut, then with brakes applied, tighten nut to specifications. 10. Install spring washer, locknut and cotter pin. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Permanent Bearings > Page 5207 Wheel Hub: Service and Repair Replaceable Bearings REMOVAL Fig. 14 Hub removal Fig. 12 Removing bearing from knuckle 1. Remove steering knuckle as previously described. 2. Remove hub using tool No. C-4811-14 or equivalent. 3. Remove four bearing retainer to knuckle attaching screws, then the bearing retainer. 4. Pry bearing seal from machined recess in knuckle assembly. 5. Remove bearing from knuckle using tool No. C-4811-2 or equivalent. INSTALLATION Fig. 13 Installing bearing into knuckle Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Permanent Bearings > Page 5208 Fig. 14 Installing hub into knuckle 1. Press new bearing into knuckle using tool No. C-4811-4 or equivalent. 2. Install bearing retainer. Tighten retainer attaching screws to specifications. 3. Press hub into bearing using tool No. C-4811-11 or equivalent. 4. Position new seal in recess, then install using oil seal installer tool No. C-4698 or equivalent. 5. Install steering knuckle refer to STEERING KNUCKLE. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Lug Nuts 95 ft.lb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations Air Conditioning Switch: Locations Lower I/P Components Center Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments Air Door Cable: Adjustments Temperature Control Cable Position and hold the TEMP lever all the way to the left side of the control panel. Slide the self adjusting clip toward the end of the cable, until the blend air door reaches its fully counter-clockwise position. Move the cable from full left to full right several times checking for smooth operation. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Front End Components Behind Center Of Grill Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair Blower Motor: Service and Repair REMOVAL AND INSTALLATION 1. Locate and disconnect the 2-way connector at the blower motor lead under the instrument panel on the passenger side of the vehicle (the wire connector insulator is wrapped with a foam silencer material). 2. Remove blower attaching (5) screws securing the blower to the heater-A/C unit. 3. Allow the blower assembly to drop downward to clear the instrument panel, and remove the blower from the vehicle. To install, reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Engine Compartment Components. RH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair Compressor Clutch: Service and Repair REMOVAL 1. Remove a/c drive belt 2. Disconnect compressor clutch wires from the harness. 3. Remove compressor mounting bolts and lift compressor from its mounting bracket. 4. Rotate the compressor assembly to gain access to the front of the compressor clutch. Support the compressor so that the weight of the compressor is not on the hoses. DO NOT let the compressor hang from the hoses. Front Plate Retaining Nut R&R; (VDC) 5. Use a 13mm socket and a spanner wrench to remove the shaft nut and lock washer. 6. Thread the front plate removal tool into the hub. Front Plate R&R; (VDC) 7. Tighten the center bolt of the removal tool to pull off the front plate. Front Plate Shims 8. Remove and save the shaft shim(s). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Page 5233 A/C Pulley Snap Ring R&R; 9. Remove the pulley retaining snap ring with suitable snap ring pliers. A/C Pulley R&R; 10. Slide the pulley off the compressor. A/C Coil Snap Ring R&R; 11. Remove the coil retaining snap ring using suitable snap ring pliers. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Page 5234 A/C Coil R&R; 12. Remove the screw that anchors the coil wires to the compressor housing. Remove the coil from the compressor end plate. INSTALLATION A/C Coil Alignment 1. Align the hole in the back of the coil with the pin in the compressor end plate. A/C Coil Snap Ring R&R; 2. Install the coil retaining snap ring with the beveled side facing outward and both of the snap ring ends away from the alignment pin. Make sure the snap ring is properly seated in the groove. 3. Fasten the coil wires to the compressor housing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Page 5235 A/C Pulley R&R; 4. Install the pulley and bearing assembly onto the compressor. A/C Pulley Snap Ring R&R; 5. Install the pulley retaining snap ring with the beveled side outward. Make sure that the snap ring is properly seated in the groove. Front Plate Shims 6. Install the original shim(s) on the compressor shaft. If the original shims are not available, use a temporary set of shims that equal 0.100 in (2.54 mm). 7. Install the front plate, making sure the key on the compressor shaft aligns with the keyway on the front plate. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Page 5236 Air Gap 8. Use a feeler gauge to measure the air gap between the front plate and the pulley face. The air gap should be between 0.020 and 0.035 in. (0.05 and 0.9 mm.). If the air gap is incorrect, add or remove shims on the compressor shaft to obtain the proper air gap. Front Plate Retaining Nut R&R; (VDC) 9. Install lock washer and shaft nut. torque the shaft nut to 155 +/- 20 in.lbs. (17.5 +/- 2 N-m.). 10. Recheck the air gap after torquing the shaft and adjust shim thickness if necessary. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair Compressor Clutch Coil: Service and Repair REMOVAL 1. Remove a/c drive belt 2. Disconnect compressor clutch wires from the harness. 3. Remove compressor mounting bolts and lift compressor from its mounting bracket. 4. Rotate the compressor assembly to gain access to the front of the compressor clutch. Support the compressor so that the weight of the compressor is not on the hoses. DO NOT let the compressor hang from the hoses. Front Plate Retaining Nut R&R; (VDC) 5. Use a 13mm socket and a spanner wrench to remove the shaft nut and lock washer. 6. Thread the front plate removal tool into the hub. Front Plate R&R; (VDC) 7. Tighten the center bolt of the removal tool to pull off the front plate. Front Plate Shims 8. Remove and save the shaft shim(s). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 5240 A/C Pulley Snap Ring R&R; 9. Remove the pulley retaining snap ring with suitable snap ring pliers. A/C Pulley R&R; 10. Slide the pulley off the compressor. A/C Coil Snap Ring R&R; 11. Remove the coil retaining snap ring using suitable snap ring pliers. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 5241 A/C Coil R&R; 12. Remove the screw that anchors the coil wires to the compressor housing. Remove the coil from the compressor end plate. INSTALLATION A/C Coil Alignment 1. Align the hole in the back of the coil with the pin in the compressor end plate. A/C Coil Snap Ring R&R; 2. Install the coil retaining snap ring with the beveled side facing outward and both of the snap ring ends away from the alignment pin. Make sure the snap ring is properly seated in the groove. 3. Fasten the coil wires to the compressor housing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 5242 A/C Pulley R&R; 4. Install the pulley and bearing assembly onto the compressor. A/C Pulley Snap Ring R&R; 5. Install the pulley retaining snap ring with the beveled side outward. Make sure that the snap ring is properly seated in the groove. Front Plate Shims 6. Install the original shim(s) on the compressor shaft. If the original shims are not available, use a temporary set of shims that equal 0.100 in (2.54 mm). 7. Install the front plate, making sure the key on the compressor shaft aligns with the keyway on the front plate. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 5243 Air Gap 8. Use a feeler gauge to measure the air gap between the front plate and the pulley face. The air gap should be between 0.020 and 0.035 in. (0.05 and 0.9 mm.). If the air gap is incorrect, add or remove shims on the compressor shaft to obtain the proper air gap. Front Plate Retaining Nut R&R; (VDC) 9. Install lock washer and shaft nut. torque the shaft nut to 155 +/- 20 in.lbs. (17.5 +/- 2 N-m.). 10. Recheck the air gap after torquing the shaft and adjust shim thickness if necessary. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > A/C Compressor Clutch Cut-Out Relay Compressor Clutch Relay: Locations A/C Compressor Clutch Cut-Out Relay Engine Compartment Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > A/C Compressor Clutch Cut-Out Relay > Page 5248 Compressor Clutch Relay: Locations A/C Wide Open Throttle Cut-Out Relay Engine Compartment Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5249 Compressor Clutch Relay: Description and Operation The A/C clutch relay is connected to the A/C damped pressure switch and the A/C switch. This relay is in the On position during normal engine operation, but is closed when the SMEC senses low idle speeds or wide open throttle conditions, preventing A/C clutch engagement. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Engine Compartment Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 241194 > Jul > 94 > A/C, Heater - Temperature Lever Difficult to Move Control Assembly: Customer Interest A/C, Heater - Temperature Lever Difficult to Move NO: 24-11-94 GROUP: Heater & A/C DATE: Jul. 1, 1994 SUBJECT: A/C Heater Blend Air Door Sticking MODELS: 1989 - 1994 (AS) Town & Country/Caravan/Voyager 1984 - 1988 (S) Caravan/Voyager SYMPTOM/CONDITION: Poor heater performance, or poor A/C performance, and/or temperature control lever difficult or impossible to move. DIAGNOSIS: Check the temperature control lever for a binding condition. If the lever is difficult or impossible to move, perform the repair procedure. PARTS REQUIRED: AR 4318039 Mopar Rust Penetrant AR 4318066 Mopar White Spray Lube REPAIR PROCEDURE: This bulletin involves accessing the lower pivot and contact surfaces of the blend air door shaft to apply rust penetrant to free up the shaft and then apply lubricant to prevent further corrosion. 1. Remove the center floor console on vehicles so equipped. 2. Remove the floor air distribution duct. 3. On the extension which houses the blend air door shaft inside the heater-A/C housing (Refer to Illustration), drill a 3/32 in. (2.2 mm) hole perpendicular to the side of the extension and 3/8 in. (10 mm) up from the bottom of the extension to gain access to the blend air door shaft. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 241194 > Jul > 94 > A/C, Heater - Temperature Lever Difficult to Move > Page 5261 4. Spray a sufficient amount of Mopar Rust Penetrant into the hole drilled in step 3 and work the temperature control lever until it moves freely. 5. When the door moves freely, inject Mopar White Spray Lube into the hole for two seconds time in order to prevent further binding/sticking in this area. 6. Wipe the housing exterior clean of any excess lubricant and tape over hole in extension with black duct tape. 7. Install floor air distribution duct. 8. Install center floor console if equipped. 9. If movement of the temperature control lever is still difficult, inspect the temperature control cable where it attaches to the control for kinks. If kinked replace the temperature control cable. Refer to the appropriate service manual for cable replacement procedure, and the appropriate Labor Operation Time Schedule Manual for cable replacement time allowance. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 1984 - 1993 24-65-20-90 0.4 Hrs. 1994 24-65-20-91 0.6 Hrs. Center Floor Console (if Equipped) 24-65-20-60 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 241194 > Jul > 94 > A/C, Heater Temperature Lever Difficult to Move Control Assembly: All Technical Service Bulletins A/C, Heater - Temperature Lever Difficult to Move NO: 24-11-94 GROUP: Heater & A/C DATE: Jul. 1, 1994 SUBJECT: A/C Heater Blend Air Door Sticking MODELS: 1989 - 1994 (AS) Town & Country/Caravan/Voyager 1984 - 1988 (S) Caravan/Voyager SYMPTOM/CONDITION: Poor heater performance, or poor A/C performance, and/or temperature control lever difficult or impossible to move. DIAGNOSIS: Check the temperature control lever for a binding condition. If the lever is difficult or impossible to move, perform the repair procedure. PARTS REQUIRED: AR 4318039 Mopar Rust Penetrant AR 4318066 Mopar White Spray Lube REPAIR PROCEDURE: This bulletin involves accessing the lower pivot and contact surfaces of the blend air door shaft to apply rust penetrant to free up the shaft and then apply lubricant to prevent further corrosion. 1. Remove the center floor console on vehicles so equipped. 2. Remove the floor air distribution duct. 3. On the extension which houses the blend air door shaft inside the heater-A/C housing (Refer to Illustration), drill a 3/32 in. (2.2 mm) hole perpendicular to the side of the extension and 3/8 in. (10 mm) up from the bottom of the extension to gain access to the blend air door shaft. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 241194 > Jul > 94 > A/C, Heater Temperature Lever Difficult to Move > Page 5267 4. Spray a sufficient amount of Mopar Rust Penetrant into the hole drilled in step 3 and work the temperature control lever until it moves freely. 5. When the door moves freely, inject Mopar White Spray Lube into the hole for two seconds time in order to prevent further binding/sticking in this area. 6. Wipe the housing exterior clean of any excess lubricant and tape over hole in extension with black duct tape. 7. Install floor air distribution duct. 8. Install center floor console if equipped. 9. If movement of the temperature control lever is still difficult, inspect the temperature control cable where it attaches to the control for kinks. If kinked replace the temperature control cable. Refer to the appropriate service manual for cable replacement procedure, and the appropriate Labor Operation Time Schedule Manual for cable replacement time allowance. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 1984 - 1993 24-65-20-90 0.4 Hrs. 1994 24-65-20-91 0.6 Hrs. Center Floor Console (if Equipped) 24-65-20-60 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5268 Control Assembly: Locations Lower I/P Components Center Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement Evaporator Core: Service and Repair Evaporator Core Replacement REMOVAL 1. Drain cooling system and discharge A/C system, if equipped. See: Service and Repair/Refrigerant Recovery 2. Disconnect vacuum line at brake booster. If equipped, disconnect vacuum line at water valve. 3. Disconnect heater hoses at heater core. Plug heater core tubes to prevent spilling coolant. Expansion Valve 4. On models with A/C, disconnect A/C plumbing at expansion valve and remove the expansion valve from the evaporator. Resistor Block And Drain Tube 5. Remove the condensate drain tube. 6. On all models, remove 4 nuts from unit mounting studs. 7. Remove steering column cover from left lower instrument panel. 8. Remove lower reinforcement from below steering column. 9. Remove right side cowl and sill trim. 10. Remove bolt attaching right side instrument panel to right cowl. 11. Loosen two brackets supporting lower edge of instrument panel to A/C and heater or heater housing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 5273 Instrument Panel Assembly 12. Remove the instrument panel trim moulding from the right side dash panel. 13. Remove the nine screws that attach the lower instrument panel to the upper instrument panel. 14. Carefully pull the right side of lower instrument panel rearward until it reaches passenger seat. 15. Disconnect the blower motor and resistor electrical connectors and temperature control cable. 16. Disconnect hanger strap from evaporator heater assembly and bend rearward. 17. Pull heater-a/c assembly rearward from dash panel and remove from vehicle. 18. Place heater-a/c assembly on workbench, then remove vacuum harness attaching screw. Feed harness through hole in cover. 19. Remove thirteen cover attaching screws, then the cover. Temperature control door will come out with cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 5274 Fig. 15 Evaporator heater assembly 20. Remove heater core tube retaining bracket attaching screw, then lift the heater core straight up. 21. Lift evaporator up and out of unit. 22. Remove sound shield attaching screws, then blower motor assembly. INSTALLATION Fig. 15 Evaporator heater assembly 1. Install the blower motor and sound shield. 2. Install the evaporator to the heater-a/c housing. 3. Install the heater core and secure with one screw through the attaching bracket. 4. Install the top cover, making sure the blend-air door is properly located in the bottom of the heater-a/c housing. Secure top cover with 13 screws. 5. Feed the vacuum harness through the hole and secure with one screw. 6. Slide the heater-a/c unit under the lower right instrument panel. Feed the vacuum hoses through the hole in the firewall. 7. Raise and install the heater-a/c unit to the firewall, making sure the mounting studs go completely through and the vacuum hoses are not pinched. 8. Secure the heater-a/c unit with one screws through the hangar strap and four nuts on the mounting studs. 9. Attach the temperature control cable, blower motor wiring, and resistor wiring. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 5275 Instrument Panel Assembly 10. Position the right lower instrument panel and attach with 9 screws through the upper instrument panel and one bolt in the right side cowl. 11. Reinstall instrument panel trim moulding. 12. Reattach all previously removed dash wiring. 13. Install steering column reinforcement, lower steering column cover and right cowl and sill trim panels. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 5276 Resistor Block And Drain Tube 14. Install the condensate drain tube. 15. Connect the vacuum hoses to the engine and water valve. 16. Connect the heater hoses and refill the engine coolent system. Expansion Valve 17. Connect the expansion valve to the evaporator with a new gasket. Torque the torx head screws to 100 +/- 30 in.lbs. (11 +/- 3 N-m.). 18. Connect the a/c plumbing to the expansion valve. Torque the bolt to 200 +/- 30 in.lbs. (23 +/- 3 N-m.). 19. Evacuate and recharge the a/c system. 20. Test system for overall performance. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 5277 Evaporator Core: Service and Repair Rear Evaporator and Expansion Valve Replacement REMOVAL 1. Remove rear heat-a/c unit.See: Housing Assembly HVAC/Service and Repair 2. Remove rear unit top cover. 3. Remove the evaporator by carefully lifting it straight up and out of the rear unit. 4. Remove the two 1/4-20 torx head screws that anchor the expansion valve to the evaporator. 5. Measure and record the amount of refrigeration oil removed from the evaporator. INSTALLATION 1. Replace the amount of refrigeration oil previously measured with clean oil. 2. Attach the expansion valve to the evaporator with a new gasket. Torque the torx head screws to 100 +/- 30 in.lbs. (11 +/- 3 N-m.). 3. Install the evaporator into the rear heat-a/c unit. 4. Install the rear unit top cover. 5. Install the rear unit in the vehicle.See: Housing Assembly HVAC/Service and Repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair Expansion Valve: Service and Repair REMOVAL 1. Remove rear heat-a/c unit.See: Housing Assembly HVAC/Service and Repair 2. Remove rear unit top cover. 3. Remove the evaporator by carefully lifting it straight up and out of the rear unit. 4. Remove the two 1/4-20 torx head screws that anchor the expansion valve to the evaporator. 5. Measure and record the amount of refrigeration oil removed from the evaporator. INSTALLATION 1. Replace the amount of refrigeration oil previously measured with clean oil. 2. Attach the expansion valve to the evaporator with a new gasket. Torque the torx head screws to 100 +/- 30 in.lbs. (11 +/- 3 N-m.). 3. Install the evaporator into the rear heat-a/c unit. 4. Install the rear unit top cover. 5. Install the rear unit in the vehicle.See: Housing Assembly HVAC/Service and Repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Blower Motor, Evaporator & Heater Core Heater Core: Service and Repair Blower Motor, Evaporator & Heater Core REMOVAL 1. Drain cooling system and discharge A/C system, if equipped. See: Service and Repair/Refrigerant Recovery 2. Disconnect vacuum line at brake booster. If equipped, disconnect vacuum line at water valve. 3. Disconnect heater hoses at heater core. Plug heater core tubes to prevent spilling coolant. Expansion Valve 4. On models with A/C, disconnect A/C plumbing at expansion valve and remove the expansion valve from the evaporator. Resistor Block And Drain Tube 5. Remove the condensate drain tube. 6. On all models, remove 4 nuts from unit mounting studs. 7. Remove steering column cover from left lower instrument panel. 8. Remove lower reinforcement from below steering column. 9. Remove right side cowl and sill trim. 10. Remove bolt attaching right side instrument panel to right cowl. 11. Loosen two brackets supporting lower edge of instrument panel to A/C and heater or heater housing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Blower Motor, Evaporator & Heater Core > Page 5285 Instrument Panel Assembly 12. Remove the instrument panel trim moulding from the right side dash panel. 13. Remove the nine screws that attach the lower instrument panel to the upper instrument panel. 14. Carefully pull the right side of lower instrument panel rearward until it reaches passenger seat. 15. Disconnect the blower motor and resistor electrical connectors and temperature control cable. 16. Disconnect hanger strap from evaporator heater assembly and bend rearward. 17. Pull heater-a/c assembly rearward from dash panel and remove from vehicle. 18. Place heater-a/c assembly on workbench, then remove vacuum harness attaching screw. Feed harness through hole in cover. 19. Remove thirteen cover attaching screws, then the cover. Temperature control door will come out with cover. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Blower Motor, Evaporator & Heater Core > Page 5286 Fig. 15 Evaporator heater assembly 20. Remove heater core tube retaining bracket attaching screw, then lift the heater core straight up. 21. Lift evaporator up and out of unit. 22. Remove sound shield attaching screws, then blower motor assembly. INSTALLATION Fig. 15 Evaporator heater assembly 1. Install the blower motor and sound shield. 2. Install the evaporator to the heater-a/c housing. 3. Install the heater core and secure with one screw through the attaching bracket. 4. Install the top cover, making sure the blend-air door is properly located in the bottom of the heater-a/c housing. Secure top cover with 13 screws. 5. Feed the vacuum harness through the hole and secure with one screw. 6. Slide the heater-a/c unit under the lower right instrument panel. Feed the vacuum hoses through the hole in the firewall. 7. Raise and install the heater-a/c unit to the firewall, making sure the mounting studs go completely through and the vacuum hoses are not pinched. 8. Secure the heater-a/c unit with one screws through the hangar strap and four nuts on the mounting studs. 9. Attach the temperature control cable, blower motor wiring, and resistor wiring. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Blower Motor, Evaporator & Heater Core > Page 5287 Instrument Panel Assembly 10. Position the right lower instrument panel and attach with 9 screws through the upper instrument panel and one bolt in the right side cowl. 11. Reinstall instrument panel trim moulding. 12. Reattach all previously removed dash wiring. 13. Install steering column reinforcement, lower steering column cover and right cowl and sill trim panels. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Blower Motor, Evaporator & Heater Core > Page 5288 Resistor Block And Drain Tube 14. Install the condensate drain tube. 15. Connect the vacuum hoses to the engine and water valve. 16. Connect the heater hoses and refill the engine coolent system. Expansion Valve 17. Connect the expansion valve to the evaporator with a new gasket. Torque the torx head screws to 100 +/- 30 in.lbs. (11 +/- 3 N-m.). 18. Connect the a/c plumbing to the expansion valve. Torque the bolt to 200 +/- 30 in.lbs. (23 +/- 3 N-m.). 19. Evacuate and recharge the a/c system. 20. Test system for overall performance. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Blower Motor, Evaporator & Heater Core > Page 5289 Heater Core: Service and Repair Heater Core Removal and Installation 1. Remove rear heat-a/c unit.See: Housing Assembly HVAC/Service and Repair 2. Remove rear unit top cover. 3. Remove the heater core by carefully lifting it straight up and out of the rear unit. 4. Reverse procedure to reinstall. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 240395 > Jan > 95 > A/C System - Poor Cooling Performance Hose/Line HVAC: Customer Interest A/C System - Poor Cooling Performance NO: 24-03-95 GROUP: Heater & A/C DATE: Jan. 27, 1995 SUBJECT: Revised Underbody Refrigerant Line Gasket MODELS: 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1995 (ES) Chrysler Voyager (European Market) 1989 (S) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE (LWB) VEHICLES EQUIPPED WITH AUXILIARY REAR A/C OPTION. SYMPTOM/CONDITION: Poor A/C system cooling performance. DIAGNOSIS: Check for low refrigerant charge and inspect the connection of the A/C underbody refrigerant lines to the rear auxiliary A/C unit. If refrigerant is detected at the connection, perform the repair procedure. PARTS REQUIRED: 1 4798270 Gasket, Underbody Refrigerant Line REPAIR PROCEDURE: This bulletin involves installing a revised underbody refrigerant line gasket. 1. Recover any residual refrigerant in the A/C system. 2. Disconnect the A/C underbody refrigerant lines from the rear auxiliary A/C unit. 3. Inspect and clean the A/C plumbing surfaces that contact the gasket. Do not scratch the surfaces. 4. Install the revised gasket, P/N 4798270. This gasket is rubber coated stainless steel. 5. Evacuate and recharge the A/C system using the procedure outlined in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-45-62-90 ....................................................................................................... ................................................................ 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 240490 > Sep > 90 > Air Conditioning System Moaning/Growling Noise Hose/Line HVAC: Customer Interest Air Conditioning System - Moaning/Growling Noise NO.: 24-04-90 GROUP: HEATER & A/C DATE: Sept. 10, 1990 SUBJECT: Air Conditioning System Noise - 3.OL Engine MODELS: 1989 Dodge Caravan, Grand Caravan, Caravan C/V, Plymouth Voyager, Grand Voyager, Chrysler Town & Country SYMPTOM/CONDITION Some vehicles equipped with the 3.OL engine may exhibit a moaning or growling noise when the air conditioning system is on. This noise is caused by refrigerant gas pulsation being transmitted through the A/C discharge line. This noise is NOT the fault of the A/C compressor. DIAGNOSIS Verify that the vehicle has a moaning or growling noise when the air conditioning is on. Inspect the entire length of the discharge, suction and liquid lines for grounding. These lines should not touch any sheet metal or underhood component. Also inspect these lines for grounding during engine roll and where the lines go through the bulkhead. Inspect for proper foam or rubber isolation at all brackets and the radiator support and correct as necessary. If the noise persists, proceed to the following repair procedure. Remember, the compressor should not be replaced unless it has failed the output test outlined in TSB 24-03-89 Revision A or is making metallic noises. REPLACING THE COMPRESSOR FOR THE A/C DISCHARGE LINE NOISE WILL NOT CORRECT THE PROBLEM. PARTS REQUIRED 1 4419464 A/C Discharge Line Assembly REPAIR PROCEDURE This procedure involves inspection and replacement of the A/C discharge line assembly with a revised discharge line. 1. Check to see if the A/C discharge line muffler is approximately two inches from the condenser. If so, remove the discharge line according to the procedure outlined in the service manual. A/C systerns should be evacuated using an approved recovery station. 2. Install a new discharge line assembly (PN 4419464) that has a muffler located near the compressor attachment flange. 3. Verify A/C operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 24-45-25-91 . . . . . . . . . . . . . . . . 1.2 Hrs. Replace A/C Discharge Line Assembly 24-01-10-01 . . . . . . . . . . . . . . . . 0.2 Hrs. Additional Time Required When R12 Recovery Station Is Used FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 240395 > Jan > 95 > A/C System - Poor Cooling Performance Hose/Line HVAC: All Technical Service Bulletins A/C System - Poor Cooling Performance NO: 24-03-95 GROUP: Heater & A/C DATE: Jan. 27, 1995 SUBJECT: Revised Underbody Refrigerant Line Gasket MODELS: 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1995 (ES) Chrysler Voyager (European Market) 1989 (S) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE (LWB) VEHICLES EQUIPPED WITH AUXILIARY REAR A/C OPTION. SYMPTOM/CONDITION: Poor A/C system cooling performance. DIAGNOSIS: Check for low refrigerant charge and inspect the connection of the A/C underbody refrigerant lines to the rear auxiliary A/C unit. If refrigerant is detected at the connection, perform the repair procedure. PARTS REQUIRED: 1 4798270 Gasket, Underbody Refrigerant Line REPAIR PROCEDURE: This bulletin involves installing a revised underbody refrigerant line gasket. 1. Recover any residual refrigerant in the A/C system. 2. Disconnect the A/C underbody refrigerant lines from the rear auxiliary A/C unit. 3. Inspect and clean the A/C plumbing surfaces that contact the gasket. Do not scratch the surfaces. 4. Install the revised gasket, P/N 4798270. This gasket is rubber coated stainless steel. 5. Evacuate and recharge the A/C system using the procedure outlined in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-45-62-90 ....................................................................................................... ................................................................ 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 240490 > Sep > 90 > Air Conditioning System Moaning/Growling Noise Hose/Line HVAC: All Technical Service Bulletins Air Conditioning System - Moaning/Growling Noise NO.: 24-04-90 GROUP: HEATER & A/C DATE: Sept. 10, 1990 SUBJECT: Air Conditioning System Noise - 3.OL Engine MODELS: 1989 Dodge Caravan, Grand Caravan, Caravan C/V, Plymouth Voyager, Grand Voyager, Chrysler Town & Country SYMPTOM/CONDITION Some vehicles equipped with the 3.OL engine may exhibit a moaning or growling noise when the air conditioning system is on. This noise is caused by refrigerant gas pulsation being transmitted through the A/C discharge line. This noise is NOT the fault of the A/C compressor. DIAGNOSIS Verify that the vehicle has a moaning or growling noise when the air conditioning is on. Inspect the entire length of the discharge, suction and liquid lines for grounding. These lines should not touch any sheet metal or underhood component. Also inspect these lines for grounding during engine roll and where the lines go through the bulkhead. Inspect for proper foam or rubber isolation at all brackets and the radiator support and correct as necessary. If the noise persists, proceed to the following repair procedure. Remember, the compressor should not be replaced unless it has failed the output test outlined in TSB 24-03-89 Revision A or is making metallic noises. REPLACING THE COMPRESSOR FOR THE A/C DISCHARGE LINE NOISE WILL NOT CORRECT THE PROBLEM. PARTS REQUIRED 1 4419464 A/C Discharge Line Assembly REPAIR PROCEDURE This procedure involves inspection and replacement of the A/C discharge line assembly with a revised discharge line. 1. Check to see if the A/C discharge line muffler is approximately two inches from the condenser. If so, remove the discharge line according to the procedure outlined in the service manual. A/C systerns should be evacuated using an approved recovery station. 2. Install a new discharge line assembly (PN 4419464) that has a muffler located near the compressor attachment flange. 3. Verify A/C operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 24-45-25-91 . . . . . . . . . . . . . . . . 1.2 Hrs. Replace A/C Discharge Line Assembly 24-01-10-01 . . . . . . . . . . . . . . . . 0.2 Hrs. Additional Time Required When R12 Recovery Station Is Used FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair Housing Assembly HVAC: Service and Repair Rear Heater-A/C Components REMOVAL 1. Discharge the A/C system.See: Service and Repair/Refrigerant Recovery 2. Drain the engine coolent. Rear Heater Plumbing 3. Disconnect the rear heater hoses at the rear heater-a/c unit. Plug the heater core tubes to prevent spilling. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 5314 Rear A/C Plumbing 4. Disconnect the a/c plumbing at the rear heat-a/c unit. 5. Remove the left rear quarter trim panels. 6. Remove the attaching screws at the air distribution duct. 7. Remove the attaching screws that anchor the rear heat-a/c unit to the floor and the quarter panel support. 8. Lift the unit up and remove it from the car. INSTALLATION 1. Place the rear heat-a/c unit in the vehicle and anchor to the floor and the quarter panel support with original screws. 2. Install air distribution duct. 3. Install rear coolent hoses and refill engine coolent system. 4. Install rear a/c lines using new gaskets. 5. Evacuate and recharge a/c system.See: Service and Repair/Refrigerant System Evacuate 6. Test for leaks and overall performance of system. 7. Install left rear quarter trim panels. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > A/C System Refrigerant: Specifications A/C System REFRIGERANT CAPACITIES DODGE/PLYMOUTH TRUCKS 1992 Ram 50 pickup ............................................................................................................................ .............................................. 0.8 kg (30 oz.) Ramcharger .................................................................. ............................................................................................................. 1.3 kg (44 oz.) 1992-91 Dakota ................................................................................................................................... ................................................... 1.2 kg (40 oz.) B-Series van ............................................................ .................................................................................................................. 1.3 kg (44 oz.) with rear unit ....................................................................................................................................................... ...................... 1.8 kg (62 oz.) 1992-90 Caravan, Mini Ram, Voyager ................................................................................................................................................... 0.9 kg (32 oz.) with rear unit ........................................................................................................................... .................................................. 1.2 kg (43 oz.) 1992-88 D/W-Series pickup ................................................................................................................. .................................................. 1.3 kg (44 oz.) 1990-87 Dakota ................................................................................................................................... ................................................... 1.3 kg (44 oz.) 1990-83 B-Series van .......................................................................................................................... .................................................... 1.4 kg (48 oz.) with rear unit ........................................................... .................................................................................................................. 1.8 kg (62 oz.) 1989-84 Caravan, Mini-Ram, Voyager ................................................................................................................................................... 1.1 kg (38 oz.) with rear AC ............................................................................................................................ ................................................. 1.3 kg (44 oz.) 1987-83 D/W-Series pickup ................................................................................................................. .................................................. 1.1 kg (40 oz.) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > A/C System > Page 5319 Refrigerant: Specifications Capacities Capacities Capacity 2.38 lb (US) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > A/C System > Page 5320 Refrigerant: Specifications Capacities Capacities Capacity 2.70 lb (US) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications Fig. 10 A/C Component Oil Capacity Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Oil Charge Additions Refrigerant Oil: Service and Repair Oil Charge Additions If there are no signs of external oil leakage, proceed as follows to add oil to system during component replacement. 1. Discharge system refer to, Heating and Air Conditioning/Service and Repair and measure amount of oil collected in discharge container. The amount of oil collected when discharging system must be replaced with new refrigeration oil to maintain proper oil charge. 2. Remove defective components. Measure amount of oil remaining in compressor, if removed. 3. Add correct amount of oil to components. Refer to Air Conditioning/Specifications/Capacities. 4. Install replacement components, then evacuate and recharge system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Oil Charge Additions > Page 5326 Refrigerant Oil: Service and Repair Refrigerant Oil Level Check Compressor oil level need only be checked when there is evidence of oil loss from the system as in the case of a broken line, leaking fitting or component, defective compressor seal or collision damage to system. A wet, shiny surface around a leak point is evidence of oil loss. These compressors must be removed from vehicle and drained to check the oil level, proceed as follows: 1. Discharge system refer to, DISCHARGING & EVACUATING SYSTEM, and repair leak as necessary. 2. Disconnect suction and discharge lines from compressor, then remove compressor and clutch assembly from vehicle. 3. Invert compressor and drain oil through suction and discharge ports. 4. Determine the correct amount of oil to add to compressor by subtracting the amount of oil remaining in other components. Refer to . 5. On all models, add oil to compressor through suction port. 6. Reinstall compressor using new gaskets on refrigerant line fittings, then evacuate and recharge system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations Engine Components. A/C High Pressure Switch located at rear Of A/C Clutch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Engine Compartment Components. RH Rear Corner Of Engine Compartment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > A/C Compressor Clutch Cut-Out Relay Compressor Clutch Relay: Locations A/C Compressor Clutch Cut-Out Relay Engine Compartment Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > A/C Compressor Clutch Cut-Out Relay > Page 5339 Compressor Clutch Relay: Locations A/C Wide Open Throttle Cut-Out Relay Engine Compartment Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5340 Compressor Clutch Relay: Description and Operation The A/C clutch relay is connected to the A/C damped pressure switch and the A/C switch. This relay is in the On position during normal engine operation, but is closed when the SMEC senses low idle speeds or wide open throttle conditions, preventing A/C clutch engagement. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Engine Compartment Components. On LH Fender Apron Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations Air Conditioning Switch: Locations Lower I/P Components Center Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Front End Components Behind Center Of Grill Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations Engine Components. A/C High Pressure Switch located at rear Of A/C Clutch Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Engine Compartment Components. RH Rear Corner Of Engine Compartment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Fig. 11 Charging Valve Location Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming 1. Place ignition switch in lock position. 2. Disconnect and tape battery ground cable connector. 3. Wait at least 1 minute after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy airbag for a short time even after battery has been disconnected. 4. After repairs are performed, connect battery ground cable. 5. From passenger side of vehicle, turn ignition switch to On position. 6. SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate if SRS system is functioning correctly. 7. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Fig. 45 Airbag system diagnostic module Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Fig. 45 Airbag system diagnostic module Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming 1. Place ignition switch in lock position. 2. Disconnect and tape battery ground cable connector. 3. Wait at least 1 minute after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy airbag for a short time even after battery has been disconnected. 4. After repairs are performed, connect battery ground cable. 5. From passenger side of vehicle, turn ignition switch to On position. 6. SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate if SRS system is functioning correctly. 7. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether Installation NUMBER: 23-029-08 GROUP: Body DATE: October 24, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR MILEAGE. SUBJECT: Child Seat Tether Anchor Installation OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on Customer Request. NOTE: Dealers are encouraged to honor any customers request for the installation of the Child Seat Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for reimbursement detail. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shawdow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5382 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. NOTE: This bulletin is provided to identify the parts and labor operation numbers necessary to install a Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits regardless of vehicle age or mileage. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5383 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5384 PARTS REQUIRED: POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5385 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5386 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5387 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5388 Technical Service Bulletin # 232288 Date: 881230 Child Seat Anchor - Installation Models 1989 AA-, AC-, AG-, AH-, AJ-, AK-, AL-, AM-, AP-, & BB-Body Passenger Car AB- & AS-Body Truck (See Body Code Legend) Subject Child Seat Tether Anchor Installation Index BODY Date December 30, 1988 No. 23-22-88 P-5444 (C23-11) BODY CODE LEGEND Passenger Cars AA - Spirit Acclaim AC - Dynasty/New Yorker/Landau AG - Daytona AH - Lancer/LeBaron GTS AJ - LeBaron (2-Door Coupe/Convertible) AK - Aries/Reliant AL - Omni/Horizon AM Diplomat/Newport/Fifth Avenue AP - Shadow/Sundance BB - Premier Trucks AB - Dodge Ram Van/Wagon (Rear-Wheel-Drive) AS - Caravan/Voyager Due to increased customer interest, child seat tether anchor packages have been made available. Upon customer request, the appropriate vehicle package and install according to attached instructions. POLICY: Information Only - These packages to be installed at the customer's expense. Pkg. No. 4519077 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5389 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5390 INSTALLATION INSTRUCTIONS CHILD SEAT TETHER ANCHORAGE CHRYSLER LEBARON, PLYMOUTH CARAVELLE SALON AND DODGE DIPLOMAT SALON AND DIPLOMAT S.E., CHRYSLER NEWPORT AND FIFTH AVENUE EAGLE PREMIER, DODGE ARIES AND PLYMOUTH RELIANT INSTALLATION INSTRUCTIONS PACKAGE NO. 4519077 CHILD SEAT TETHER ANCHORAGE CHRYSLER LeBARON PLYMOUTH CARAVELLE SALON AND GRAN FURY SALON DODGE DIPLOMAT SALON AND DIPLOMAT S.E. CHRYSLER NEWPORT AND FIFTH AVENUE EAGLE PREMIER DODGE ARIES AND PLYMOUTH RELIANT CAUTION: THIS PACKAGE IS ONLY FOR 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE SPECIFIED PARTS. PACKAGE CONSISTS OF: Call Out Description Quantity A Instructions - Child Seat 1 Tether Anchorage Installation Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5391 B Spacer - Child Seat Tether 1 Anchorage C Bolt - Child Seat Tether 1 Anchorage D Nut - Child Seat Tether 1 Anchorage E Reinforcement - Child Seat 1 Tether Anchorage F Plate - Child Seat Tether 1 Anchorage INSTALLATION PROCEDURE 1. Locate one of three holes in the shelf panel. (They can be seen by looking through the elliptical slots in the shelf panel reinforcement from inside the trunk.) 2. Insert a sharp pencil through the hole and pierce the carpet covering the shelf panel. 3. Locate (from inside the rear passenger compartment) the access hole in the panel covered by the carpet (this is the area around the pencil tip). 4. Using a sharp knife, remove 30 mm of carpeting around the pencil. 5. Only for: Eagle Premier Enlarge the 9 mm access hole by cutting the gated tabs on the trim panel. Only for: Plymouth Caravelle Salon and Gran Fury Salon Dodge Diplomat Salon and Diplomat S.E. Chrysler Newport and Fifth Avenue With a screw driver, enlarge the 9 mm access hole by separating the 32 mm perforated hole from the shelf trim panel. 6. Insert the bolt through the plate, spacer, and shelf panel. 7. From the underside of the shelf panel, place the reinforcement on the bolt and hand tighten the flanged nut. 8. (NOTE: THIS OPERATION REQUIRES THE ASSISTANCE OF ANOTHER PERSON.) While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250 inch-pounds torque). Pkg. No. 4519071 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5392 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5393 INSTALLATION INSTRUCTIONS CHILD SEAT TETHER ANCHORAGE PLYMOUTH ACCLAIM AND DODGE SPIRIT CHRYSLER NEW YORKER FIFTH AVE. CHRYSLER IMPERIAL INSTALLATION INSTRUCTIONS PACKAGE NO. 4519071 CHILD SEAT TETHER ANCHORAGE PLYMOUTH ACCLAIM AND DODGE SPIRIT CHRYSLER NEW YORKER FIFTH AVENUE CHRYSLER IMPERIAL CAUTION: THIS PACKAGE IS ONLY FOR 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5394 ANY OTHER VEHICLE. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE ENCLOSED PARTS. PACKAGE CONSISTS OF: Cut Out Description Quantity A Instruction - Child Seat 1 Tether Anchorage Installation B Spacer - Child Seat Tether 1 Anchorage C Bolt - Child Seat Tether 1 Anchorage D Nut - Child Seat Tether 1 Anchorage E Reinforcement - Child Seat 1 Tether Anchorage F Plate - Child Seat Tether 1 Anchorage INSTALLATION PROCEDURE 1. Open deck lid and remove luggage compartment front liner (if applicable). 2. Locate one of three 9 mm holes in shelf panel. (They can be seen by looking through the elliptical slots in the shelf panel reinforcement from inside the trunk.) 3. Insert a sharp pencil through the 9 mm hole and pierce the carpet covering the shelf panel. 4. Locate (from inside the rear passenger compartment) the access hole in the panel covered by the carpet (this is the area around the pencil tip). 5. Using a sharp knife, remove 30 mm of carpeting around the pencil. 6. Insert a screw driver through the 9 mm hole and remove the perforated 32 mm hole plug in the shelf trim panel. 7. Insert the bolt through the plate, spacer, and shelf panel. 8. From the underside of the shelf panel, place the reinforcement on the bolt and hand tighten the flanged nut. 9. (NOTE: THIS OPERATION REQUIRES THE ASSISTANCE OF ANOTHER PERSON). While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250 inch-pounds torque). 10. REPLACE THE LUGGAGE COMPARTMENT FRONT LINER (IF APPLICABLE). Pkg. No. 4358469 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5395 INSTALLATION INSTRUCTIONS CHILD SEAT TETHER ANCHORAGE PLYMOUTH AND DODGE RAM WAGON INSTALLATION INSTRUCTIONS PACKAGE NO. 4358469 CHILD SEAT TETHER ANCHORAGE PACKAGE DODGE RAM WAGON CAUTION: THIS PACKAGE IS ONLY FOR 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE ENCLOSED PARTS. PACKAGE CONSISTS OF: Cut Out Description Quantity Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5396 A Instructions - Child Seat 1 Anchorage B Spacer - Child Seat Tether 1 Anchorage C Bolt - Child Seat Tether 1 Anchorage D Nut - Child Seat Tether 1 Anchorage E Reinforcement - Child Seat 1 Tether Anchorage Sealing Washer F Plate - Child Seat Tether 1 Anchorage G Template - Child Seat Tether 1 Anchorage Locating INSTALLATION PROCEDURE 1. Remove the first rear seat (and the second rear seat if applicable) from the vehicle. 2. Place the template on the floor carpet. 3. Position the template over the rear attaching cups in the floor pan for the first rear passenger seat. 4. Locate the center of one of the two anchor locations shown on the template and transfer this location to the carpet. 5. Remove the template 6. Using a sharp knife, cut a one-inch cross cut in the carpet and carpet underlayment at the transferred mark established in Step 4. 7. Locate the depression (dimple) in the floor pan, located beneath the cross cuts in the carpet. 8. Drill a 9 mm (3/8 inch) hole into the floor at the point marked by the depression. 9. Cut a 25.4 mm (1.00 inch) diameter hole in the carpet and underlayment around the hole in the floor pan. 10. Insert the bolt through the plate, spacer, and floor. 11. From the underside of the vehicle, place the reinforcement on the bolt and hand tighten the flanged nut (assure that the sealer side of the reinforcement is placed against the floor). 12. (NOTE: THIS OPERATION REQUIRES THE ASSISTANCE OF ANOTHER PERSON.) While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250 inch-pounds torque). Pkg. No. 4519072 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5397 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5398 INSTALLATION INSTRUCTIONS CHILD SEAT TETHER ANCHORAGE DODGE DYNASTY AND CHRYSLER NEW YORKER AND CHRYSLER NEW YORKER LANDAU INSTALLATION INSTRUCTIONS PACKAGE NO. 4519072 CHILD SEAT TETHER ANCHORAGE DODGE DYNASTY, CHRYSLER NEW YORKER AND CHRYSLER NEW YORKER LANDAU CAUTION: THIS PACKAGE IS ONLY FOR THE OUTBOARD REAR SEATING POSITIONS OF THE 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE SPECIFIED PARTS. PACKAGE CONSISTS OF: Cut Out Description Quantity A Instructions - Child Seat 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5399 Tether Anchorage Installation B Spacer - Child Seat Tether 1 Anchorage C Bolt - Child Seat Tether 1 Anchorage D Nut - Child Seat Tether 1 Anchorage E Reinforcement - Child Seat 1 Tether Anchorage F Plate - Child Seat Tether 1 Anchorage INSTALLATION PROCEDURES 1. Open deck lid and remove the luggage compartment front liner (if applicable). 2. Locate the three 9 mm bumps in the shelf panel. (They can be seen, from inside the trunk, at the center of the circular formations in the shelf panel.) 3. (NOTE: USE ONE OF THE TWO OUTBOARD BUMPS.) Insert a screwdriver at the bump and remove the 32 mm perforated hole plug in the shelf trim panel foundation. 4. Insert a sharp pencil through the hole and pierce the carpet covering the shelf panel. 5. Locate (from inside the rear passenger compartment) the access hole in the panel covered by the carpet (this is area around the pencil tip). 6. Using a sharp knife, remove the carpeting covering the hole. 7. Insert the bolt through the plate, spacer, and shelf panel. 8. From the underside of the shelf panel, place the reinforcement on the bolt and hand tighten the flanged nut. 9. (NOTE: THIS OPERATION REQUIRES THE ASSISTANCE OF ANOTHER PERSON.) While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250 inch-pounds torque). 10. Replace the luggage compartment front liner. Pkg. No. 4519073 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5400 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5401 INSTALLATION INSTRUCTIONS CHILD SEAT TETHER ANCHORAGE DODGE DYNASTY AND CHRYSLER NEW YORKER CHRYSLER NEW YORKER LANDAU INSTALLATION INSTRUCTIONS PACKAGE NO. 4519073 CHILD SEAT TETHER ANCHORAGE DODGE DYNASTY AND CHRYSLER NEW YORKER CHRYSLER NEW YORKER LANDAU CAUTION: THIS PACKAGE IS ONLY FOR THE REAR CENTER SEATING POSITION OF THE 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE SPECIFIED PARTS. PACKAGE CONSISTS OF: Cut Out Description Quantity A Instructions - Child Seat 1 Tether Anchorage Installation B Spacer - Child Seat Tether 1 Anchorage C Bolt - Child Seat Tether 1 Anchorage Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5402 D Nut Child Seat Tether 1 Anchorage E Reinforcement - Child Seat 1 Tether Anchorage F Plate - Child Seat Tether 1 Anchorage INSTALLATION PROCEDURES 1. Open deck lid and remove the luggage compartment front liner (if applicable). 2. Locate the three 9 mm bumps in the shelf panel. (They can be seen, from inside the trunk, at the center of the circular formations in the shelf panel.) 3. (NOTE: USE ONLY THE CENTER LOCATION.) Insert a screwdriver at the bump and remove the 32 mm perforated hole plug in the shelf trim panel foundation. 4. Insert a sharp pencil through the hole and pierce the carpet covering the shelf panel. 5. Locate (from inside the rear passenger compartment) the access hole in the panel covered by the carpet (this is area around the pencil tip). 6. Using a sharp knife, remove the carpeting covering the hole. 7. Insert the bolt through the plate, spacer, and shelf panel. 8. From the underside of the shelf panel, place the reinforcement on the bolt and hand tighten the flanged nut. 9. (NOTE: THIS OPERATION REQUIRES THE ASSISTANCE OF ANOTHER PERSON.) While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250 inch-pounds torque). 10. Replace the luggage compartment front liner (if applicable). Pkg. No. 4519074 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5403 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5404 INSTALLATION INSTRUCTIONS CHILD SEAT TETHER ANCHORAGE DODGE DAYTONA SHELBY Z AND DODGE DAYTONA PACIFICA INSTALLATION INSTRUCTIONS PACKAGE NO. 4519074 CHILD SEAT TETHER ANCHORAGE PACKAGE DODGE DAYTONA, DAYTONA SHELBY Z, AND DAYTONA PACIFICA CAUTION: THIS PACKAGE IS ONLY FOR 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE SPECIFIED PARTS. PACKAGE CONSISTS OF: Cut Out Description Quantity Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5405 A Instructions - Child Seat 1 Tether Anchorage Installation B Spacer - Child Seat Tether 1 Anchorage C Bolt - Child Seat Tether 1 Anchorage D Plate - Child Seat Tether 1 Anchorage INSTALLATION PROCEDURES 1. Dodge Daytona (Plastic Trim Panel) Open the hatch and locate the two plastic plugs in the hatch trim panel and remove one of the plugs. Dodge Daytona Shelby Z or a Dodge Daytona Pacifica There are no plugs. The holes for the anchorage in the hatch opening lower trim panel will be covered with carpet. Locate one of the two holes through the unsupported carpet. Using a sharp knife, remove the carpet covering the hole. 2. Insert the bolt through the plate and spacer. 3. Hand start the bolt into the rear fascia attaching bracket located behind the trim panel. 4. While holding the plate as shown in the illustration, tighten the bolt (tighten nut to 250 inch-pounds torque). Pkg. No. 4519075 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5406 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5407 INSTALLATION INSTRUCTIONS CHILD SEAT TETHER ANCHORAGE DODGE LANCER AND LANCER ES AND CHRYSLER LE BARON GTS INSTALLATION INSTRUCTIONS PACKAGE NO. 4519075 CHILD SEAT TETHER ANCHORAGE PACKAGE DODGE LANCER AND LANCER ES AND CHRYSLER LeBARON GTS CAUTION: THIS PACKAGE IS ONLY FOR THE REAR OUTBOARD SEATING POSITIONS FOR THE 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE SPECIFIED PARTS. PACKAGE CONSISTS OF: Cut Out Description Quantity A Instructions - Child Seat 1 Tether Anchorage Installation B Spacer - Child Seat Tether 1 Anchorage C Bolt - Child Seat Tether 1 Anchorage D Nut - Child Seat Tether 1 Anchorage E Reinforcement - Child Seat 1 Tether Anchorage Sealing Washer Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5408 F Plate - Child Seat Tether 1 Anchorage INSTALLATION PROCEDURES 1. Open the hatch and locate the three plastic caps (approximately 30 mm diameter) in the lower trim panel. 2. (NOTE: USE ONE OF THE TWO OUTBOARD LOCATIONS.) Remove the plastic cap. 3. Using a screw driver, push the steel plug out of the sheet metal panel (the plug can be seen through the hole in the trim panel where the plastic cap was located). 4. Insert the bolt through the plate, spacer, and the hatch opening panel. 5. From the underside of the bumper, place the reinforcement on the bolt and hand tighten the flanged nut (assure that the foam sealer is positioned next to the panel). 6. While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250 inch-pounds torque). Pkg. No. 4519076 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5409 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5410 INSTALLATION INSTRUCTIONS CHILD SEAT TETHER ANCHORAGE DODGE LANCER AND LANCER ES AND CHRYSLER LE BARON GTS INSTALLATION INSTRUCTIONS PACKAGE NO. 4519076 CHILD SEAT TETHER ANCHORAGE PACKAGE DODGE LANCER AND LANCER ES AND CHRYSLER LeBARON GTS CAUTION: THIS PACKAGE IS ONLY FOR THE REAR CENTER SEATING POSITION FOR THE 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE SPECIFIED PARTS. PACKAGE CONSISTS OF: Cut Out Description Quantity A Instructions - Child Seat 1 Tether Anchorage Installation B Spacer - Child Seat Tether 1 Anchorage C Bolt - Child Seat Tether 1 Anchorage D Nut - Child Seat Tether 1 Anchorage E Reinforcement - Child Seat 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5411 Tether Anchorage Sealing Washer F Plate - Child Seat Tether 1 Anchorage INSTALLATION PROCEDURES 1. Open the hatch and locate the three plastic caps (approximately 30 mm diameter) in the lower trim panel. 2. (NOTE: ONLY USE THE CENTER LOCATION FOR THIS APPLICATION). Remove the plastic cap. 3. Using a screw driver, push the steel plug out of the sheet metal panel (the plug can be seen through the hole in the trim panel where the plastic cap was removed). 4. Insert the bolt through the plate, spacer, and the hatch opening panel. 5. From the undersigned of the bumper, place the reinforcement on the bolt and hand tighten the flanged nut (assure that the foam sealer is positioned next to the panel). 6. While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250 inch-pounds torque). Pkg. No. 4519080 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5412 INSTALLATION INSTRUCTIONS CHILD SEAT TETHER ANCHORAGE PLYMOUTH HORIZON AND DODGE OMNI INSTALLATION INSTRUCTIONS PACKAGE NO. 4519080 CHILD SEAT TETHER ANCHORAGE PLYMOUTH HORIZON AND DODGE OMNI CAUTION: THIS PACKAGE IS ONLY FOR THE REAR OUTBOARD SEATING LOCATIONS FOR THE 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE SPECIFIED PARTS. PACKAGE CONSISTS OF: Cut Out Description Quantity Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5413 A Instructions - Child Seat 1 Tether Anchorage Installation B Bolt - Child Seat Tether 1 Anchorage C Nut - Child Seat Tether 1 Anchorage D Reinforcement - Child Seat 1 Tether Anchorage E Plate - Child Seat Tether 1 Anchorage INSTALLATION PROCEDURES 1. Open cargo hatch. 2. Lift the floor carpet up, exposing the sheet metal. 3. Locate three steel plugs located on the floor. 4. Select one of the two outboard plugs and remove with a screwdriver. NOTE: DO NOT USE THE CENTER LOCATION. 5. Insert the bolt through the plate and the floor. 6. From the underside of the vehicle, place the reinforcement on the bolt and hand tighten the flanged nut (assure that the sealer side of the reinforcement is placed against the floor). 7. (NOTE: THIS OPERATION MAY REQUIRE THE ASSISTANCE OF ANOTHER PERSON.) While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250 inch-pounds torque). 8. Lower the carpet into its normal position and with a sharp knife cut a slot in the carpet over the anchor to expose the plate end, as shown in the illustration. 9. Slip the carpet over the plate and press the outside edge of the carpet onto the velcro strip. Pkg. No. 4519081 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5414 INSTALLATION INSTRUCTIONS CHILD SEAT TETHER ANCHORAGE PLYMOUTH HORIZON AND DODGE OMNI INSTALLATION INSTRUCTIONS PACKAGE NO. 4519081 CHILD SEAT TETHER ANCHORAGE PLYMOUTH HORIZON AND DODGE OMNI - REAR CENTER CAUTION: THIS PACKAGE IS ONLY FOR THE REAR CENTER SEATING LOCATION FOR THE 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE SPECIFIED PARTS. PACKAGE CONSISTS OF: Cut Out Description Quantity Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5415 A Instructions - Child Seat 1 Tether Anchorage Installation B Bolt - Child Seat Tether 1 Anchorage C Nut - Child Seat Tether 1 Anchorage D Reinforcement - Child Seat 1 Tether Anchorage E Plate - Child Seat Tether 1 Anchorage INSTALLATION PROCEDURES 1. Open cargo hatch. 2. Lift the floor carpet up exposing the sheet metal. 3. Locate three steel plugs located on the floor. 4. Remove the center plug with a screw driver. Do not use the outboard plugs. 5. Insert the bolt through the plate and the floor. 6. From the underside of the vehicle, place the reinforcement on the bolt and hand tighten the flanged nut (assure that the sealer side of the reinforcement is placed against the floor). 7. (NOTE: THIS OPERATION MAY REQUIRE THE ASSISTANCE OF ANOTHER PERSON.) While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250 inch-pounds torque). 8. Lower the carpet into its normal position and with a sharp knife cut slot in the carpet over the anchor to expose the plate end, as shown in the illustration. 9. Slip the carpet over the plate and press the outside edge of the carpet onto the velcro strip. Pkg. No. 4519082 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5416 INSTALLATION INSTRUCTIONS CHILD SEAT TETHER ANCHORAGE PLYMOUTH VOYAGER AND GRAND VOYAGER DODGE CARAVAN AND GRAND CARAVAN 7 PASSENGER Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5417 INSTALLATION INSTRUCTIONS CHILD SEAT TETHER ANCHORAGE PLYMOUTH VOYAGER AND GRAND VOYAGER DODGE CARAVAN AND GRAND CARAVAN 5 PASSENGER INSTALLATION INSTRUCTIONS PACKAGE NO. 4519082 CHILD SEAT TETHER ANCHORAGE PLYMOUTH VOYAGER AND GRAND VOYAGER DODGE CARAVAN AND GRAND CARAVAN CAUTION: THIS PACKAGE IS ONLY FOR 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE SPECIFIED PARTS. PACKAGE CONSISTS OF: Cut Out Description Quantity A Instructions - Child Seat 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5418 Anchorage B Spacer Child Seat Tether 1 Anchorage C Bolt - Child Seat Tether 1 Anchorage D Nut - Child Seat Tether 1 Anchorage E Reinforcement - Child Seat 1 Tether Anchorage Sealing Washer F Plate - Child Seat Tether 1 Anchorage G Template - Child Seat Tether 1 Anchorage Locating INSTALLATION PROCEDURE 1. 5 Passenger Vehicle Remove the rear seat from the vehicle. 7 Passenger Vehicle. Remove the second rear seat from the vehicle. 2. Place the template on the floor carpet. 3. 5 Passenger Vehicle Position the template over the rear attaching cups in the floor pan with the passenger seat removed. 7 Passenger Vehicle Position the template over the front attaching cups in the floor pan with the passenger seat removed. 4. Locate the center of one of the two anchor locations shown on the template and transfer this location to the carpet. 5. Remove the template. 6. Using a sharp knife, cut a one-inch cross cut in the carpet and carpet underlayment at the transferred mark established in Step 4. 7. Locate the depression (dimple) in the floor pan, located beneath the cross cuts in the carpet. 8. Drill a 9 mm (3/8 inch) hole into the floor at the point marked by the depression. 9. Cut a 25.4 mm (1.00 inch diameter hole in the carpet and underlayment around the hole in the floor pan). 10. Insert the bolt through the plate, spacer, and floor. 11. From the underside of the vehicle, place the reinforcement on the bolt and hand tighten the flanged nut (assure that the sealer side of the reinforcement is placed against the floor). 12. (NOTE: THIS OPERATION REQUIRES THE ASSISTANCE OF ANOTHER PERSON.) While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250 inch-pounds torque). Pkg. No. 4519292 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5419 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5420 INSTALLATION INSTRUCTIONS CHILD SEAT TETHER ANCHORAGE DODGE SHADOW AND PLYMOUTH SUNDANCE INSTALLATION INSTRUCTIONS PACKAGE NO. 4519292 CHILD SEAT TETHER ANCHORAGE PACKAGE DODGE SHADOW AND PLYMOUTH SUNDANCE CAUTION: THIS PACKAGE IS ONLY FOR THE REAR SEATING POSITIONS FOR THE 1989 AND LATER MODELS LISTED ABOVE. DO NOT ATTEMPT INSTALLATION IN ANY OTHER VEHICLES. FOLLOW THESE INSTRUCTIONS CAREFULLY AND USE ONLY THE SPECIFIED PARTS. PACKAGE CONSISTS OF: Cut Out Description Quantity Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5421 A Instructions - Child Seat 1 Tether Anchorage Installation B Bolt - Child Seat Tether 1 Anchorage C Nut - Child Seat Tether 1 Anchorage D Reinforcement - Child Seat 1 Tether Anchorage Sealing Washer E Plate - Child Seat Tether 1 Anchorage INSTALLATION PROCEDURES 1. Open the hatch and remove the screws securing the lower trim panel. 2. Remove the trim panel and locate three scored depression rings on the back of panel. 3. Remove the scored slug from the trim panel which is in line with the seating position used for the child seat. 4. Using a sharp knife, remove the carpet covering the hole. 5. Using a screw driver, push the steel plug out of the sheet metal panel. 6. Replace the trim panel and the screws removed in Steps 1 and 2. 7. Insert the bolt through the plate and the hole in the hatch panel. 8. From the outside of the vehicle, place the reinforcement on the bolt and hand tighten the flanged nut (assure that the foam sealer is positioned next to the sheet metal panel). 9. While holding the plate as shown in the illustration, tighten the flange nut (tighten nut to 250 inch-pounds torque). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5422 Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts Identification NUMBER: 23-35-99 Rev. A GROUP: Body DATE: Oct. 1, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME ALLOWANCES. SUBJECT: Child Seat Tether Anchors NOTE: THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) LeBaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2000 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5423 detailed instruction sheet. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5424 PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5425 POLICY: Customer Satisfaction Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5426 TIME ALLOWANCE: Failure Code: CG - Customer Satisfaction Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Customer Interest: > 231491 > Nov > 91 > Seat Belt Anti-Rotation Tab - Modification Seat Belt: Customer Interest Seat Belt Anti-Rotation Tab - Modification NO.: 23-14-91 GROUP: BODY DATE: Nov. 18, 1991 MODELS: 1984-1990 S-AS Caravan/Grand Caravan, Voyager/Grand Voyager/Town & Country DISCUSSION: On the listed models, when the first rear seat is removed from the vehicle and the second rear seat is moved forward, it is possible for passengers to come in contact with the tip of the right outboard seat belt assembly when entering the vehicle. To prevent contact with the outboard belt when entering the vehicle, the belt assembly can be removed and the anti-rotation tab bent so the belt assembly swings freely. This modification will allow the seat belt assembly to rotate toward the floor allowing entry without contacting the tip of the belt. CAUTION: OWNERS WHO HAVE THIS SERVICE PERFORMED ON THEIR VEHICLE SHOULD BE ADVISED THAT THE MODIFIED SEAT BELT RETRACTOR ASSEMBLY MUST BE HELD VERTICALLY WHEN INSTALLING THE SEAT IN THE SECOND REAR SEAT POSITION. REPAIR PROCEDURE: Figure 1 This procedure involves bending the anti-rotation tab in the right outboard seat belt assembly on the rear seat. 1. Remove the right outboard seat belt assembly from the second rear seat assembly. 2. Bend the anti-rotation tab inward so the belt assembly will rotate freely (Figure 1). 3. Install the belt, tightening the retaining bolt to 350 in.lbs. (28 N-m) torque. POLICY: Information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 231491 > Nov > 91 > Seat Belt Anti-Rotation Tab Modification Seat Belt: All Technical Service Bulletins Seat Belt Anti-Rotation Tab - Modification NO.: 23-14-91 GROUP: BODY DATE: Nov. 18, 1991 MODELS: 1984-1990 S-AS Caravan/Grand Caravan, Voyager/Grand Voyager/Town & Country DISCUSSION: On the listed models, when the first rear seat is removed from the vehicle and the second rear seat is moved forward, it is possible for passengers to come in contact with the tip of the right outboard seat belt assembly when entering the vehicle. To prevent contact with the outboard belt when entering the vehicle, the belt assembly can be removed and the anti-rotation tab bent so the belt assembly swings freely. This modification will allow the seat belt assembly to rotate toward the floor allowing entry without contacting the tip of the belt. CAUTION: OWNERS WHO HAVE THIS SERVICE PERFORMED ON THEIR VEHICLE SHOULD BE ADVISED THAT THE MODIFIED SEAT BELT RETRACTOR ASSEMBLY MUST BE HELD VERTICALLY WHEN INSTALLING THE SEAT IN THE SECOND REAR SEAT POSITION. REPAIR PROCEDURE: Figure 1 This procedure involves bending the anti-rotation tab in the right outboard seat belt assembly on the rear seat. 1. Remove the right outboard seat belt assembly from the second rear seat assembly. 2. Bend the anti-rotation tab inward so the belt assembly will rotate freely (Figure 1). 3. Install the belt, tightening the retaining bolt to 350 in.lbs. (28 N-m) torque. POLICY: Information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 232189 > Aug > 89 > Rear Seat Shoulder Belt - Retrofit Kits Seat Belt: All Technical Service Bulletins Rear Seat Shoulder Belt - Retrofit Kits Models 1984-1990 S/AS Bodies Subject Rear Seat Shoulder Belt Retrofit Kits Index BODY & SHEET METAL Date August 21, 1989 No. 23-21-89 (C23-25-9) P-3131 BODY CODE LEGEND S/AS - CARAVAN/VOYAGER/CARAVAN C/V/MINI RAM VAN/GRAND CARAVAN/GRAND VOYAGER THIS TECHNICAL SERVICE BULLETIN IS AN ADDENDUM TO TECHNICAL SERVICE BULLETIN # 23-06-87 ISSUED ON MARCH 16, 1987. PROCEDURE In response to customer interest, rear seat shoulder belt retrofit kits have been developed and are now available for the Caravan and Voyager vehicles. Upon customer request, the kits listed below can be ordered and installed per the instructions enclosed in each kit. The customer is responsible for all parts and labor expenses incurred. Body Model Type Qty. Part No. S/AS 1984-1990 All 1 4571683 112" Wheelbase 5-Passenger S/AS 1984-1990 All 2 4571683 112" Wheelbase 7-Passenger S/AS 1987-1990 All 1 4571687 119" Wheelbase 5-Passenger S/AS 1987-1990 All 2 4571687 119" Wheelbase 7-Passenger NOTE: EACH KIT CONTAINS THE PARTS, TEMPLATES AND INSTRUCTION SHEETS REQUIRED TO INSTALL ONE LEFT SIDE AND ONE RIGHT SIDE REAR SEAT SHOULDER BELT. THE 7-PASSENGER MODELS REQUIRE TWO (2) KITS AS SHOWN ABOVE. POLICY: For information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 232189 > Aug > 89 > Rear Seat Shoulder Belt - Retrofit Kits Seat Belt: All Technical Service Bulletins Rear Seat Shoulder Belt - Retrofit Kits Models 1984-1990 S/AS Bodies Subject Rear Seat Shoulder Belt Retrofit Kits Index BODY & SHEET METAL Date August 21, 1989 No. 23-21-89 (C23-25-9) P-3131 BODY CODE LEGEND S/AS - CARAVAN/VOYAGER/CARAVAN C/V/MINI RAM VAN/GRAND CARAVAN/GRAND VOYAGER THIS TECHNICAL SERVICE BULLETIN IS AN ADDENDUM TO TECHNICAL SERVICE BULLETIN # 23-06-87 ISSUED ON MARCH 16, 1987. PROCEDURE In response to customer interest, rear seat shoulder belt retrofit kits have been developed and are now available for the Caravan and Voyager vehicles. Upon customer request, the kits listed below can be ordered and installed per the instructions enclosed in each kit. The customer is responsible for all parts and labor expenses incurred. Body Model Type Qty. Part No. S/AS 1984-1990 All 1 4571683 112" Wheelbase 5-Passenger S/AS 1984-1990 All 2 4571683 112" Wheelbase 7-Passenger S/AS 1987-1990 All 1 4571687 119" Wheelbase 5-Passenger S/AS 1987-1990 All 2 4571687 119" Wheelbase 7-Passenger NOTE: EACH KIT CONTAINS THE PARTS, TEMPLATES AND INSTRUCTION SHEETS REQUIRED TO INSTALL ONE LEFT SIDE AND ONE RIGHT SIDE REAR SEAT SHOULDER BELT. THE 7-PASSENGER MODELS REQUIRE TWO (2) KITS AS SHOWN ABOVE. POLICY: For information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5454 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5455 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5456 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5461 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5462 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5463 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 Vehicle Information Center Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions Radio/Stereo: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 Radio/Stereo: Electrical Diagrams Radio Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 Radio Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 5478 Radio/Stereo: Service and Repair 1. If equipped, remove forward console. 2. Disconnect battery ground cable. 3. Remove three attaching screws from top of bezel, then remove ashtray. 4. Remove two attaching screws at lower edge of bezel, then pull bezel rearward to release clip at left side of bezel. 5. Remove two radio to instrument panel attaching screws, then pull radio through front face of panel. 6. Disconnect radio electrical connector, antenna lead and ground strap. 7. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Trailer Tow Wiring/Components - Installation Cautions Trailer Adapter Kit: Technical Service Bulletins Trailer Tow Wiring/Components - Installation Cautions NO.: 08-05-91 GROUP: ELECTRICAL DATE: Apr. 22, 1991 SUBJECT: Trailer Tow Wiring Installation MODELS: ALL DODGE TRUCKS DISCUSSION: Improper installation of trailer tow wiring or electrical components can cause erratic operation of the vehicles electrical system. When installing wiring or additional components, or diagnosing a vehicle with erratic electrical operation, observe the following guidelines. ^ Inspect trailer wiring for bare or broken wires, corroded splices and terminals, shorted lamp sockets, poor or insufficient grounding between the trailer wiring system and trailer frame. ^ When connecting lighting circuits, use a factory trailer tow wiring harness or a Mopar service kit if available. Mopar kits include mating connectors and do not require cutting or splicing of vehicle wiring. If cutting or splicing is required, the attached Wiring Procedure should be followed. ^ When installing any electrical equipment (such as electric brakes, battery chargers, lighting, and winches) make sure that the tow vehicles electrical ground is hard wired to the trailer electrical ground. Ground wires should be attached to a clean, bare metal surface, not to a painted surface. DO NOT rely on the trailer hitch coupling for ground. ^ When using butt splice connectors, test the splice integrity by pulling on the wires after crimping. ^ DO NOT use insulation displacement or insulation piercing crimp type terminals. ^ Some electrical equipment will require splicing into the vehicle wiring. Follow the attached Wiring Procedure when installing these components. WIRING PROCEDURE 1. With the ignition key in the OFF position, disconnect the battery. 2. Remove one inch of insulation from each wire to be connected. 3. Slide a piece of heat shrink tubing (PN 4419644) onto one wire. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Trailer Tow Wiring/Components - Installation Cautions > Page 5484 4. Spread the strands of each wire apart (Example 1). 5. Push the ends of the wire together until the strands are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the twisted wire ends using a ROSIN CORE SOLDER. 8. Slide the piece of heat shrink tubing down to cover the splice. Be careful to center the tubing on the splice. Using a heat gun, heat the tubing until it shrinks and seals the splice. 9. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Trailer Lighting Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5489 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5490 Trailer Lighting Module: Electrical Diagrams Rear Lighting & Trailer Tow Wiring Circuit SH-68 - Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5491 Rear Lighting & Trailer Tow Wiring Circuit SH-79 - Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Customer Interest: > 070190 > Jan > 90 > Bumper Fascia - Causing Engine Overheating Front Bumper Cover / Fascia: Customer Interest Bumper Fascia - Causing Engine Overheating Models 1988 S Body 1989-1990 AS Body Subject Engine Overheating, LE Model Equipped With Premium Front Bumper Soft Fascia Index COOLING Date January 29, 1990 No. 07-01-90 P-123 (C07-02-9) BODY CODE LEGEND S - MINI RAM VAN/VOYAGER/CARAVAN/GRAND CARAVAN VOYAGER AS CARAVAN/GRAND CARAVAN/CARAVAN C/V/VOYAGER GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION 1988, 1989, and 1990 Caravan/Voyager "LE" Model equipped with the premium front bumper soft fascia may experience an overheating condition ( temperature gauge reads in the red zone) when one or more of the following conditions is present. 1. Vehicle is fully loaded and/or pulling a trailer. 2. Vehicle is being operated in hilly or mountainous terrain. 3. Ambient temperatures are 90~F or above. DIAGNOSIS Verify the vehicle is equipped with the premium front bumper soft fascia, the cooling system level is correct and no cooling system leaks are evident. PARTS REQUIRED Package - Air Dam and Front Fascia Template PN 5263408 Consists of: 1 Air Dam 7 Screws and Washers 1 Template Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Customer Interest: > 070190 > Jan > 90 > Bumper Fascia - Causing Engine Overheating > Page 5509 Figure 1 REPAIR PROCEDURE The repair procedure involves modifying the bumper fascia and the installation of an air dam. 1. Raise vehicle on a hoist. 2. Position and temporarily affix the template to the bottom of the fascia with masking tape as shown in Figure 1. 3. Using the template as a guide drill fourteen (14) pilot holes through the fascia at the areas indicated on the template using a 1/8" (.125 inch) drill bit. 4. Remove the template. 5. Using a 2-1/2" hole saw and the 1/8" pilot hole as a guide, saw fourteen (14) 2-1/2" holes through the bottom of the fascia. 6. Remove the five (5) lower fascia plastic retainers that secure the fascia to the lower radiator crossmember. 7. Position the air dam as shown in Figure 1. Starting at the center of the air dam and proceeding toward the outer ends of the air dam, loosely install the seven (7) screw/washer assembly in the existing holes in the lower radiator crossmember. 8. Starting at the center and working outward, tighten the seven screws. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 13-20-01-91 . . . . . . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 9R - Engine runs hot Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Cover / Fascia: > 070190 > Jan > 90 > Bumper Fascia - Causing Engine Overheating Front Bumper Cover / Fascia: All Technical Service Bulletins Bumper Fascia - Causing Engine Overheating Models 1988 S Body 1989-1990 AS Body Subject Engine Overheating, LE Model Equipped With Premium Front Bumper Soft Fascia Index COOLING Date January 29, 1990 No. 07-01-90 P-123 (C07-02-9) BODY CODE LEGEND S - MINI RAM VAN/VOYAGER/CARAVAN/GRAND CARAVAN VOYAGER AS CARAVAN/GRAND CARAVAN/CARAVAN C/V/VOYAGER GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION 1988, 1989, and 1990 Caravan/Voyager "LE" Model equipped with the premium front bumper soft fascia may experience an overheating condition ( temperature gauge reads in the red zone) when one or more of the following conditions is present. 1. Vehicle is fully loaded and/or pulling a trailer. 2. Vehicle is being operated in hilly or mountainous terrain. 3. Ambient temperatures are 90~F or above. DIAGNOSIS Verify the vehicle is equipped with the premium front bumper soft fascia, the cooling system level is correct and no cooling system leaks are evident. PARTS REQUIRED Package - Air Dam and Front Fascia Template PN 5263408 Consists of: 1 Air Dam 7 Screws and Washers 1 Template Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Cover / Fascia: > 070190 > Jan > 90 > Bumper Fascia - Causing Engine Overheating > Page 5515 Figure 1 REPAIR PROCEDURE The repair procedure involves modifying the bumper fascia and the installation of an air dam. 1. Raise vehicle on a hoist. 2. Position and temporarily affix the template to the bottom of the fascia with masking tape as shown in Figure 1. 3. Using the template as a guide drill fourteen (14) pilot holes through the fascia at the areas indicated on the template using a 1/8" (.125 inch) drill bit. 4. Remove the template. 5. Using a 2-1/2" hole saw and the 1/8" pilot hole as a guide, saw fourteen (14) 2-1/2" holes through the bottom of the fascia. 6. Remove the five (5) lower fascia plastic retainers that secure the fascia to the lower radiator crossmember. 7. Position the air dam as shown in Figure 1. Starting at the center of the air dam and proceeding toward the outer ends of the air dam, loosely install the seven (7) screw/washer assembly in the existing holes in the lower radiator crossmember. 8. Starting at the center and working outward, tighten the seven screws. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 13-20-01-91 . . . . . . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 9R - Engine runs hot Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 Absolute Pressure Sensor: All Technical Service Bulletins PCM - Cold Start Hesitation/Tip In Sag/DTC 13 NO: 18-06-94 GROUP: Vehicle Performance DATE: Apr. 22, 1994 SUBJECT: Cold Start Hesitation, Tip In Sag and/or DTC 13 (MAP Pneumatic) MODELS: 1989 (AA) Acclaim/Spirit 1989 (AC) Dynasty/New Yorker/Landau 1989 (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND AUTOMATIC TRANSAXLES. SYMPTOM/CONDITION: In warm ambient temperatures (over 60 degrees F), vehicle exhibits a cold start up tip in sag or hesitation. Also, some vehicles may set Diagnostic Trouble Code 13 (MAP Pneumatic). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes other than DTC 13 (MAP Pneumatic) are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the Powertrain Control Module with a module that has revised software. 1. With the ignition switch in the OFF position, disconnect the battery. 2. Remove the PCM as outlined in the appropriate Service Manual and replace it with a unit called out in "PARTS REQUIRED". 3. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 180694 > Apr > 94 > PCM - Cold Start Hesitation/Tip In Sag/DTC 13 > Page 5521 4. Type the required information on the Authorized Modification Label (as illustrated), and attach near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-19-01-94 0.5 Hrs. FAILURE CODE: NP - Sags, Hesitates Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 Absolute Pressure Sensor: All Technical Service Bulletins Check Engine Lamp Comes On and Fault Code 13 NO.: 18-09-91 GROUP: DRIVEABILITY DATE: Sept. 23, 1991 SUBJECT: Check Engine/Power Loss Lamp On - 3.0L Engine MODELS: 1989 (AA) SPIRIT/ACCLAIM 1988-89 (AC) DYNASTY/NEW YORKER/LANDAU/SALON 1989 (AG) DAYTONA 1989 (AJ) LEBARON COUPE/LEBARON CONVERTIBLE 1987-89 (AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER SYMPTOM/CONDITION: The vehicle's "Check Engine/Power Loss" lamp comes on and Fault Code 13 "Map Pneumatic Change" is set into the diagnostic system. DIAGNOSIS: Using the DRB II tester and the appropriate diagnostic manual, verify that Fault Code 13 "MAP Pneumatic Change", and no other fault code, is present. Visually inspect both the MAP sensor vacuum hose and wiring connector to insure proper installation. Perform the applicable tests in the diagnostic manual to verify that the MAP sensor is operating properly. PARTS REQUIRED: 1 MAP Sensor Relocation Package 4638458 Package Contents: 1 Cap Plug (1987-88 vehicles) 3580172 1 Cap Plug (1989 vehicles) 4241618 1 Purge Jumper Assembly 4669038 Consisting of: 1 In-Line Vacuum Connector 4201275 1 Vacuum Tee 33000227 1 11" Vacuum Hose 4104272 1 Bleed/Hose Assembly 4669042 Consisting of: 1 Vent 53007494 1 1" Vacuum Hose 4713956 1 Vacuum Tee 4669041 2 Vacuum Hose With 90 Degree Bend 4669044 1 Bracket 4686013 1 Wiring Harness 4687141 5 Tie Wraps 6015756 REPAIR PROCEDURE: This repair involves relocation of the MAP sensor. 1. Being sure that ignition key is in the OFF position, disconnect the negative battery cable. 2. Disconnect wiring connector, vacuum hose and attaching bolts. Remove MAP sensor from its present location. 3. Remove MAP sensor hose from vacuum tree on right side of intake manifold and install cap plug (3580172 for 1987 and 1988 vehicles or 4241618 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 5526 for 1989 vehicles) in its place. 4. Loosen clamps and remove throttle body/air filter intake hose. 5. Wiring Harness Installation Procedure: If MAP sensor was mounted on the alternator bracket follow Step A. If MAP sensor was mounted on the right side shock tower or on the bulkhead follow Step B. A) Connect the FEMALE end of the wiring harness (4687141) to the original MAP sensor connector. Route the harness along the backside of the intake manifold toward the throttle body. The harness should be secured to the fuel line and to the two wiring support brackets at the rear of the intake manifold using the supplied tie wraps. B) Remove the two pieces of tape on the wiring harness and extend the harness to its full length. Connect the FEMALE end of the harness to the original MAP sensor connector. If MAP sensor was mounted on the shock tower; route the harness to the right side of the motor mount and the two rear engine wiring support brackets. Secure using the supplied tie wraps. If MAP sensor was mounted on the bulkhead; route the harness to the alternator bracket and the two rear engine wiring support brackets. Secure using the supplied tie wraps. 6. Attach original MAP sensor to the bracket (4686013) supplied in the package. Figure 1 7. Loosen throttle body retaining nut, shown in Figure 1, enough to allow MAP sensor bracket to slide over throttle body stud. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 5527 Figure 2 8. Position MAP sensor and bracket so that MAP sensor vacuum port points straight down. Torque nut to 25 N-m (225 in.lbs.). 9. Disconnect the intake manifold end of the formed purge hose that extends from the intake manifold nipple to the "F" shaped connector (Figure 2). Figure 3 10. Assemble the MAP sensor bleed/hose assembly (4669042) as shown in Figure 3. Install to nipple on intake manifold. Position the MAP bleed valve as close to vertical as possible. Figure 4 11. Cut the existing PVC hose as shown in Figure 2. 12. Assemble the purge jumper assembly (4669038) as shown in Figure 4. Install between the formed purge hose (disconnected in Step 9) and the PVC hose (cut in Step 11). Connect the "Tee" end to the PVC hose and "In-line" end to the formed purge hose. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 180991 > Sep > 91 > Check Engine Lamp Comes On and Fault Code 13 > Page 5528 Figure 5 NOTE: TO PREVENT INTERFERENCE WITH THE THROTTLE LINKAGE, THE PURGE JUMPER ASSEMBLY MUST BE ROUTED UNDER THE INTAKE MANIFOLD (Figure 5). DO NOT ROUTE IT OVER THE TOP OF THROTTLE LINKAGE. 13. Connect vacuum hose to MAP sensor. 14. Connect wiring harness connector to MAP sensor. 15. Install throttle body/air filter intake hose and tighten clamps. 16. Use the DRB II to erase any fault codes and perform the applicable verification tests. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-14-15-94 . . . . . . . . . . . . . . . . . 0.8 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 180390 > Jan > 90 > MAP Sensor - DTC's 13 or 14 Set Absolute Pressure Sensor: All Technical Service Bulletins MAP Sensor - DTC's 13 or 14 Set Models 1987-90 AA, C/AC, E, G/AG, H/AH, J/AJ, K/AK, P/AP, S/AS Bodies Subject MAP Sensor ReplacementVehicles With 2.2L EFI, 2.5L EFI or 3.0L Engines Index DRIVEABILITY Date January 29, 1990 No. 18-03-90 (C18-20-9) P-164 BODY CODE LEGEND AA - ACCLAIM/,SPIRIT LEBARON LANDAU C/AC - DYNASTY/NEW YORKER LANDAU/SALON E - CARAVELLE/600 G/AG - DAYTONA H/AH - LANCER/LEBARON GTS J/AJ - LEBARON COUPE/LEBARON CONVERTIBLE K/AK - ARIES/RELIANT P/AP - SHADOW/SUNDANCE S/AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION The Driveability Test Procedure reveals a fault code (13 or 14) or a fault message (MAP Pneumatic Signal, MAP Pneumatic Change, or MAP Voltage too Low [or too High]), set in the vehicle diagnostic memory. PARTS REQUIRED 1 MAP Sensor PN 5227351 1 Sensor Hose (3.0L Engine Only) PN 4557138 REPAIR PROCEDURE When it is necessary to replace the MAP sensor, use Part Number 5227351 as the replacement part on all vehicles listed under Models above. Additionally, for 3.0L applications, replace the MAP sensor-to-intake manifold hose with Part Number 4557138. Refer to the appropriate Service Manual for replacement procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 091689 > Oct > 89 > Engine - Oil Consumption Absolute Pressure Sensor: All Technical Service Bulletins Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 5537 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > Page 5538 Front Bumper Cover / Fascia: By Symptom Technical Service Bulletin # 070190 Date: 900129 Bumper Fascia - Causing Engine Overheating Models 1988 S Body 1989-1990 AS Body Subject Engine Overheating, LE Model Equipped With Premium Front Bumper Soft Fascia Index COOLING Date January 29, 1990 No. 07-01-90 P-123 (C07-02-9) BODY CODE LEGEND S - MINI RAM VAN/VOYAGER/CARAVAN/GRAND CARAVAN VOYAGER AS CARAVAN/GRAND CARAVAN/CARAVAN C/V/VOYAGER GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION 1988, 1989, and 1990 Caravan/Voyager "LE" Model equipped with the premium front bumper soft fascia may experience an overheating condition ( temperature gauge reads in the red zone) when one or more of the following conditions is present. 1. Vehicle is fully loaded and/or pulling a trailer. 2. Vehicle is being operated in hilly or mountainous terrain. 3. Ambient temperatures are 90~F or above. DIAGNOSIS Verify the vehicle is equipped with the premium front bumper soft fascia, the cooling system level is correct and no cooling system leaks are evident. PARTS REQUIRED Package - Air Dam and Front Fascia Template PN 5263408 Consists of: 1 Air Dam 7 Screws and Washers 1 Template Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > Page 5539 Figure 1 REPAIR PROCEDURE The repair procedure involves modifying the bumper fascia and the installation of an air dam. 1. Raise vehicle on a hoist. 2. Position and temporarily affix the template to the bottom of the fascia with masking tape as shown in Figure 1. 3. Using the template as a guide drill fourteen (14) pilot holes through the fascia at the areas indicated on the template using a 1/8" (.125 inch) drill bit. 4. Remove the template. 5. Using a 2-1/2" hole saw and the 1/8" pilot hole as a guide, saw fourteen (14) 2-1/2" holes through the bottom of the fascia. 6. Remove the five (5) lower fascia plastic retainers that secure the fascia to the lower radiator crossmember. 7. Position the air dam as shown in Figure 1. Starting at the center of the air dam and proceeding toward the outer ends of the air dam, loosely install the seven (7) screw/washer assembly in the existing holes in the lower radiator crossmember. 8. Starting at the center and working outward, tighten the seven screws. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 13-20-01-91 . . . . . . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 9R - Engine runs hot Technical Service Bulletin # 070190 Date: 900129 Bumper Fascia - Causing Engine Overheating Models 1988 S Body 1989-1990 AS Body Subject Engine Overheating, LE Model Equipped With Premium Front Bumper Soft Fascia Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > Page 5540 Index COOLING Date January 29, 1990 No. 07-01-90 P-123 (C07-02-9) BODY CODE LEGEND S - MINI RAM VAN/VOYAGER/CARAVAN/GRAND CARAVAN VOYAGER AS CARAVAN/GRAND CARAVAN/CARAVAN C/V/VOYAGER GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION 1988, 1989, and 1990 Caravan/Voyager "LE" Model equipped with the premium front bumper soft fascia may experience an overheating condition ( temperature gauge reads in the red zone) when one or more of the following conditions is present. 1. Vehicle is fully loaded and/or pulling a trailer. 2. Vehicle is being operated in hilly or mountainous terrain. 3. Ambient temperatures are 90~F or above. DIAGNOSIS Verify the vehicle is equipped with the premium front bumper soft fascia, the cooling system level is correct and no cooling system leaks are evident. PARTS REQUIRED Package - Air Dam and Front Fascia Template PN 5263408 Consists of: 1 Air Dam 7 Screws and Washers 1 Template Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > Page 5541 Figure 1 REPAIR PROCEDURE The repair procedure involves modifying the bumper fascia and the installation of an air dam. 1. Raise vehicle on a hoist. 2. Position and temporarily affix the template to the bottom of the fascia with masking tape as shown in Figure 1. 3. Using the template as a guide drill fourteen (14) pilot holes through the fascia at the areas indicated on the template using a 1/8" (.125 inch) drill bit. 4. Remove the template. 5. Using a 2-1/2" hole saw and the 1/8" pilot hole as a guide, saw fourteen (14) 2-1/2" holes through the bottom of the fascia. 6. Remove the five (5) lower fascia plastic retainers that secure the fascia to the lower radiator crossmember. 7. Position the air dam as shown in Figure 1. Starting at the center of the air dam and proceeding toward the outer ends of the air dam, loosely install the seven (7) screw/washer assembly in the existing holes in the lower radiator crossmember. 8. Starting at the center and working outward, tighten the seven screws. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 13-20-01-91 . . . . . . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 9R - Engine runs hot Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > System Information > Service and Repair > Interior Door Handle Front Door Handle: Service and Repair Interior Door Handle Front Door Trim Panel 1. Remove trim panel and liner. 2. Raise glass with switch or window crank. Latch Assembly, Striker, And Linkage 3. Unclip links at the door latch. 4. Remove links from anti-rattle clips. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > System Information > Service and Repair > Interior Door Handle > Page 5549 Front Door Assembly 5. Remove remote control assembly by removing three screws and pulling links out of the door. 6. Remove links from the remote handle as required to replace handle or link. 7. Reverse removal procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > System Information > Service and Repair > Interior Door Handle > Page 5550 Front Door Handle: Service and Repair Exterior Door Handle Front Door Trim Panel 1. Remove door trim panel. 2. Remove liner to clear rear of major access hole and door. 3. Roll glass up. Latch Assembly, Striker, And Linkage 4. Disconnect outside handle and lock cylinder links at the latch. 5. Remove the lock cylinder link. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > System Information > Service and Repair > Interior Door Handle > Page 5551 Outside Handle/Lock Cylinder 6. Remove two attaching nuts, outside handle and reinforcing plate. 7. Reverse procedure to install. Adjust latch prior to trim panel installation. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair Front Door Latch: Service and Repair Front Door Trim Panel 1. Remove trim panel and liner. 2. Raise window to full-up position. Latch Assembly, Striker, And Linkage 3. Disconnect all links at latch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 5555 Front Door Assembly 4. Remove three torx screws from the door inside panel. 5. Remove latch assembly. 6. To assemble reverse removal procedure. Adjust outside handle at the latch as soon as all links are secured. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair REMOVAL Front Door Trim Panel 1. Lower the door glass until it is 3 inches (75 mm) from the full-down position. 2. Remove the remote handle bezel with the door unlocked by prying the front of the bezel out and rearward. 3. Remove the screw in the armrest pocket. 4. Pry out the door lock switch bezel. 5. Remove the window crank (if equipped with manual windows). 6. Remove the door trim panel, (retained with frog legged clips) and push the power lock switch through the door trim panel. 7. Disconnect the courtesy light pigtail. 8. Remove plastic and foam composite door liner where access is required. INSTALLATION 1. Apply adhesive to the door liner and fasten it to the inner door panel. 2. Connect the courtesy light pigtail. 3. Push the power lock switch through the door trim panel and install the door trim panel. 4. Push the power lock switch into place. 5. Attach the window crank (if equipped with manual windows). 6. Install the screw through the armrest pocket. 7. Install the remote handle bezel with the door unlocked by pushing the bezel in and forward. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair Front Door Trim Panel 1. Remove trim panel. 2. Remove five outer belt weatherstrip screws, and remove weatherstrip, using an offset screwdriver. 3. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair Glass To Regulator REMOVAL 1. Remove trim panel and door liner. See: Front Door Panel/Service and Repair 2. Raise the door glass until the two (2) nuts align with access holes in the inner door panel. 3. Remove the two (2) glass plate nuts that hold the door glass to the front window regulator assembly. 4. Remove the glass through the belt opening, using the notch at the rear of the door to clear the glass fasteners (pull the glass towards the inside of the vehicle when removing). INSTALLATION 1. Slide the door glass into the door through the belt opening, using the notch at the rear of the door to clear the glass fasteners. 2. Install the two (2) glass plate nuts that hold the door glass to the front window regulator assembly and tighten finger tight. 3. To adjust the door glass, raise glass to full up position and secure glass attaching nuts. 3. Install the door liner and door trim panel. See: Front Door Panel/Service and Repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Power Window Regulator Assembly REMOVAL 1. Remove trim panel and door liner. See: Front Door Panel/Service and Repair 2. Remove the front door glass. See: Front Door Window Glass/Service and Repair 3. Remove the power window regulator assembly. See: Windows and Glass/Windows/Window Regulator/Service and Repair/Power Window Regulator Replacement 4. Drill out the two (2) rivets mounting the power window lift motor to the window regulator. 5. Remove the power window lift motor off of the regulator. INSTALLATION 1. Position the power window lift motor onto the power window regulator and install two (2) 1/4-20 X 1/2 screws in place of the rivets that were drilled out for removal. Torque the mounting screws to 90 lb-ft (11 Nm). 2. Install the power window regulator assembly. See: Windows and Glass/Windows/Window Regulator/Service and Repair/Power Window Regulator Replacement 3. Install the front door glass. See: Front Door Window Glass/Service and Repair 4. Install the door liner and door trim panel. See: Front Door Panel/Service and Repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Adjustments Sliding Door Handle: Adjustments Four areas of the latch remote locking control can be adjusted: the lock knob, inside handle, outside handle, and the front hook. These components should be adjusted when they fail to operate properly. Latch Remote Locking Control To simplify service of the sliding door latches and locks, a latch remote locking control is used. This assembly consolidates the door locks and latch remote control mechanisms into one unit. It can be accessed for removal and replacement by removing the door trim panel. Adjusting The Lock Knob Perform the lock knob adjustment with the door open. Loosen the lowermost allen head screw on the control assembly. Then lock the latch by pulling the locking link forward and tighten the allen head screw to 25 in. lbs. (3 Nm). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Adjustments > Page 5572 Adjusting The Inside Handle Adjust the inside handle setting by loosening the uppermost allen head screw on the left side of the assembly. Insert a screwdriver through the square hole in the assembly and pull the latch link upward far enough to remove any free play. Then tighten the allen head screw to 25 in. lbs. (3 Nm). Adjusting The Outside Handle The outside handle can be adjusted by loosening the lowermost allen head screw of the central pivot. Then hold the central pivot cam against the outside handle actuator button and tighten the all en head screw to 25 in lbs. (3 Nm). Adjusting The Front Hook Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Adjustments > Page 5573 The front hook adjustment must be performed with the door closed. Begin this adjustment by loosening the uppermost allen head screw at the central pivot. Push the front hook actuator link forward until it bottoms on the hook and tighten the allen head screw to 25 in. lbs. (3 Nm). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Adjustments > Page 5574 Sliding Door Handle: Service and Repair Sliding Door Trim Panel 1. Remove trim panel. Latch Remote Locking Control 2. Remove 8 control assembly to door bolts. 3. Disconnect linkage and wiring harness. 4. Remove control assembly. 5. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Interior Trim Panel > Component Information > Service and Repair Sliding Door Interior Trim Panel: Service and Repair *** THIS ARTICLE HAS BEEN UPDATED BY TSB # 23-08-88 DATED MAY 16, 1988 REMOVAL Sliding Door Trim Panel 1. With door closed, remove door latch remote control bezel. 2. Remove two (2) plugs and screws holding upper arm cover to the trim panel. 3. Remove seven (7) plastic trim panel fasteners. 4. Remove one (1) plug and screw from the trim panel. 5. On carpet trim panel models, remove the hidden screw from the upper rearward corner of the carpet insert. 6. Disengage five (5) frogleg fasteners used to retain the trim panel to the door. 7. Remove the christmas tree fastener from the center of the carpet insert (if applicable). 7. Remove the trim panel. INSTALLATION 1. Raise the trim panel to the door and push the five (5) frogleg fasteners, and the one (1) christmas fastener (if applicable), into the door. 2. Install one (1) screw and plug through the trim panel into the door. 3. On carpet trim panel models, install the hidden screw into the upper rearward corner of the carpet insert. 3. Install the seven (7) plastic trim panel fasteners. 4. Install the two (2) screws and plugs used to fasten the upper arm trim cover to the door. 5. Install the door latch remote control bezel. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Service and Repair Sliding Door Latch: Service and Repair 1. Remove trim panel. 2. Open door and remove linkage from connectors at the latch. 3. After removing three latch retaining screws, remove the latch. 4. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Release Cable > Component Information > Service and Repair Fuel Door Release Cable: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Remove the four nuts that fasten the driver's seat riser to the floor pan. 3. Lower the hoist. Fuel Door Remote Cable 4. Tilt the seat backwards, reach under the front of the seat and grab the cable close to the clip that retains it to the lever assembly. 5. Pull the cable towards the drivers door until it is released from the lever assembly. 6. Turn the cable 90° and push inward to separate the cable end from the lever assembly. 7. Remove the driver's seat and riser assembly. Rear Seat Removal (5 Passenger) 8. Remove the rear seat(s) by lifting the release lever on the front of both seat riser assemblies. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Release Cable > Component Information > Service and Repair > Page 5585 9. Remove the left windshield side garnish moulding. 10. Remove the left front door scuff plate. 11. Remove the left "B" pillar garnish moulding and seat belt. 12. Remove the liftgate scuff plate. Garnish Mouldings And Trim Panels, Left Side 13. Remove the lower quarter trim panel. Fuel Door Remote Cable 14. Lift carpet at the liftgate opening and remove the emergency release cable from the spare tire winch actuating bolt and from the retaining clip. 15. Remove the fuel door remote cable retaining nut that is located inside of the fuel door opening. 16. Remove the cable assembly, 17. Reverse this procedure to install the cable. Observe and use all torque specifications as shown on the illustrations. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations Power Trunk / Liftgate Lock Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Recalls: > 95I001004 > Mar > 95 > Recall 95I001004: Liftgate Latch Defect Trunk / Liftgate Latch: Recalls Recall 95I001004: Liftgate Latch Defect Light duty passenger minivans without remote release. This is not a safety recall. There has been no determination that a safety defect exists with the minivan latches. Chrysler is conducting a service campaign to replace the liftgate latch assembly of the affected minivans. In a collision, the rear liftgate latch assembly could open. If the liftgate latch opens, occupants can be ejected resulting in significantly increased risk of injury or death. Chrysler dealers will replace the liftgate latch with a new stronger latch assembly without charge. Chrysler began notifying owners during November 1995. This is not a safety recall. There has been no determination that a safety defect exists with the minivan latches. However, Chrysler has decided to provide a stronger latch without charge. Owners can contact Chrysler at 1-800-MINIVAN (1-800-646-4826). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Recalls: > 95I001008 > Mar > 95 > Recall 95I001008: Liftgate Latch Defect Trunk / Liftgate Latch: Recalls Recall 95I001008: Liftgate Latch Defect Light duty passenger minivans with remote release. This is not a safety recall. There has been no determination that a safety defect exists with the minivan latches. Chrysler is conducting a service campaign to replace the liftgate latch assembly of the affected minivans. In a collision, the rear liftgate latch assembly could open. If the liftgate latch opens, occupants can be ejected resulting in significantly increased risk of injury or death. Chrysler dealers will replace the liftgate latch with a new stronger latch assembly without charge. Chrysler began notifying owners of these vehicles during July 1996. This is not a safety recall. There has been no determination that a safety defect exists with the minivan latches. However, Chrysler has decided to provide a stronger latch without charge. Owners can contact Chrysler at 1-800-MINIVAN (1-800-646-4826). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95I001004 > Mar > 95 > Recall 95I001004: Liftgate Latch Defect Trunk / Liftgate Latch: All Technical Service Bulletins Recall 95I001004: Liftgate Latch Defect Light duty passenger minivans without remote release. This is not a safety recall. There has been no determination that a safety defect exists with the minivan latches. Chrysler is conducting a service campaign to replace the liftgate latch assembly of the affected minivans. In a collision, the rear liftgate latch assembly could open. If the liftgate latch opens, occupants can be ejected resulting in significantly increased risk of injury or death. Chrysler dealers will replace the liftgate latch with a new stronger latch assembly without charge. Chrysler began notifying owners during November 1995. This is not a safety recall. There has been no determination that a safety defect exists with the minivan latches. However, Chrysler has decided to provide a stronger latch without charge. Owners can contact Chrysler at 1-800-MINIVAN (1-800-646-4826). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95I001008 > Mar > 95 > Recall 95I001008: Liftgate Latch Defect Trunk / Liftgate Latch: All Technical Service Bulletins Recall 95I001008: Liftgate Latch Defect Light duty passenger minivans with remote release. This is not a safety recall. There has been no determination that a safety defect exists with the minivan latches. Chrysler is conducting a service campaign to replace the liftgate latch assembly of the affected minivans. In a collision, the rear liftgate latch assembly could open. If the liftgate latch opens, occupants can be ejected resulting in significantly increased risk of injury or death. Chrysler dealers will replace the liftgate latch with a new stronger latch assembly without charge. Chrysler began notifying owners of these vehicles during July 1996. This is not a safety recall. There has been no determination that a safety defect exists with the minivan latches. However, Chrysler has decided to provide a stronger latch without charge. Owners can contact Chrysler at 1-800-MINIVAN (1-800-646-4826). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch: > 091689 > Oct > 89 > Engine - Oil Consumption Positive Crankcase Ventilation Valve: All Technical Service Bulletins Engine - Oil Consumption Models 1987-89 S/AS Bodies 1988-89 C/AC Bodies 1989 AA Body All Equipped With 3.0L Engine Subject Abnormal Oil Consumption Index ENGINE Date October 16, 1989 No. 09-16-89 (C09-15-9) P-3753 BODY CODE LEGEND AA - SPIRIT/ACCLAIM C/AC - DYNASTY/NEW YORKER/LANDAU S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Some owners may express concern of abnormal oil consumption (1 qt. per 400-500 miles) on 1987-89 domestic vehicles equipped with the 3.0L engine. In addition they may complain of lack of power, rough idle, hesitation and driveway dieout. This condition may be the result of sludge accumulation in the left bank (FRONT) rocker cover baffle oil drain hole. Plugging or restricting of the baffle oil drain hole may result in oil pull-over into the PCV system. Figure 1 DIAGNOSIS Remove the MAP sensor hose and PCV hose, inspect hoses for evidence of oil accumulation. If oil is present, remove the left (FRONT) rocker cover. Inspect the inside of the rocker cover for sludge accumulation and/or a restricted drain hole, Figure 1. If there is an accumulation of sludge or drain hole is restricted perform the following repair procedure. If the rocker cover is free of sludge and the drain hole is clear, perform an oil consumption diagnosis as outlined in the appropriate Technical Service Manual. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 5616 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch: > 091689 > Oct > 89 > Engine - Oil Consumption > Page 5622 Figure 2 PARTS REQUIRED 1 Rocker Cover P/N MD156425 1 PCV Valve P/N MD102195 1 Gasket, Rocker Cover P/N MD133671 1 Silicone Rubber Adhesive (RTV) P/N 4318025 REPAIR PROCEDURE This repair involves replacing the left rocker cover, PCV valve and cleaning the PCV and MAP sensor hose. 1. Remove the left rocker cover (FRONT). 2. Position the new rocker gasket P/N MD133671 in the new rocker cover P/N MD156425. 3. Apply silicone rubber adhesive (RTV) P/N 4318025 to the cover ends, Figure 2. 4. Install the rocker cover on the cylinder head, tighten the rocker cover screws to 88 in.lbs. (10 N-m) torque. 5. Install new PCV valve P/N MD102195 in the rocker cover. 6. Clean the MAP sensor hose and PCV hose with compressed air. 7. Install the MAP sensor hose and PCV hose. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 09-35-20-91 . . . . . . . . . . . . . . . . 0.3 Hrs. FAILURE CODE: 70 - Oil Consumption Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations Trunk / Liftgate Solenoid: Locations Liftgate Components Bottom Center Of Liftgate Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55 MPH Cross-Member: Customer Interest Exhaust System - Drone At 40-55 MPH Models 1987-90 S/AS Bodies With 2.5L & 3.0L Engines Subject Exhaust Drone At 40-55 MPH Index EXHAUST Date September 18, 1989 No. 11-02-89 (C11-01-9) P-3455 BODY CODE LEGEND S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH). DIAGNOSIS Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from under the floor pan area in front of the first bench seat. The vibration will also be present if the engine is run through the 2350-2450 RPM range with the transmission in neutral. PARTS REQUIRED 1 Crossmember Assembly PN 4427322 1 Muffler Support Bracket PN 4427295 1 Heat Shield PN 4401855 4 Screw & Washer Assembly PN 6501305 4 U-Nut PN 6101283 REPAIR PROCEDURE 1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the exhaust insulators to remain on the muffler. 2. Remove the muffler support bracket, crossmember, and heat shield. 3. Install new heat shield, using the fasteners just removed. 4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250 +/- 50 in. lbs., washer should bottom out on sleeve. 5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN 6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs. 6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs. 7. Road test vehicle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55 MPH > Page 5638 TIME ALLOWANCE: Labor Operation No. 11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55 MPH Cross-Member: All Technical Service Bulletins Exhaust System - Drone At 40-55 MPH Models 1987-90 S/AS Bodies With 2.5L & 3.0L Engines Subject Exhaust Drone At 40-55 MPH Index EXHAUST Date September 18, 1989 No. 11-02-89 (C11-01-9) P-3455 BODY CODE LEGEND S/AS - CARAVAN/VOYAGER/CARAVAN C/V/TOWN & COUNTRY SYMPTOM/CONDITION Exhaust drone or floor pan vibration, at approximately 2400 rpm (40-55 MPH). DIAGNOSIS Test drive the vehicle in the 40-55 MPH range to verify the presence of a mechanical vibration from under the floor pan area in front of the first bench seat. The vibration will also be present if the engine is run through the 2350-2450 RPM range with the transmission in neutral. PARTS REQUIRED 1 Crossmember Assembly PN 4427322 1 Muffler Support Bracket PN 4427295 1 Heat Shield PN 4401855 4 Screw & Washer Assembly PN 6501305 4 U-Nut PN 6101283 REPAIR PROCEDURE 1. Remove exhaust system insulator shoulder bolts from muffler support bracket, allowing the exhaust insulators to remain on the muffler. 2. Remove the muffler support bracket, crossmember, and heat shield. 3. Install new heat shield, using the fasteners just removed. 4. Install crossmember using screw and washer assembly (PN 6501305). Torque assembly to 250 +/- 50 in. lbs., washer should bottom out on sleeve. 5. Attach new muffler support bracket (PN 4427295) to crossmember using new U-nuts (PN 6101283) and the existing fasteners. Torque to 250 +/- 50 in. lbs. 6. Attach U-nuts (PN 6101283) to the muffler support bracket, install the exhaust insulators to the bracket with original shoulder bolts. Torque to 250 +/- 50 in. lbs. 7. Road test vehicle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 110289 > Sep > 89 > Exhaust System - Drone At 40-55 MPH > Page 5644 TIME ALLOWANCE: Labor Operation No. 11-40-10-92 . . . . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Trailer Tow Wiring/Components - Installation Cautions Trailer Adapter Kit: Technical Service Bulletins Trailer Tow Wiring/Components - Installation Cautions NO.: 08-05-91 GROUP: ELECTRICAL DATE: Apr. 22, 1991 SUBJECT: Trailer Tow Wiring Installation MODELS: ALL DODGE TRUCKS DISCUSSION: Improper installation of trailer tow wiring or electrical components can cause erratic operation of the vehicles electrical system. When installing wiring or additional components, or diagnosing a vehicle with erratic electrical operation, observe the following guidelines. ^ Inspect trailer wiring for bare or broken wires, corroded splices and terminals, shorted lamp sockets, poor or insufficient grounding between the trailer wiring system and trailer frame. ^ When connecting lighting circuits, use a factory trailer tow wiring harness or a Mopar service kit if available. Mopar kits include mating connectors and do not require cutting or splicing of vehicle wiring. If cutting or splicing is required, the attached Wiring Procedure should be followed. ^ When installing any electrical equipment (such as electric brakes, battery chargers, lighting, and winches) make sure that the tow vehicles electrical ground is hard wired to the trailer electrical ground. Ground wires should be attached to a clean, bare metal surface, not to a painted surface. DO NOT rely on the trailer hitch coupling for ground. ^ When using butt splice connectors, test the splice integrity by pulling on the wires after crimping. ^ DO NOT use insulation displacement or insulation piercing crimp type terminals. ^ Some electrical equipment will require splicing into the vehicle wiring. Follow the attached Wiring Procedure when installing these components. WIRING PROCEDURE 1. With the ignition key in the OFF position, disconnect the battery. 2. Remove one inch of insulation from each wire to be connected. 3. Slide a piece of heat shrink tubing (PN 4419644) onto one wire. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Trailer Tow Wiring/Components - Installation Cautions > Page 5649 4. Spread the strands of each wire apart (Example 1). 5. Push the ends of the wire together until the strands are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the twisted wire ends using a ROSIN CORE SOLDER. 8. Slide the piece of heat shrink tubing down to cover the splice. Be careful to center the tubing on the splice. Using a heat gun, heat the tubing until it shrinks and seals the splice. 9. Connect the battery. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions Console: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 5655 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 5656 Console: Electrical Diagrams Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 Overhead Console Lamps Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 Overhead Console Lamps Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 5660 Console: Service and Repair EXTENDED CONSOLE Mounting Brackets 1. Install forward and rear mounting brackets with four screws. 2. Attach rear console, first making sure headliner is between housing and upper plastic. Mounting Console Assembly 3. Slide console rearwards until console stops. 4. Attach vent switch wire harness to vent switch carrier. 5. Attach main wiring harness into compass module. Connecting Harness 6. Press console to headliner, centering console between visor tip pin retainers. 7. While pressing console upwards, slide console forward to attach console on front mounting tang. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 5661 Installing Console Assembly 8. Press upwards until consoles snap onto mounting bracket. SHORT CONSOLE 1. Install forward and rear mounting brackets with four screws. 2. Attach vent switch wire harness to vent switch carrier. 3. Press console to headliner, centering console between visor tip pin retainers. 4. While pressing console upwards, slide console forward to attach console on front mounting tang. 5. Press upwards until console snaps onto mounting brackets. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming 1. Place ignition switch in lock position. 2. Disconnect and tape battery ground cable connector. 3. Wait at least 1 minute after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy airbag for a short time even after battery has been disconnected. 4. After repairs are performed, connect battery ground cable. 5. From passenger side of vehicle, turn ignition switch to On position. 6. SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate if SRS system is functioning correctly. 7. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair Headliner 1. Remove rear vent remote control handle covers. 2. Unscrew and remove both remote control handles. 3. Disconnect battery negative cable and remove reading lamp, dome lamp, and cargo lamps. 4. Remove the sun visors and sun visor clips. 5. Remove the windshield side garnish mouldings. 6. Remove the first rear seat. 7. Remove front door scuff plates, side door scuff plate, and liftgate scuff plate. 8. Remove "B" pillar garnish mouldings and seat belts. 9. Remove upper track cover. 10. Remove lower quarter trim panel from left side. 11. Remove upper quarter trim panel from left side. 12. Remove right quarter trim panel. 13. Remove headliner fasteners, and then headliner. 14. Reverse this procedure for installation. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair Trim Panel: Service and Repair Interior Panels (Extended Wheelbase) GENERAL INFORMATION Because of the longer wheelbase made available in some of these vehicles, trim panels and interior garnish mouldings have been extended or modified to meet the specifications of this vehicle. INTERIOR TRIM PANELS AND GARNISH MOULDINGS Excellent fit and appearance are two benefits of overlapping garnish and trim panels on the interior of the vehicle. With the exception of the windshield side garnish mouldings, sliding side door scuff plate, and the liftgate scuff plate, a series of trim components must be removed in order to service any other trim panel or garnish moulding. The following list is the sequence of removal that has been found to be most effective. Right Side 1. Right windshield side garnish moulding. 2. Right front door scuff plate. 3. Right "B" pillar garnish moulding and seat belt. 4. Sliding side door upper track cover. 5. Sliding side door scuff plate. 6. Liftgate scuff plate. 7. Right quarter trim panel. 8. Reverse the order of trim components to install. Left Side 1. Left windshield side garnish moulding. 2. Left front door scuff plate. 3. Left "B" pillar garnish moulding and seat belt. 4. Liftgate scuff plate. 5. Lower quarter trim panel. 6. Upper quarter trim panel. 7. Reverse the order of trim components to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Front Doors Door Lock Cylinder: Service and Repair Front Doors Outside Handle/Lock Cylinder 1. Remove outside handle. 2. Remove two screws, retainer and lock cylinder. 3. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Front Doors > Page 5678 Door Lock Cylinder: Service and Repair Sliding Side Door Sliding Door Trim Panel 1. Remove trim panel. Latch Remote Locking Control 2. Remove latch remote locking control assembly. 3. Remove 2 retainer nuts from inside of the door and then pull the handle assembly from the outside of the door. 4. Remove 2 screws, and separate lock cylinder from outside handle assembly. 5. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Front Door Power Door Lock Actuator: Locations Front Door Front Door Assembly The power door lock motor is located in the bottom rear corner of the door, just below the door latch assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Front Door > Page 5684 Power Door Lock Actuator: Locations Sliding Side Door Sliding Side Door Power Lock Assembly The power door lock motor, for the sliding door, is located behind the door lock contact plate at the front of the door. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 5685 Power Door Lock Actuator: Testing and Inspection Power Door Lock Motor NOTE: Perform CIRCUIT BREAKER TEST prior to this test, and verify that the battery is fully charged. 1. Check each door for lock and unlock or disconnect the motor connections one at a time while operating the door lock switch. 2. If none of the door lock motors work, the problem may be caused by a shorted motor. Disconnecting the defective motor will allow the others to work. NOTE: If one of the motors has a broken pigtail connector, it should have no effect on the operation of the other door lock motors. 3. To test an individual lock motor, disconnect the lock motor electrical connector and do the following: ^ Connect a 12 volt power source to the Orange wire terminal of the lock motor electrical connector and ground the Pink wire terminal, this should lock the door. ^ Reverse the wires from the previous step (12 volts to the Pink wire and ground the Orange wire) and the door should unlock. ^ If both results do not occur, check for a broken wire between the electrical connector and the lock motor. If there are no broken wires, replace the lock motor. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Power Door Lock Actuator: Service and Repair Front Door Front Door Assembly REMOVAL 1. Remove door trim panel and liner. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 2. Raise door glass with service power window switch or crank. 3. Disconnect the power door lock electrical connector. 4. Drill out the two (2) lock motor mounting rivets. 5. Disconnect the lock motor link at the motor and remove the motor through the access hole. INSTALLATION 1. Connect the lock motor to the linkage rod. 2. Attach the lock motor to its mounting bracket with two (2) 1/4-20 X 1/2 inch screws and nuts. Torque to 90 lb-in (11 Nm). 3. Connect the lock motor electrical connector. 4. Install liner and trim panel. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair NOTE: If the rubber boot on the power door lock motor is twisted, the movement of the motor will be restricted. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door > Page 5688 Power Door Lock Actuator: Service and Repair Sliding Door REMOVAL Sliding Door Power Lock Components 1. Remove door trim panel. See: Doors, Hood and Trunk/Doors/Sliding Door/Sliding Door Interior Trim Panel/Service and Repair 2. Remove eight (8) control assembly to door mounting bolts. 3. Disconnect the lock linkage and the wiring harness. 4. Pull the control assembly out of the sliding door. 5. Disconnect the lock linkage from the lock motor and remove the lock motor from the control assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door > Page 5689 INSTALLATION 1. Mount the lock motor to the control assembly and connect its lock linkage. 2. Connect the wiring harness and the lock linkage to the sliding door. 3. Install the control assembly into the sliding door. 4. Install and tighten the eight (8) control assembly mounting bolts. 5. Install the door trim panel. See: Doors, Hood and Trunk/Doors/Sliding Door/Sliding Door Interior Trim Panel/Service and Repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Front Door Components In Front Door Armrest Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Sliding Door Circuit Test Power Door Lock Switch: Testing and Inspection Sliding Door Circuit Test Sliding Side Door Power Lock Assembly 1. Connect one lead of a test light to the upper contact of the pillar, and place the other lead to the lower contact. 2. If the test light illuminates when the lock switch is depressed, the wiring circuit to the contacts is good. If the test light does not illuminate, check the electrical connectors at the right side cowl, check for a broken wire, or see Circuit Breaker Test. 3. With the sliding door partially open, connect jumper wires across contacts on pillar to contacts on the door. The door should lock or unlock when Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 5695 these jumper wires are connected and the switch is depressed. 4. If the door locks and unlocks, the problem is in the door and pillar contacts (check for proper shim at the door contact plate). If lock and unlock does not occur, remove trim panel and check for voltage at the lock motor. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 5696 Power Door Lock Switch: Testing and Inspection Switch Voltage Test NOTE: The following test determines whether voltage is continuous through the wiring harness to the power door lock switch. 1. Remove the door lock switch from the door trim panel. 2. Separate the multiple terminal block on the wiring harness from the door lock switch. 3. Connect one lead of a test light to the black wire terminal and the other lead to the red wire terminal. If the test light illuminates, the wiring circuit between the battery and switch is functioning properly. If the test light does not illuminate, check the 30 amp main fuse (circuit breaker) or check for an open in the wiring harness. 4. If the wiring circuit is functioning properly, See: Power Door Lock Actuator/Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 5697 Power Door Lock Switch: Testing and Inspection Door Lock Switch Test Door Lock Switch Continuity Remove each door lock switch from the door trim panel. Connect an ohmmeter to the switch and check that there is continuity in lock and unlock positions (refer to the image shown). If these results are not obtained, replace the switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Page 5698 Power Door Lock Switch: Service and Repair 1. Pry up rear of switch bezel releasing it from clips. Pull bezel out of door trim. 2. Disconnect wiring harness. 3. Remove switch screws and switch. 4. Reverse removal sequence to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Front Door Components In Center Of Door Panel Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Variance Program Paint: Technical Service Bulletins Paint - Variance Program SUBJECT: Color Variance Program NO.: 23-02-91 GROUP: BODY DATE: Feb. 11, 1991 MODELS: 1984 - 1991 All Domestic Models DISCUSSION: The color variance charts from BASF, Sherwin-Williams, Martin Senour, Acme and Rogers are being sent for use in solving off-color paint problems. The variance charts provide an alternate color that will help the painter achieve a good match or a closer match than the factory pack. Other manufacturers have paint variance programs available that are in a format not suitable for mailing with a bulletin. Check with your local jobber. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Variance Program > Page 5708 Technical Service Bulletin # 230889 Date: 890410 Paint - Codes/Applications/Cross References Models 1989 Domestic & Import Passenger Cars & Trucks Subject 1989 Standard Paint Colors Index BODY & SHEET METAL Date April 10, 1989 No. 23-08-89 P-1364 (C23-53) The 1989 paint information is being provided for Chrysler, Plymouth, Dodge, Jeep, Eagle and import models in one bulletin. Paint codes are located on the vehicle information plate on each vehicle. THIS BULLETIN DOES NOT LIST SALES CODES. The vehicle information plate locations are as follows: CHRYSLER-PLYMOUTH-DODGE Body Vehicle Code Plate Location AC Left radiator yoke support/closure panel AL Left radiator yoke support/closure panel AP Left radiator yoke support/closure panel AK Left radiator yoke support/closure panel AG Center radiator yoke/closure panel AH Left radiator yoke/closure panel AM Middle of left inner fender shield above tire AE Left radiator yoke/closure panel AJ Center radiator yoke/closure panel AS Right cowl/dash panel (under hood) AN On floor pan under jack (Quick reference label under hood) AD Right plenum - (View through cowl grill) (Quick reference label under hood) AD/AW Right plenum - (View through cowl grill) (Quick reference label under hood) AB Behind battery on cowl/dash panel (Quick reference under hood) Definitions of the body letter codes can be found on the model chart in the appropriate technical service manual. JEEP-EAGLE Body Vehicle Code Plate Location YJ Left side of dash panel in the engine compartment XJ Left radiator support in the engine compartment MJ Left radiator support in the engine compartment SJ Left side of the dash panel in the engine compartment BB Right front strut tower in the engine compartment BC Right front strut tower in the engine compartment B2 Right center cowl/dash panel (under hood) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Variance Program > Page 5709 CHRYSLER-PLYMOUTH-DODGE IMPORTS Body Vehicle Code Plate Location AQ (Maserati) Under hood near the left rear corner B1 (Colt) Right center cowl/dash panel (under hood) B3 (Vista) Left front inner fender shield B4 (RAM 50) Right center cowl dash panel B5 (Conquest) Center cowl/dash panel B6 (Raider) Right center cowl/dash panel The listed paint manufacturers have service representatives who are trained in the latest refinishing methods and painting techniques. They can assist body shop personnel when necessary. Color chip charts are available from the respective manufacturers through the local jobbers or representatives. NOTE: THIS INFORMATION SHOULD BE DIRECTED TO THE BODY SHOP FOREMAN AND/OR BODY REPAIR PERSONNEL. POLICY: For information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Variance Program > Page 5710 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Variance Program > Page 5711 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Variance Program > Page 5712 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Variance Program > Page 5713 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Variance Program > Page 5714 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Variance Program > Page 5715 Paint: Technical Service Bulletins Stone Guard - Paint Repair NO.: 23-37-93 GROUP: Body DATE: Jun. 25, 1993 SUBJECT: Anti-Chip (Stone Guard) Paint Repair MODELS: DISCUSSION: To compete and stay in the forefront of paint technology, Chrysler Corporation introduced a stone guard protector material in the 1980's. The stone guard material is applied to varied exterior surfaces on all passenger cars and light trucks. These surfaces can include: Hoods, lower fenders, rocker panels, lower doors, and lower quarter panels. The following recommended repair procedures are provided by Chrysler paint suppliers, "BASF" and "PPG". Other stone guard repair systems are available. Specific questions should be directed to your local paint distributors. "BASF" STONE GUARD REPAIR PROCEDURES 1. Wash the entire vehicle with water and a mild detergent soap, rinse thoroughly and let dry. 2. Clean the entire vehicle with R-M 909 Pre-Kleano for California and R-M 900 where the R-M 909 is not available or use Gasurit 541-5. 3. Using a "DA" sander, sand the damaged areas using 80 grit, or finer, to featheredge the damage. Follow with 120 grit and final sanding with 240 grit. NOTE 1: EXTEND THE FEATHEREDGE 1-1/2 TO 2 INCHES OUT. THIS WILL PREVENT A BULLS EYE FROM APPEARING WHEN THE JOB IS DONE. 4. Mix either an epoxy primer or self-etch primer (DE 15 or DE 17). 5. Apply 1-2 light coats over the bare metal areas. 6. Allow the material to dry for 15 to 20 minutes before applying the stone ship protector. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Variance Program > Page 5716 7. Apply the Stone Chip Protector Glassohyd 1109-12406 over the prepared areas. NOTE 2: GUN TECHNIQUE IS ESSENTIAL. BY CONTROLLING THE SPRAY-GUN OVER THE PREPARED AREA, THE PAINTER CAN FEATHER THE STONE CHIP PROTECTOR AS IT IS BEING SPRAYED. THE WETTER YOU APPLY THE MATERIAL, THE SMOOTHER IT WILL FLOW OUT. 8. Allow the stone chip material to dry. Heat may be used to accelerate the dry times. 9. After the Stone Chip Protector has been applied, it may be top coated with a single or base-clear urethane system. "PPG" STONE GUARD REPAIR PROCEDURE 1. DX330 (Acryli-Clean Wax and Grease Remover). 2. Perform necessary repair*. 3. Re-clean with DX330. 4. DP (Epoxy Primer)**. 5. K-36 (Prima Primer-Surfacer). 6. DBU (Deltron Basecoat). 7. Apply Acrylic Urethane Clear. *Ensure substrate is properly abraded to maintain optimum product performance. ** Apply if bare metal is exposed. NOTE: ADHERE TO SPECIFIC PRODUCT BULLETINS FOR MIXING RATIOS AND PROPER FLASH TIMES. POLICY: Information only. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Front Body Components Front Center Of Headliner Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations Power Seat Motor: Locations Power Seat Components On Bottom Of Seat Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations Power Seat Components Outboard Side Of Seat Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Lower I/P Components Center Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair Seat Track: Service and Repair SEAT ADJUSTER, LEFT SIDE Removal 1. Remove the seat riser covers. 2. Remove the four nuts that fasten the adjuster assembly to the seat risers. 3. Remove the adjuster covers. 4. Remove the four bolts that fasten the adjuster assembly to the seat. Installation 1. Hold the seat and adjuster together and install four bolts. Torque the bolts to 23 Nm (200 In. Lbs.). 2. Install the adjuster covers and torque the screws to 3 Nm (24 In. Lbs.). 3. Place the seat and adjuster assembly on the seat riser, install the four nuts, and torque the nuts to 23 Nm (200 In. Lbs.). 4. Install the seat riser covers. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Front Door Components In Front Door Armrest Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Sliding Door Circuit Test Power Door Lock Switch: Testing and Inspection Sliding Door Circuit Test Sliding Side Door Power Lock Assembly 1. Connect one lead of a test light to the upper contact of the pillar, and place the other lead to the lower contact. 2. If the test light illuminates when the lock switch is depressed, the wiring circuit to the contacts is good. If the test light does not illuminate, check the electrical connectors at the right side cowl, check for a broken wire, or see Circuit Breaker Test. 3. With the sliding door partially open, connect jumper wires across contacts on pillar to contacts on the door. The door should lock or unlock when Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 5741 these jumper wires are connected and the switch is depressed. 4. If the door locks and unlocks, the problem is in the door and pillar contacts (check for proper shim at the door contact plate). If lock and unlock does not occur, remove trim panel and check for voltage at the lock motor. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 5742 Power Door Lock Switch: Testing and Inspection Switch Voltage Test NOTE: The following test determines whether voltage is continuous through the wiring harness to the power door lock switch. 1. Remove the door lock switch from the door trim panel. 2. Separate the multiple terminal block on the wiring harness from the door lock switch. 3. Connect one lead of a test light to the black wire terminal and the other lead to the red wire terminal. If the test light illuminates, the wiring circuit between the battery and switch is functioning properly. If the test light does not illuminate, check the 30 amp main fuse (circuit breaker) or check for an open in the wiring harness. 4. If the wiring circuit is functioning properly, See: Locks/Power Locks/Power Door Lock Actuator/Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Sliding Door Circuit Test > Page 5743 Power Door Lock Switch: Testing and Inspection Door Lock Switch Test Door Lock Switch Continuity Remove each door lock switch from the door trim panel. Connect an ohmmeter to the switch and check that there is continuity in lock and unlock positions (refer to the image shown). If these results are not obtained, replace the switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Page 5744 Power Door Lock Switch: Service and Repair 1. Pry up rear of switch bezel releasing it from clips. Pull bezel out of door trim. 2. Disconnect wiring harness. 3. Remove switch screws and switch. 4. Reverse removal sequence to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Front Door Components In Center Of Door Panel Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations Power Seat Components Outboard Side Of Seat Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations Power Trunk / Liftgate Lock Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Lower I/P Components Center Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Front Body Components Front Center Of Headliner Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Service and Repair Spare Tire Carrier: Service and Repair REMOVAL 1. Open liftgate, lower and remove the spare tire from the winch assembly. 2. Raise vehicle on a hoist. Deflector Assembly 3. Remove the deflector assembly. Spare Tire Support Assembly 4. Remove the spare tire support assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Service and Repair > Page 5766 Winch Assembly 5. Remove the spare tire winch assembly. INSTALLATION 1. Install spare tire winch assembly and torque the bolts to 28 Nm (250 In. Lbs.). Spare Tire Support Assembly 2. Install spare tire support assembly and torque the bolts closest to the winch to 28 Nm (250 In. Lbs.). Torque the two remaining bolts to 4 Nm (35 In. Lbs.). 3. Install the deflector assembly and torque the bolts closest to the winch to 28 Nm (250 In. Lbs.). Torque the two remaining bolts to 4 Nm (35 In. Lbs.). 4. Install the spare tire on winch and hoist it to proper position. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Technical Service Bulletins > Customer Interest for Air Dam: > 070190 > Jan > 90 > Bumper Fascia - Causing Engine Overheating Air Dam: Customer Interest Bumper Fascia - Causing Engine Overheating Models 1988 S Body 1989-1990 AS Body Subject Engine Overheating, LE Model Equipped With Premium Front Bumper Soft Fascia Index COOLING Date January 29, 1990 No. 07-01-90 P-123 (C07-02-9) BODY CODE LEGEND S - MINI RAM VAN/VOYAGER/CARAVAN/GRAND CARAVAN VOYAGER AS CARAVAN/GRAND CARAVAN/CARAVAN C/V/VOYAGER GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION 1988, 1989, and 1990 Caravan/Voyager "LE" Model equipped with the premium front bumper soft fascia may experience an overheating condition ( temperature gauge reads in the red zone) when one or more of the following conditions is present. 1. Vehicle is fully loaded and/or pulling a trailer. 2. Vehicle is being operated in hilly or mountainous terrain. 3. Ambient temperatures are 90~F or above. DIAGNOSIS Verify the vehicle is equipped with the premium front bumper soft fascia, the cooling system level is correct and no cooling system leaks are evident. PARTS REQUIRED Package - Air Dam and Front Fascia Template PN 5263408 Consists of: 1 Air Dam 7 Screws and Washers 1 Template Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Technical Service Bulletins > Customer Interest for Air Dam: > 070190 > Jan > 90 > Bumper Fascia - Causing Engine Overheating > Page 5776 Figure 1 REPAIR PROCEDURE The repair procedure involves modifying the bumper fascia and the installation of an air dam. 1. Raise vehicle on a hoist. 2. Position and temporarily affix the template to the bottom of the fascia with masking tape as shown in Figure 1. 3. Using the template as a guide drill fourteen (14) pilot holes through the fascia at the areas indicated on the template using a 1/8" (.125 inch) drill bit. 4. Remove the template. 5. Using a 2-1/2" hole saw and the 1/8" pilot hole as a guide, saw fourteen (14) 2-1/2" holes through the bottom of the fascia. 6. Remove the five (5) lower fascia plastic retainers that secure the fascia to the lower radiator crossmember. 7. Position the air dam as shown in Figure 1. Starting at the center of the air dam and proceeding toward the outer ends of the air dam, loosely install the seven (7) screw/washer assembly in the existing holes in the lower radiator crossmember. 8. Starting at the center and working outward, tighten the seven screws. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 13-20-01-91 . . . . . . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 9R - Engine runs hot Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Dam: > 070190 > Jan > 90 > Bumper Fascia - Causing Engine Overheating Air Dam: All Technical Service Bulletins Bumper Fascia - Causing Engine Overheating Models 1988 S Body 1989-1990 AS Body Subject Engine Overheating, LE Model Equipped With Premium Front Bumper Soft Fascia Index COOLING Date January 29, 1990 No. 07-01-90 P-123 (C07-02-9) BODY CODE LEGEND S - MINI RAM VAN/VOYAGER/CARAVAN/GRAND CARAVAN VOYAGER AS CARAVAN/GRAND CARAVAN/CARAVAN C/V/VOYAGER GRAND VOYAGER/TOWN & COUNTRY SYMPTOM/CONDITION 1988, 1989, and 1990 Caravan/Voyager "LE" Model equipped with the premium front bumper soft fascia may experience an overheating condition ( temperature gauge reads in the red zone) when one or more of the following conditions is present. 1. Vehicle is fully loaded and/or pulling a trailer. 2. Vehicle is being operated in hilly or mountainous terrain. 3. Ambient temperatures are 90~F or above. DIAGNOSIS Verify the vehicle is equipped with the premium front bumper soft fascia, the cooling system level is correct and no cooling system leaks are evident. PARTS REQUIRED Package - Air Dam and Front Fascia Template PN 5263408 Consists of: 1 Air Dam 7 Screws and Washers 1 Template Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Dam: > 070190 > Jan > 90 > Bumper Fascia - Causing Engine Overheating > Page 5782 Figure 1 REPAIR PROCEDURE The repair procedure involves modifying the bumper fascia and the installation of an air dam. 1. Raise vehicle on a hoist. 2. Position and temporarily affix the template to the bottom of the fascia with masking tape as shown in Figure 1. 3. Using the template as a guide drill fourteen (14) pilot holes through the fascia at the areas indicated on the template using a 1/8" (.125 inch) drill bit. 4. Remove the template. 5. Using a 2-1/2" hole saw and the 1/8" pilot hole as a guide, saw fourteen (14) 2-1/2" holes through the bottom of the fascia. 6. Remove the five (5) lower fascia plastic retainers that secure the fascia to the lower radiator crossmember. 7. Position the air dam as shown in Figure 1. Starting at the center of the air dam and proceeding toward the outer ends of the air dam, loosely install the seven (7) screw/washer assembly in the existing holes in the lower radiator crossmember. 8. Starting at the center and working outward, tighten the seven screws. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 13-20-01-91 . . . . . . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 9R - Engine runs hot Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Front Shock Tower - Metal Screws/Bolts Precautions Strut / Shock Tower: Technical Service Bulletins Front Shock Tower - Metal Screws/Bolts Precautions NO.: 02-08-92 GROUP: Suspension DATE: Dec. 14, 1992 SUBJECT: Installation Of Sheet Metal Screws Or Bolts Into The Front Shock Towers MODELS: 1989 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 (AH) Lanced LeBaron GTS 1989 - 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1990 (AQ) Horizon/Omni 1989 - 1993 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler's TC (Maserati Coupe) 1989 - 1993 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 (C) Dynasty/New Yorker 1984 - 1988 (E) Caravelle/600/New Yorker Turbo 1984 - 1988 (G) Daytona/Laser 1985 - 1988 (H) Lancer/LeBaron GTS 1987 - 1988 (J) LeBaron Coupe/LeBaron Convertible 1984 - 1988 (K) Reliant/Aries/LeBaron 4-Door/Town & Country 1984 - 1988 (L) Horizon/Omni 1987 - 1988 (P) Shadow/Sundance 1984 - 1988 (S) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country DISCUSSION: It is very important that no sheet metal screws, bolts or other metal fasteners be installed in the shock towers in place of plastic clips. Also, no holes should be drilled in the shock tower for installation of any metal fasteners (see illustration, area "A"). Because of the minimum clearance in this area, installation of metal fasteners could damage the coil spring coating. If a plastic clip is lost or broken, replace the clip with the equivalent part called out in the appropriate Mopar Parts Catalog. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Front Shock Tower - Metal Screws/Bolts Precautions > Page 5787 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair Front Door Trim Panel 1. Remove trim panel. 2. Remove five outer belt weatherstrip screws, and remove weatherstrip, using an offset screwdriver. 3. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection 1. Disconnect six cavity connector from stop lamp switch pigtail. 2. Using an ohmmeter, check continuity at switch side of connector. 3. With brake pedal released, there should be continuity between the dark blue/red and yellow/red wires, and between white/pink and white wires. There should be no continuity between pink and white wires. 4. With brake pedal depressed, there should be continuity between pink and white wires. There should be no continuity between the dark blue/red and yellow/red wires, or between white/pink and white wires. 5. If the above results are not obtained the stop lamp switch is defective or out of adjustment. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Clutch Switch: Locations I/P, Cowl & Steering Column Components Top Of Clutch Pedal Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations Lower Instrument Panel Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 5802 Cruise Control Module: Testing and Inspection Fig. 5 Engine Controller 60-Way Connector, Shown From Terminal End 1. Set voltmeter to read 12 volts, then connect negative lead to chassis ground. 2. Connect positive lead to pin 7 of module connector then drive vehicle at speeds between 40 - 50 mph. 3. Turn speed control switch to the On position. Voltmeter should read 12 volts. 4. Press and release the speed control Set button. The voltmeter should indicate from 5 - 9 volts and fluctuate 1 - 2 volts at a rapid rate. 5. Speed control system should be performing throttle control at this time, maintaining set speed. If not, replace control module. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations Engine Compartment Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 5806 Cruise Control Servo: Description and Operation The speed control servo is a diaphragm and cable assembly. It is electrically actuated and vacuum operated. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 5807 Cruise Control Servo: Testing and Inspection Fig. 72 Servo Harness Connector 1. Turn ignition switch and speed control switch to the On position. 2. Set voltmeter to read battery voltage. Connect negative lead to chassis ground. 3. Disconnect the 4-way connector to the servo. Pin 2 should read approximately battery voltage. If not, check for loose connections or repair main harness as necessary. 4. Connect a jumper wire between pin 2 of the 4-way connector and pin 2 of the speed control servo. The other three male terminals from the servo should show battery voltage. 5. Using an ohmmeter, connect one lead to ground, then touch the other lead to pin 1 of the 4-way connector of the main harness. The meter should indicate continuity. If not, repair ground circuit. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 5808 Cruise Control Servo: Service and Repair REMOVAL 1. Remove two nuts attaching throttle cable and mounting bracket to servo. 2. Remove two screws attaching servo mounting bracket to U-nuts on battery tray. 3. Remove servo mounting bracket. 4. Disconnect electrical connector and vacuum hose. 5. Pull cable away from servo to expose retaining clip and remove clip attaching cable to servo. INSTALLATION 1. With throttle in full open position align hole in throttle cable sleeve with hole in servo pin and install retaining clip. 2. Connect vacuum hose to reservoir. 3. Connect electrical connector. 4. Position mounting bracket, install two screws attaching bracket to battery tray and tighten to 105 in. lbs. (12 N-m). 5. Insert servo studs through holes in throttle cable and mounting bracket. 6. Install nuts and tighten to 80 in lbs. (9 N-m). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair Cruise Control Servo Cable: Service and Repair Fig. 6 Speed Control Cable Adjustment 1. Remove air cleaner assembly. 2. On carbureted models, disconnect cable from carburetor stud by removing spring clip. 3. Disconnect cable from throttle body by removing retaining clip. 4. Disconnect cable from servo, then remove cable assembly. 5. Locate cable through servo mounting bracket. 6. Connect cable sleeve to servo stud, align holes, then install clip. 7. Insert servo studs through holes in cable and holes in bracket, then install nut-washers. 8. Route cable from servo, through cable support bracket and clip, then install cable end on stud of throttle body. 9. On carbureted models, adjust control cable as follows: a. Start engine and let run, until normal operating temperature is reached. b. Remove retaining clip. c. Adjust clip until 1/16 inch clearance is achieved between throttle stud and cable clevis. 10. Replace air cleaner. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations I/P, Cowl & Steering Column Components Top Of Brake pedal Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 5815 Cruise Control Switch: Testing and Inspection Fig. 6 Speed Control Continuity Chart. 1988-90 Rear Wheel Drive Models Fig. 7 Speed Control Continuity Chart. 1988-90 Front Wheel Drive Models Fig. 8 Speed Control Connector Terminal Identification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 5816 Fig. 9 Speed Control Continuity Chart. 1991 Models 1. Disconnect the blade type four wire electrical connector from base of steering column. 2. Using a continuity tester, or an ohmmeter, check for continuity at connector wires. Do not use a test light. 3. Results should be obtained according to the charts. If these results are not obtained, replace switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 5817 Cruise Control Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove lower steering column cover. 3. Remove four plastic retaining clips from underside of steering column, then the trough. 4. Disconnect speed control switch electrical connector from instrument panel harness connector. 5. Remove wiper control knob from end of turn signal lever, then the silencer from lever. 6. Remove two screws attaching speed control switch to column. 7. On tilt columns, remove steering wheel, then attach a flexible guide wire to lower end of speed control switch harness. 8. Remove switch and harness from column by gently pulling wires through lock housing between lock plate and side of housing. 9. On standard columns, remove attaching screws and the upper steering lock housing cover, then pull harness up through column. 10. On tilt columns, insert harness connector through turn signal lever opening in column, then pull upward through upper housing. 11. Attach guide wire to switch wiring harness, then gently pull downward through column opening, between lock plate and side of housing. 12. On standard columns, insert harness and connector through turn signal lever opening in column, then pull down and out lower end. 13. On all models, remove slack from all wires. 14. On tilt column, remove guide wires. 15. On all models, install wiring trough with plastic clips. 16. Connect speed control switch electrical connector to instrument panel harness connector. 17. Secure speed control switch to column with two screws. 18. Position silencer on lever, then push wiper control knob in place on end of lever. 19. On tilt columns, replace steering wheel. 20. On standard columns, install upper steering column lock housing cover. 21. On all models, install lower steering column cover. 22. Connect battery ground cable, then test operation of speed control. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Lower Instrument Panel Components Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 5822 Cruise Control Module: Testing and Inspection Fig. 5 Engine Controller 60-Way Connector, Shown From Terminal End 1. Set voltmeter to read 12 volts, then connect negative lead to chassis ground. 2. Connect positive lead to pin 7 of module connector then drive vehicle at speeds between 40 - 50 mph. 3. Turn speed control switch to the On position. Voltmeter should read 12 volts. 4. Press and release the speed control Set button. The voltmeter should indicate from 5 - 9 volts and fluctuate 1 - 2 volts at a rapid rate. 5. Speed control system should be performing throttle control at this time, maintaining set speed. If not, replace control module. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection 1. Disconnect six cavity connector from stop lamp switch pigtail. 2. Using an ohmmeter, check continuity at switch side of connector. 3. With brake pedal released, there should be continuity between the dark blue/red and yellow/red wires, and between white/pink and white wires. There should be no continuity between pink and white wires. 4. With brake pedal depressed, there should be continuity between pink and white wires. There should be no continuity between the dark blue/red and yellow/red wires, or between white/pink and white wires. 5. If the above results are not obtained the stop lamp switch is defective or out of adjustment. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Clutch Switch: Locations I/P, Cowl & Steering Column Components Top Of Clutch Pedal Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations I/P, Cowl & Steering Column Components Top Of Brake pedal Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 5833 Cruise Control Switch: Testing and Inspection Fig. 6 Speed Control Continuity Chart. 1988-90 Rear Wheel Drive Models Fig. 7 Speed Control Continuity Chart. 1988-90 Front Wheel Drive Models Fig. 8 Speed Control Connector Terminal Identification Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 5834 Fig. 9 Speed Control Continuity Chart. 1991 Models 1. Disconnect the blade type four wire electrical connector from base of steering column. 2. Using a continuity tester, or an ohmmeter, check for continuity at connector wires. Do not use a test light. 3. Results should be obtained according to the charts. If these results are not obtained, replace switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 5835 Cruise Control Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove lower steering column cover. 3. Remove four plastic retaining clips from underside of steering column, then the trough. 4. Disconnect speed control switch electrical connector from instrument panel harness connector. 5. Remove wiper control knob from end of turn signal lever, then the silencer from lever. 6. Remove two screws attaching speed control switch to column. 7. On tilt columns, remove steering wheel, then attach a flexible guide wire to lower end of speed control switch harness. 8. Remove switch and harness from column by gently pulling wires through lock housing between lock plate and side of housing. 9. On standard columns, remove attaching screws and the upper steering lock housing cover, then pull harness up through column. 10. On tilt columns, insert harness connector through turn signal lever opening in column, then pull upward through upper housing. 11. Attach guide wire to switch wiring harness, then gently pull downward through column opening, between lock plate and side of housing. 12. On standard columns, insert harness and connector through turn signal lever opening in column, then pull down and out lower end. 13. On all models, remove slack from all wires. 14. On tilt column, remove guide wires. 15. On all models, install wiring trough with plastic clips. 16. Connect speed control switch electrical connector to instrument panel harness connector. 17. Secure speed control switch to column with two screws. 18. Position silencer on lever, then push wiper control knob in place on end of lever. 19. On tilt columns, replace steering wheel. 20. On standard columns, install upper steering column lock housing cover. 21. On all models, install lower steering column cover. 22. Connect battery ground cable, then test operation of speed control. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5844 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5850 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5859 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5865 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The Anti-Lock warning light will normally come on for approximately one to two seconds when the ignition switch is first turned to the ON position. Anytime the Controller Anti-Lock Brake (CAB) detects a condition which results in a shutdown of the ABS function other than when the ignition switch is first turned on it will activate the ABS warning lamp. When the light is on only the Anti-Lock function of the brake system is affected. The standard brake system and ability to stop the vehicle will not be affected. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Locations Audible Warning Device Control Module: Locations Center Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Locations Brake Warning Indicator: Locations Engine Compartment Components. LH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Locations > Page 5876 Engine Compartment & Transaxle Components. LH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Locations > Page 5877 Brake Warning Indicator: Description and Operation The brake warning light is designed to light only when either: The parking brake is applied with the ignition key turned "ON". - One of the two service brake systems has failed. Bulb Check The instrument panel bulb can be checked each time the ignition switch is turned to the start position or the parking brake is set. Pressure Differential Warning Light Switch Purpose The function of the Pressure Differential Switch is to alert the driver to a malfunction in the brake system. Operation The hydraulic brake system is split diagonally. The left front and right rear brakes are part of one system and the right front and left rear are part of another. Both systems are routed through, but hydraulically separated by the Pressure Differential Switch. If hydraulic pressure is lost in one system, the warning light switch will activate a red light on the instrument panel, when the brake pedal is depressed. At this point the brakes require service. - However, since the brake systems are split diagonally the vehicle will retain 50% of its stopping capability in the event of a failure in either half. The warning light switch is the latching type. It will automatically recenter itself after the repair is made and the brake pedal Is depressed. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Locations > Page 5878 Brake Warning Indicator: Testing and Inspection Bulb Check The instrument panel bulb can be checked each time the ignition switch is turned to the start position or the parking brake is set. Pressure Differential Warning Light Switch Circuit Check 1. Raise and support vehicle, then open a wheel cylinder bleeder valve. 2. Press down on brake pedal and observe brake warning lamp. If lamp fails to illuminate, inspect for the following: a. Faulty bulb. b. Disconnected electrical socket. c. A broken or disconnected wire at the switch, located in the brake line "T" fitting, mounted on frame rail in engine compartment below master cylinder. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Locations Fig. 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Diagrams > Diagram Information and Instructions Check Gauges Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 Fig. 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 Test 12D Repairing The Electro/Mechanical Cluster "NO RESPONSE" Condition Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Diagrams > Page 5887 Check Gauges Lamp: Testing and Inspection LOW OIL PRESSURE WARMING LAMP/CHECK GAGES TEST The oil pressure/check gage warning lamp will illuminate under any of the following conditions: 1. Lamp check when the ignition key is turned to the ON position for about two seconds. 2. The oil pressure switch is closed to ground The switch grounds the lamp and is in put to the body controller which turns on the lamp over the bus. 3. Oil pressure sending unit is high resistance, low pressure. The body controller will turn on lamp over the bus. The lamp also illuminates when the engine oil pressure drops below a safe oil pressure level. To test the system, turn the ignition key to the ON position. If the lamp fails to light, during the two second lamp, inspect for a burned out lamp or disconnected socket in the cluster. CONDITION: WARNING LAMP DOES NOT LIGHT Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Diagrams > Page 5888 If the lamp goes out after the lamp check, inspect the connection to the oil pressure switch and sensor. Check that the wires are going to the correct terminals of the sending unit. Both the switch and sensor must fail to result in the light going out. If the connector and wiring are OK, use the DRB II to read the oil pressure switch at the body controller. Disconnect the sending unit connector. Using an jumper wire, connect one end to the switch terminal and the other to ground. If the lamp fails to light check for continuity to the cluster and body controller from the pressure switch. Check for short from pressure sensor circuit to ground. Check the wiring go to the body controller connector for proper terminals. CONDITION: LAMP STAYS ON WITH ENGINE RUNNING If the light stays on with engine running, perform the combination sending unit tests. If the sending unit is OK perform the following: 1. Using a DRB II monitor the oil pressure switch with the sending unit connector disconnected. The switch should read open. If it does not, there is a short in the wiring. Repair as necessary. The circuit goes from the switch to the body controller and the cluster. 2. Connect the sending unit. Start the engine. Using the DRB II, read the oil pressure level. If the DRB II reads ignition voltage, there is a open circuit in the sensor wiring circuit. Repair open circuit. COMBINATION OIL SENDING UNIT TESTS The combination oil unit has two functions: 1. The normally closed circuit keeps the oil pressure warning lamp on until there is oil pressure. 2. The sending unit provides a resistance that varies with oil pressure. 3. To test the normally closed oil lamp circuit, disconnect the locking connector and measure the resistance between the switch terminal and the metal housing. The ohmmeter should read zero ohms. 4. Start the engine. If there is oil pressure, the ohmmeter should read an open circuit. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Diagrams > Page 5889 5. To test the sending unit, measure the resistance between the sending unit terminal and the metal housing. The ohmmeter should read open. 6. Start the engine. The ohmmeter should read between 30 and 55 ohms, depending on engine speed, oil temperature, and oil viscosity. 7. If the switch and sensor read low pressure with the engine running, remove the sending unit. Connect a pressure gauge in place of the sending unit to test pressure. For oil pressure specifications, refer to Group 9, Engine. If OK, go to step 8. 8. If the above results are not obtained, replace the switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming 1. Place ignition switch in lock position. 2. Disconnect and tape battery ground cable connector. 3. Wait at least 1 minute after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy airbag for a short time even after battery has been disconnected. 4. After repairs are performed, connect battery ground cable. 5. From passenger side of vehicle, turn ignition switch to On position. 6. SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate if SRS system is functioning correctly. 7. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Locations Door/Trunk Ajar Indicator/Lamp: Locations Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Dome Lamp Switch Door Switch: Locations Dome Lamp Switch Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Dome Lamp Switch > Page 5901 Door Switch: Locations Door Ajar Switches Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5906 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5907 Vehicle Information Center Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Component Information > Locations Emissions Maintenance Light: Locations Upper I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Component Information > Locations > Page 5911 Emissions Maintenance Light: Service and Repair Refer to Powertrain Management/Emission Control Systems/Service and Repair for reset procedures. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection Fuel Gauge: Testing and Inspection Fuel Gauge Pins Fuel Gauge Pins - Optional Cluster 1. Remove fuel gauge from the cluster. 2. Check for continuity in wire between fuel tank sending unit and gauge (fuel level input pin). 3. With ignition switch in On position, check for battery voltage across B+ pin and ground pin. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Top Of Fuel Tank Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 5918 Fuel Gauge Sender: Testing and Inspection Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by clamps, check to see whether the insulation has been severed thereby grounding the wire. In the case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of the tank unit. 1. Disconnect wiring from fuel tank sending unit. 2. Connect wiring to a known good sending unit. 3. Connect a jumper wire between sending unit pick up tube and ground. Fuel Tank Sending Unit (Typical) 4. Check fuel gauge as follows: Allow at least two minutes for gauge to settle at each test point. a. Move and clip float arm to its empty stop and turn ignition to the On position, gauge should read Empty or below. b. Move and clip float arm to the Full position, gauge should read Full or above. 5. If gauge does not meet specifications, check the following items for possible malfunction: a. Wiring and connections between gauge sending unit and multiple connector behind left kick panel. b. Wiring and connections between multiple connector and printed circuit board terminals. c. Circuit continuity between printed circuit board terminals and gauge terminals. If the above items are satisfactory, the gauge is defective and must be replaced. 6. If fuel gauge meets specifications check original fuel tank sending unit as follows: a. Remove fuel tank sending unit from fuel tank and connect a jumper wire between sending unit pick up tube and ground. 7. Repeat step 4. 8. If fuel gauge is now within specifications, check the following as possible cause: a. Ground wire from sending unit to left side cowl for continuity. b. Sending unit deformed. Ensure float arm moves freely and pick up tube is not bent. c. Inspect float. d. Sending unit improperly installed. Install correctly. e. Mounting flange on fuel tank for sending unit deformed. f. Fuel tank bottom deformed causing improper positioning of pick-up tube. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming 1. Place ignition switch in lock position. 2. Disconnect and tape battery ground cable connector. 3. Wait at least 1 minute after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy airbag for a short time even after battery has been disconnected. 4. After repairs are performed, connect battery ground cable. 5. From passenger side of vehicle, turn ignition switch to On position. 6. SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate if SRS system is functioning correctly. 7. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions Instrument Panel Circuit Board: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 5927 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 5928 Instrument Panel Circuit Board: Connector Views Printed Circuit Board Connector Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 5929 Printed Circuit Board Connector. Mechanical Cluster Less Tach Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 5930 Printed Circuit Board Connector. Warning Light Module Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 5931 Instrument Panel Circuit Board: Electrical Diagrams Printed Circuit Board. Mechanical Cluster Less Tach Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 5932 Printed Circuit Board. Mechanical Cluster w/Tach Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 5933 Printed Circuit Board. Warning Light Module Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Low Fuel Indicator Relay > Component Information > Locations Low Fuel Indicator Relay: Locations Low Fuel Relay The low fuel relay is located on the back of the instrument cluster, behind the message center. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation On-Board Diagnosis Connector Location On-Board Diagnosis Connector Location On-Board Diagnosis Connector Location Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Page 5941 On-Board Diagnosis Connector Location On-Board Diagnosis Connector Location This reminder system uses ignition on time to calculate maintenance intervals. After necessary emission maintenance has been performed, connect Diagnosis Read-Out Box II (DRB II) to the on-board diagnostic connector. Follow instructions indicated by DRB II tool. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Page 5942 Maintenance Required Lamp/Indicator: Service and Repair On-Board Diagnosis Connector Location On certain models, this Emission Maintenance Reminder System is incorporated into the engine controller. The controller stores vehicle mileage into its memory every 8 miles, then at 60,000, 82,500 or 120,000 miles it will illuminate the EMR lamp. When the indicated mileage is reached or the EMR lamp is on at all times, the following parts must be replaced and the EMR lamp reset. 1. At 60,00 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. 2. At 82,500 miles, proceed as follows: a. Replace oxygen sensor. 3. At 120,000 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. 4. On 1990-95 models, after necessary emission maintenance has been performed, connect Diagnosis Read-Out Box II (DRB II) to the on-board diagnosis connector. See images above. 5. On all models, Follow instructions indicated by DRB II tool. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Malfunction Indicator Lamp Driver Module > Component Information > Locations Malfunction Indicator Lamp Driver Module: Locations Upper I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Gauge: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5951 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5952 Oil Pressure & Temperature System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Page 5953 Oil Pressure Gauge: Description and Operation The oil pressure indicating system consists of an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuates the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, increasing current flow to the gauge, resulting in an increased gauge reading. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Diagrams > Page 5954 Oil Pressure Gauge: Testing and Inspection Oil Pressure Gauge Pins Combination Oil Pressure Sending Unit 1. Remove oil pressure gauge assembly from the cluster. 2. Check for continuity in wire between oil pressure sending unit and gauge (sensor input pin). 3. With ignition switch in On position, check for battery voltage across B+ pin and ground pin. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Lower LH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5960 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5961 Oil Pressure & Temperature System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations I/P, Cowl & Steering Column Components LH Kickpanel On Park Brake Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations Audible Warning Device Control Module: Locations Center Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Low Fuel Indicator Relay > Component Information > Locations Low Fuel Indicator Relay: Locations Low Fuel Relay The low fuel relay is located on the back of the instrument cluster, behind the message center. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Malfunction Indicator Lamp Driver Module > Component Information > Locations Malfunction Indicator Lamp Driver Module: Locations Upper I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Dome Lamp Switch Door Switch: Locations Dome Lamp Switch Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Dome Lamp Switch > Page 5980 Door Switch: Locations Door Ajar Switches Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Top Of Fuel Tank Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 5984 Fuel Gauge Sender: Testing and Inspection Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by clamps, check to see whether the insulation has been severed thereby grounding the wire. In the case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of the tank unit. 1. Disconnect wiring from fuel tank sending unit. 2. Connect wiring to a known good sending unit. 3. Connect a jumper wire between sending unit pick up tube and ground. Fuel Tank Sending Unit (Typical) 4. Check fuel gauge as follows: Allow at least two minutes for gauge to settle at each test point. a. Move and clip float arm to its empty stop and turn ignition to the On position, gauge should read Empty or below. b. Move and clip float arm to the Full position, gauge should read Full or above. 5. If gauge does not meet specifications, check the following items for possible malfunction: a. Wiring and connections between gauge sending unit and multiple connector behind left kick panel. b. Wiring and connections between multiple connector and printed circuit board terminals. c. Circuit continuity between printed circuit board terminals and gauge terminals. If the above items are satisfactory, the gauge is defective and must be replaced. 6. If fuel gauge meets specifications check original fuel tank sending unit as follows: a. Remove fuel tank sending unit from fuel tank and connect a jumper wire between sending unit pick up tube and ground. 7. Repeat step 4. 8. If fuel gauge is now within specifications, check the following as possible cause: a. Ground wire from sending unit to left side cowl for continuity. b. Sending unit deformed. Ensure float arm moves freely and pick up tube is not bent. c. Inspect float. d. Sending unit improperly installed. Install correctly. e. Mounting flange on fuel tank for sending unit deformed. f. Fuel tank bottom deformed causing improper positioning of pick-up tube. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations I/P, Cowl & Steering Column Components LH Kickpanel On Park Brake Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Cable > Component Information > Testing and Inspection Fig. 1 Speedometer & cable diagnosis. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation Information in this database covers only service on speedometers which can be performed by the average service man. Repairs on the units themselves are not included as they require special tools and extreme care when making repairs and adjustments and only an experienced speedometer mechanic should attempt such servicing. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Page 5994 Fig. 1 Speedometer & cable diagnosis. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection Tachometer: Testing and Inspection 1. Remove instrument cluster. 2. with ignition switch in On position, check for battery voltage at cavity "F" of instrument cluster right side (black) connector and cavity "A" of instrument panel cluster left side (red) connector. 3. Check cavity "H" of instrument cluster left side connector for continuity to ground. 4. Check for tachometer signal from the engine controller by connecting an AC Digital Voltmeter to cavity "D" of the black instrument cluster connector and ground. A minimum of 1 volt should be present with engine running. 5. If there is less than 1 volt present in above step, check for continuity between cavity "D" of instrument cluster and pin 43 of engine controller connector. If there is no continuity, repair wire as required. Also check connector at engine controller for damaged pins or terminal push outs. 6. If voltage reading from step 5 is less than 1 volts and no continuity between cavity "D" and pin 43 is evident, replace the engine controller. 7. If above tests are correct, replace the tachometer drive module. 8. If tachometer continues to be inoperable, replace the tachometer assembly. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation This system consists of a sending unit, electrical temperature gauge and an instrument voltage regulator. As engine temperature increases or decreases, resistance of the sending unit changes, in turn controlling current flow to the gauge. When engine temperature is low, the resistance of the sending unit is high, restricting current flow to the gauge, in turn indicating low engine temperature. As engine temperature increases, resistance of the sending unit decreases, permitting an increased current flow to the gauge, resulting in an increased temperature reading. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis Temperature Gauge: Testing and Inspection Temperature Gauge Diagnosis Fig. 1 Cooling System Diagnosis (Part 1 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 6003 Fig. 1 Cooling System Diagnosis (Part 2 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 6004 Fig. 1 Cooling System Diagnosis (Part 3 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 6005 Fig. 1 Cooling System Diagnosis (Part 4 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 6006 Fig. 1 Cooling System Diagnosis (Part 5 of 5) Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Temperature Gauge Diagnosis > Page 6007 Temperature Gauge: Testing and Inspection Temperature Gauge Test Temperature Gauge Pins 1. Remove temperature gauge assembly from the cluster. 2. Check for continuity in wire between temperature sending unit and gauge (sensor input pin). 3. With ignition switch in On position, check for battery voltage across B+ pin and ground pin. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Top RH Side Of Engine Applicable to: 1989 V6-181/3.0L Engine Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions Temperature Sensor (Gauge): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 6013 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 6014 Oil Pressure & Temperature System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 6015 Temperature Sensor (Gauge): Testing and Inspection When a malfunction occurs with a cluster gauge, before disassembling the cluster to check the gauge, check for a defective sending unit or wiring as follows: 1. Ground sending unit connector leads, at the sending unit, in the vehicle. 2. With ignition in On position, a grounded input will cause the fuel or temperature gauge to read maximum or above. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation Volt Meter Gauge: Description and Operation The voltmeter gauge measures electrical flow from the battery to indicate battery output tolerances. The voltmeter reading can range from 13.5-14.0 volts under normal operating conditions. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation > Page 6019 Volt Meter Gauge: Testing and Inspection Voltmeter Pins 1. Remove voltmeter assembly from cluster. 2. Connect a volt/ohmmeter between the B+ pin and the Ground pin. Turn the ignition switch to the ON position and check meter reading. ^ The instrument panel voltmeter indicates regulated alternator output or battery voltage, which ever is greater. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > 4 Speed A/T Backup Lamp Relay: Locations 4 Speed A/T Engine Compartment. The Backup Lamp Relay is located in the right rear corner of the engine compartment, on the side shield. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > 3 Speed A/T Backup Lamp Switch: Locations 3 Speed A/T Neutral/Park Safety Switch Neutral Starting And Back-Up Lamp Switch The neutral starting switch is the center terminal of the 3 terminal switch. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6032 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6033 Backup Lamp Switch: Electrical Diagrams 3 Speed A/T Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at the vehicle level. See: Diagrams/Electrical Diagrams 4 Speed A/T Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6034 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6035 Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at the vehicle level. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Description and Operation > 3 Speed A/T Backup Lamp Switch: Description and Operation 3 Speed A/T Neutral Starting And Back-Up Lamp Switch The neutral starting switch is the center terminal of the 3 terminal switch. - It provides ground for the starter solenoid circuit through the selector lever in only Park and Neutral positions. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Testing and Inspection > 3 Speed A/T Backup Lamp Switch: Testing and Inspection 3 Speed A/T Neutral Starting And Back-Up Lamp Switch Replacement And Test 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in Park or Neutral. 2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to Park and then to Neutral positions, and inspect to see that the switch operating lever fingers are centered in switch opening in the case. 4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 8. Continuity should exist only with transaxle in Reverse position. 9. No continuity should exist from either pin to the case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > 3 Speed A/T Backup Lamp Switch: Service and Repair 3 Speed A/T Neutral Starting And Back-Up Lamp Switch Replacement And Test 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in Park or Neutral. 2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to Park and then to Neutral positions, and inspect to see that the switch operating lever fingers are centered in switch opening in the case. 4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 8. Continuity should exist only with transaxle in Reverse position. 9. No continuity should exist from either pin to the case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations I/P, Cowl & Steering Column Components Top Of Brake pedal Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Light Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6047 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6048 Speed Control & Stop Lamp Switch Wiring Circuit SH-25 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 6049 Brake Light Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect stop light switch electrical connector, then remove switch assembly. 3. Install new switch and connect switch electrical connector. If adjustment of switch is required, proceed as follows: a. Push switch forward until fully seated. This will move brake pedal slightly forward. b. Pull back on brake pedal until it will go back no further. This will cause switch to ratchet backward into correct position. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Center Mounted Brake Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 Center Mounted Brake Lamp: Electrical Diagrams Courtesy & Dome Lamps Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6056 Courtesy & Dome Lamps Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions Courtesy Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6061 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6062 Courtesy Lamp: Electrical Diagrams Courtesy & Dome Lamps Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6063 Courtesy & Dome Lamps Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6064 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6065 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Switch > Component Information > Locations Dome Lamp Switch: Locations Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Dome Lamp Switch Door Switch: Locations Dome Lamp Switch Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Dome Lamp Switch > Page 6074 Door Switch: Locations Door Ajar Switches Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Flasher Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Flasher: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 6082 Hazard Warning Flasher: Electrical Diagrams Hazard Flasher & Stop/Turn Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 6083 Hazard Flasher & Stop/Turn Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Service and Repair Hazard Warning Switch: Service and Repair 1. If equipped, disarm airbag system refer to MAINTENANCE PROCEDURES. 2. Remove steering wheel. Steering column cover, silencer & reinforcement removal 3. Remove steering column cover and silencer. 4. Remove shift indicator operating cable from slot in shift housing. 5. Pry off wiring trough from steering column, then disconnect control lever electrical connectors. 6. On models equipped with standard column, proceed as follows: a. Remove screws attaching turn signal lever cover to lock housing, then lever cover. b. Remove washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch. e. Remove turn signal/hazard switch attaching screws. 7. On models equipped with tilt column, proceed as follows: a. Remove tilt lever, then hazard warning knob. Push knob in and unscrew to remove. b. Remove ignition key lamp assembly, then knob off washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch. Lock plate removal. Models w/tilt column e. Depress lock plate using lock plate compressor No. C-4156 or equivalent and pry retaining ring out of groove with a suitable screwdriver. The full load of upper bearing spring should not be relieved. If full load is relieved, retaining ring will turn too easily and make removal difficult. f. Remove lock plate, cancelling cam and upper bearing spring. g. Remove turn signal/hazard switch actuator screws and arm. h. Remove turn signal/hazard switch attaching screws, Place shift bowl in Low position. Turn signal switch replacement Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Service and Repair > Page 6087 8. On all models, remove turn signal/hazard warning switch assembly by gently pulling switch up from column while straightening and guiding wires up through column opening. 9. Reverse procedure to install. Rearm airbag system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations I/P, Cowl & Steering Column Components Top Of Steering Column Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 Headlamp Dimmer Switch: Electrical Diagrams Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 6097 Headlamp Dimmer Switch: Service and Repair Dimmer switch replacement 1. Disconnect battery ground cable. 2. Remove left lower instrument panel cover, then tape dimmer switch rod to steering column to prevent rod from falling out of notch in actuator lever. 3. Remove switch to column attaching screws. 4. Disconnect switch electrical connector, then remove switch from steering column. 5. Reverse procedure to install. During installation, gently push up on switch to take up slack on rod. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 Headlamp Switch: Electrical Diagrams Headlamp Switch & Horn System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 6107 Headlamp Switch: Service and Repair Headlamp switch removal 1. Disconnect battery ground cable. 2. Remove headlight and accessory switch trim bezel. 3. Remove four screws attaching switch plate to lower panel. 4. Pull switch assembly rearward, then disconnect switch electrical connectors. 5. Remove switch knob and stem by depressing button on switch. 6. Remove two headlight switch plate to switch plate assembly attaching screws, then the headlight switch retainer and switch. 7. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions Horn: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 6112 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 6113 Horn: Electrical Diagrams Headlamp Switch & Horn System Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 Headlamp Switch & Horn System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 Interior Lighting Module: Electrical Diagrams Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Relay: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 Interior Lighting Relay: Electrical Diagrams Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > 4 Speed A/T Backup Lamp Relay: Locations 4 Speed A/T Engine Compartment. The Backup Lamp Relay is located in the right rear corner of the engine compartment, on the side shield. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 Interior Lighting Module: Electrical Diagrams Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Relay: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 Interior Lighting Relay: Electrical Diagrams Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Trailer Lighting Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6152 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6153 Trailer Lighting Module: Electrical Diagrams Rear Lighting & Trailer Tow Wiring Circuit SH-68 - Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6154 Rear Lighting & Trailer Tow Wiring Circuit SH-79 - Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > 3 Speed A/T Backup Lamp Switch: Locations 3 Speed A/T Neutral/Park Safety Switch Neutral Starting And Back-Up Lamp Switch The neutral starting switch is the center terminal of the 3 terminal switch. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6162 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6163 Backup Lamp Switch: Electrical Diagrams 3 Speed A/T Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at the vehicle level. See: Diagrams/Electrical Diagrams 4 Speed A/T Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6164 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6165 Note: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams at the vehicle level. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > 3 Speed A/T Backup Lamp Switch: Description and Operation 3 Speed A/T Neutral Starting And Back-Up Lamp Switch The neutral starting switch is the center terminal of the 3 terminal switch. - It provides ground for the starter solenoid circuit through the selector lever in only Park and Neutral positions. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Testing and Inspection > 3 Speed A/T Backup Lamp Switch: Testing and Inspection 3 Speed A/T Neutral Starting And Back-Up Lamp Switch Replacement And Test 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in Park or Neutral. 2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to Park and then to Neutral positions, and inspect to see that the switch operating lever fingers are centered in switch opening in the case. 4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 8. Continuity should exist only with transaxle in Reverse position. 9. No continuity should exist from either pin to the case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > 3 Speed A/T Backup Lamp Switch: Service and Repair 3 Speed A/T Neutral Starting And Back-Up Lamp Switch Replacement And Test 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in Park or Neutral. 2. Check gearshift cable adjustment before replacing a switch which tests bad. 3. Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to Park and then to Neutral positions, and inspect to see that the switch operating lever fingers are centered in switch opening in the case. 4. Screw the switch, with a new seal, into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 5. Add fluid to transaxle to bring up to proper level. 6. The back-up lamp switch circuit is through the two outside terminals of the 3-terminal switch. 7. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 8. Continuity should exist only with transaxle in Reverse position. 9. No continuity should exist from either pin to the case. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations I/P, Cowl & Steering Column Components Top Of Brake pedal Bracket Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Light Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6177 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6178 Speed Control & Stop Lamp Switch Wiring Circuit SH-25 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 6179 Brake Light Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect stop light switch electrical connector, then remove switch assembly. 3. Install new switch and connect switch electrical connector. If adjustment of switch is required, proceed as follows: a. Push switch forward until fully seated. This will move brake pedal slightly forward. b. Pull back on brake pedal until it will go back no further. This will cause switch to ratchet backward into correct position. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Dome Lamp Switch > Component Information > Locations Dome Lamp Switch: Locations Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Dome Lamp Switch Door Switch: Locations Dome Lamp Switch Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Dome Lamp Switch > Page 6187 Door Switch: Locations Door Ajar Switches Front Body Components In Respective Door Jamb Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair Hazard Warning Switch: Service and Repair 1. If equipped, disarm airbag system refer to MAINTENANCE PROCEDURES. 2. Remove steering wheel. Steering column cover, silencer & reinforcement removal 3. Remove steering column cover and silencer. 4. Remove shift indicator operating cable from slot in shift housing. 5. Pry off wiring trough from steering column, then disconnect control lever electrical connectors. 6. On models equipped with standard column, proceed as follows: a. Remove screws attaching turn signal lever cover to lock housing, then lever cover. b. Remove washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch. e. Remove turn signal/hazard switch attaching screws. 7. On models equipped with tilt column, proceed as follows: a. Remove tilt lever, then hazard warning knob. Push knob in and unscrew to remove. b. Remove ignition key lamp assembly, then knob off washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch. Lock plate removal. Models w/tilt column e. Depress lock plate using lock plate compressor No. C-4156 or equivalent and pry retaining ring out of groove with a suitable screwdriver. The full load of upper bearing spring should not be relieved. If full load is relieved, retaining ring will turn too easily and make removal difficult. f. Remove lock plate, cancelling cam and upper bearing spring. g. Remove turn signal/hazard switch actuator screws and arm. h. Remove turn signal/hazard switch attaching screws, Place shift bowl in Low position. Turn signal switch replacement Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Page 6191 8. On all models, remove turn signal/hazard warning switch assembly by gently pulling switch up from column while straightening and guiding wires up through column opening. 9. Reverse procedure to install. Rearm airbag system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations I/P, Cowl & Steering Column Components Top Of Steering Column Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6197 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6198 Headlamp Dimmer Switch: Electrical Diagrams Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6199 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 6200 Headlamp Dimmer Switch: Service and Repair Dimmer switch replacement 1. Disconnect battery ground cable. 2. Remove left lower instrument panel cover, then tape dimmer switch rod to steering column to prevent rod from falling out of notch in actuator lever. 3. Remove switch to column attaching screws. 4. Disconnect switch electrical connector, then remove switch from steering column. 5. Reverse procedure to install. During installation, gently push up on switch to take up slack on rod. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6206 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6207 Headlamp Switch: Electrical Diagrams Headlamp Switch & Horn System Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6208 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6209 Console Lamps, Controlled Interior Lamps & Headlamp Switch Wiring Circuit -- Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 6210 Headlamp Switch: Service and Repair Headlamp switch removal 1. Disconnect battery ground cable. 2. Remove headlight and accessory switch trim bezel. 3. Remove four screws attaching switch plate to lower panel. 4. Pull switch assembly rearward, then disconnect switch electrical connectors. 5. Remove switch knob and stem by depressing button on switch. 6. Remove two headlight switch plate to switch plate assembly attaching screws, then the headlight switch retainer and switch. 7. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > Turn Signal Switch - Canceling Pin Indexing Turn Signal Switch: Technical Service Bulletins Turn Signal Switch - Canceling Pin Indexing Models 1988 & 1989 AA-, AB-, AC-, AD-, AG-, AH-, AJ-, AK-, AL-, AM-, AN-, & AP-Body Equipped With Non-tilt Steering Column Subject Turn Signal Switch Canceling Index ELECTRICAL Date January 30, 1989 No. 08-03-89 P-196 (C08-03-9) BODY CODE LEGEND AA - Spirit/Acclaim AK - Aries/Reliant AB - Dodge Ram/Van Wagon AL - Omni/Horizon AC - Dynasty/New Yorker/Landau AM - Diplomat/Gran Fury/ AD - Dodge Ram Pickup/ Fifth Avenue Ramcharger Sport Utility AN - Dodge Dakota/ AG - Daytona Dakota/Sport AH - Lancer/LeBaron GTS AP - Shadow/Sundance AJ - Lebaron SYMPTOM/CONDITION Turn signals do not cancel properly after the steering wheel has been removed and reinstalled. REPAIR PROCEDURE Anytime the steering wheel is removed and replaced on nontilt columns, there is the possibility that the turn signals will not cancel properly until the pin in the steering wheel is properly indexed with respect to the turn signal switch. The following procedure should be used to ensure the turn signal cancel feature operates correctly. 1. Engage the turn signal lever in either the right turn or the left turn position. 2. While holding the turn signal lever to prevent movement, rotate the steering wheel two complete turns (or until the wheel stops) in the direction opposite the direction of the turn signal lever. Example: If the turn signal lever is moved downward to the left, rotate the steering wheel to the right. If the turn signal lever was moved upward to the right, then rotate the steering wheel to the left. 3. Release the turn signal lever and then return the steering wheel to the straight ahead position. 4. To check for proper canceling operation, engage the turn signal lever and then turn the steering wheel at least one-half revolution in the same direction in which the turn signal switch is engaged. 5. Return the steering wheel to the straight ahead position. The turn signal switch should cancel at this time. 6. Repeat Steps 4 and 5 to check the cancel feature in the opposite direction. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > Page 6215 Turn Signal Switch: Service and Repair Turn Signal/Hazard Warning Switch 1. If equipped, disarm airbag system refer to MAINTENANCE PROCEDURES. 2. Remove steering wheel. Steering column cover, silencer & reinforcement removal 3. Remove steering column cover and silencer. 4. Remove shift indicator operating cable from slot in shift housing. 5. Pry off wiring trough from steering column, then disconnect control lever electrical connectors. 6. On models equipped with standard column, proceed as follows: a. Remove screws attaching turn signal lever cover to lock housing, then lever cover. b. Remove washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch. e. Remove turn signal/hazard switch attaching screws. 7. On models equipped with tilt column, proceed as follows: a. Remove tilt lever, then hazard warning knob. Push knob in and unscrew to remove. b. Remove ignition key lamp assembly, then knob off washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch. Lock plate removal. Models w/tilt column e. Depress lock plate using lock plate compressor No. C-4156 or equivalent and pry retaining ring out of groove with a suitable screwdriver. The full load of upper bearing spring should not be relieved. If full load is relieved, retaining ring will turn too easily and make removal difficult. f. Remove lock plate, cancelling cam and upper bearing spring. g. Remove turn signal/hazard switch actuator screws and arm. h. Remove turn signal/hazard switch attaching screws, Place shift bowl in Low position. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > Page 6216 Turn signal switch replacement 8. On all models, remove turn signal/hazard warning switch assembly by gently pulling switch up from column while straightening and guiding wires up through column opening. 9. Reverse procedure to install. Rearm airbag system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Trailer Lighting Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6221 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6222 Trailer Lighting Module: Electrical Diagrams Rear Lighting & Trailer Tow Wiring Circuit SH-68 - Part 2 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6223 Rear Lighting & Trailer Tow Wiring Circuit SH-79 - Part 1 Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Technical Service Bulletins > Turn Signal Switch - Canceling Pin Indexing Turn Signal Switch: Technical Service Bulletins Turn Signal Switch - Canceling Pin Indexing Models 1988 & 1989 AA-, AB-, AC-, AD-, AG-, AH-, AJ-, AK-, AL-, AM-, AN-, & AP-Body Equipped With Non-tilt Steering Column Subject Turn Signal Switch Canceling Index ELECTRICAL Date January 30, 1989 No. 08-03-89 P-196 (C08-03-9) BODY CODE LEGEND AA - Spirit/Acclaim AK - Aries/Reliant AB - Dodge Ram/Van Wagon AL - Omni/Horizon AC - Dynasty/New Yorker/Landau AM - Diplomat/Gran Fury/ AD - Dodge Ram Pickup/ Fifth Avenue Ramcharger Sport Utility AN - Dodge Dakota/ AG - Daytona Dakota/Sport AH - Lancer/LeBaron GTS AP - Shadow/Sundance AJ - Lebaron SYMPTOM/CONDITION Turn signals do not cancel properly after the steering wheel has been removed and reinstalled. REPAIR PROCEDURE Anytime the steering wheel is removed and replaced on nontilt columns, there is the possibility that the turn signals will not cancel properly until the pin in the steering wheel is properly indexed with respect to the turn signal switch. The following procedure should be used to ensure the turn signal cancel feature operates correctly. 1. Engage the turn signal lever in either the right turn or the left turn position. 2. While holding the turn signal lever to prevent movement, rotate the steering wheel two complete turns (or until the wheel stops) in the direction opposite the direction of the turn signal lever. Example: If the turn signal lever is moved downward to the left, rotate the steering wheel to the right. If the turn signal lever was moved upward to the right, then rotate the steering wheel to the left. 3. Release the turn signal lever and then return the steering wheel to the straight ahead position. 4. To check for proper canceling operation, engage the turn signal lever and then turn the steering wheel at least one-half revolution in the same direction in which the turn signal switch is engaged. 5. Return the steering wheel to the straight ahead position. The turn signal switch should cancel at this time. 6. Repeat Steps 4 and 5 to check the cancel feature in the opposite direction. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Technical Service Bulletins > Page 6232 Turn Signal Switch: Service and Repair Turn Signal/Hazard Warning Switch 1. If equipped, disarm airbag system refer to MAINTENANCE PROCEDURES. 2. Remove steering wheel. Steering column cover, silencer & reinforcement removal 3. Remove steering column cover and silencer. 4. Remove shift indicator operating cable from slot in shift housing. 5. Pry off wiring trough from steering column, then disconnect control lever electrical connectors. 6. On models equipped with standard column, proceed as follows: a. Remove screws attaching turn signal lever cover to lock housing, then lever cover. b. Remove washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch. e. Remove turn signal/hazard switch attaching screws. 7. On models equipped with tilt column, proceed as follows: a. Remove tilt lever, then hazard warning knob. Push knob in and unscrew to remove. b. Remove ignition key lamp assembly, then knob off washer/wiper switch assembly. c. Pull hider up control lever, then remove control lever sleeve to washer/wiper switch attaching screws. d. Rotate control lever shaft to full clockwise position, then remove shaft from washer/wiper switch. Lock plate removal. Models w/tilt column e. Depress lock plate using lock plate compressor No. C-4156 or equivalent and pry retaining ring out of groove with a suitable screwdriver. The full load of upper bearing spring should not be relieved. If full load is relieved, retaining ring will turn too easily and make removal difficult. f. Remove lock plate, cancelling cam and upper bearing spring. g. Remove turn signal/hazard switch actuator screws and arm. h. Remove turn signal/hazard switch attaching screws, Place shift bowl in Low position. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Technical Service Bulletins > Page 6233 Turn signal switch replacement 8. On all models, remove turn signal/hazard warning switch assembly by gently pulling switch up from column while straightening and guiding wires up through column opening. 9. Reverse procedure to install. Rearm airbag system. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram Information and Instructions Underhood Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6238 How to Read Wiring Diagrams Black: BK Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6239 Underhood Lamp Wiring Circuit Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Locations Heated Glass Element Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations Heated Glass Element Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Front Door Components In Front Door Armrest Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Switch Test Power Window Switch: Testing and Inspection Power Window Switch Test Left Power Window Switch Continuity Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Switch Test > Page 6254 Right Power Window Switch Continuity 1. If the failure is in the right side door, remove the right power window switch from the door trim panel. 2. Connect jumper wires to the right power window switch connector as shown. The jumper wires take the place of a good switch in the inactive position. 3. Using the drivers side power window switch, activate the windows up and down. If the power windows now operate properly, replace the passenger side switch. If the power windows still do not operate, go to step 4. 4. Remove the drivers side power window switch from the door trim panel. 5. Connect jumper wires to the power window switch electrical connector as shown. If the power window system operates with the jumper wires connected, the power window switch is defective and needs to be replaced. If the power window system doesn't work with the jumper wires connected, check the wiring harness from the switch to the window lift motor for an open circuit. See: Windows/Power Window Motor/Testing and Inspection/Window Lift Motor Test Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Switch Test > Page 6255 Power Window Switch: Testing and Inspection Switch Voltage Test Left Power Window Switch Continuity Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Switch Test > Page 6256 Right Power Window Switch Continuity NOTE: The following test determines whether voltage is continuous through the wiring harness to the power window switch. 1. Remove the power window switch from the door trim panel. 2. Separate the multiple terminal block on the wiring harness from the power window switch. 3. Connect one lead of a test light to the black wire terminal and the other lead to the tan wire terminal. If the test light illuminates, the wiring circuit between the battery and switch is functioning properly. If the test light does not illuminate, check the 30 amp main fuse (circuit breaker) or check for an open in the wiring harness. 4. If the wiring circuit is functioning properly, See: Windows/Power Window Motor/Testing and Inspection/Window Lift Motor Test Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 6257 Power Window Switch: Service and Repair 1. Pry up rear of switch bezel releasing it from clips. Pull bezel out of door trim. 2. Disconnect wiring harness. 3. Remove switch screws and switch. 4. Reverse removal sequence to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Power Window Regulator Assembly REMOVAL 1. Remove trim panel and door liner. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 2. Remove the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair 3. Remove the power window regulator assembly. See: Window Regulator/Service and Repair/Power Window Regulator Replacement 4. Drill out the two (2) rivets mounting the power window lift motor to the window regulator. 5. Remove the power window lift motor off of the regulator. INSTALLATION 1. Position the power window lift motor onto the power window regulator and install two (2) 1/4-20 X 1/2 screws in place of the rivets that were drilled out for removal. Torque the mounting screws to 90 lb-ft (11 Nm). 2. Install the power window regulator assembly. See: Window Regulator/Service and Repair/Power Window Regulator Replacement 3. Install the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair 4. Install the door liner and door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Power Window Switch: Locations Front Door Components In Front Door Armrest Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power Window Switch Test Power Window Switch: Testing and Inspection Power Window Switch Test Left Power Window Switch Continuity Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power Window Switch Test > Page 6268 Right Power Window Switch Continuity 1. If the failure is in the right side door, remove the right power window switch from the door trim panel. 2. Connect jumper wires to the right power window switch connector as shown. The jumper wires take the place of a good switch in the inactive position. 3. Using the drivers side power window switch, activate the windows up and down. If the power windows now operate properly, replace the passenger side switch. If the power windows still do not operate, go to step 4. 4. Remove the drivers side power window switch from the door trim panel. 5. Connect jumper wires to the power window switch electrical connector as shown. If the power window system operates with the jumper wires connected, the power window switch is defective and needs to be replaced. If the power window system doesn't work with the jumper wires connected, check the wiring harness from the switch to the window lift motor for an open circuit. See: Power Window Motor/Testing and Inspection/Window Lift Motor Test Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power Window Switch Test > Page 6269 Power Window Switch: Testing and Inspection Switch Voltage Test Left Power Window Switch Continuity Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power Window Switch Test > Page 6270 Right Power Window Switch Continuity NOTE: The following test determines whether voltage is continuous through the wiring harness to the power window switch. 1. Remove the power window switch from the door trim panel. 2. Separate the multiple terminal block on the wiring harness from the power window switch. 3. Connect one lead of a test light to the black wire terminal and the other lead to the tan wire terminal. If the test light illuminates, the wiring circuit between the battery and switch is functioning properly. If the test light does not illuminate, check the 30 amp main fuse (circuit breaker) or check for an open in the wiring harness. 4. If the wiring circuit is functioning properly, See: Power Window Motor/Testing and Inspection/Window Lift Motor Test Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 6271 Power Window Switch: Service and Repair 1. Pry up rear of switch bezel releasing it from clips. Pull bezel out of door trim. 2. Disconnect wiring harness. 3. Remove switch screws and switch. 4. Reverse removal sequence to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair Glass To Regulator REMOVAL 1. Remove trim panel and door liner. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 2. Raise the door glass until the two (2) nuts align with access holes in the inner door panel. 3. Remove the two (2) glass plate nuts that hold the door glass to the front window regulator assembly. 4. Remove the glass through the belt opening, using the notch at the rear of the door to clear the glass fasteners (pull the glass towards the inside of the vehicle when removing). INSTALLATION 1. Slide the door glass into the door through the belt opening, using the notch at the rear of the door to clear the glass fasteners. 2. Install the two (2) glass plate nuts that hold the door glass to the front window regulator assembly and tighten finger tight. 3. To adjust the door glass, raise glass to full up position and secure glass attaching nuts. 3. Install the door liner and door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > Customer Interest for Window Regulator: > 232993 > Jun > 93 > Window Regulator - Inoperative Window Regulator: Customer Interest Window Regulator - Inoperative NO.: 23-29-93 GROUP: Body EFFECTIVE DATE: Jun 4, 1993 SUBJECT: Drum And Cable Window Regulator Retrofit Procedure MODELS: 1989-1990 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1984-1988 (S) Caravan/Grand Caravan/Voyager/Grand Voyager SYMPTOM/CONDITION: The window regulator may become inoperative due to the flex track portion of the window regulator being damaged. DIAGNOSIS: Inspect the flex track portion of the window regulator for damage or mis-positioning. PARTS REQUIRED: Each Manual Regulator Package Consists of: 1 Window Regulator 1 Screw & Washer Assembly, Upper Regulator to Door Attachment 6 Screw, Regulator to Door Attachment 1 Template, Window Regulator Retrofit 1 Instruction Sheet REPAIR PROCEDURE: This bulletin involves replacing flex track style window regulator(s) with drum and cable style window regulator(s). NOTE: WHEN REMOVING THE RIVETS ATTACHING THE REGULATOR TO THE DOOR, DO NOT USE A DRILL BIT LARGER THAN 1/4 IN. 1. Using the appropriate steps of the procedure outlined in section 23 of the applicable service manual, remove the damaged window regulator(s). Save the hardware attaching the glass to the regulator for use at reassembly. 2. Remove all debris from inside the door shell. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > Customer Interest for Window Regulator: > 232993 > Jun > 93 > Window Regulator - Inoperative > Page 6284 3. Use the reference holes of the template (P/N K4746908) to properly position the template on the front door(s) inner panel then tape the template in place. Refer to Figure 1. 4. Center punch and drill, 7.9 mm (5/16 in.) holes identified with an * (asterisk) on the template. Four are for the regulator cable guide bar and three are for the motor attachment (if the vehicle is equipped with electric windows). NOTE: IN THE NEXT STEP, BE CAREFUL NOT TO TWIST THE CABLES OF THE WINDOW REGULATOR ASSEMBLY. 5. Position the new drum and cable window regulator in the door and attach the cable guide bar with 5 screws (4 - P/N 6501682 and 1 - P/N 6100557) which is used at the up stop position. The top screw should be left loose for now and tightened when making the final adjustment to the up-stop in step 10. 6. A) For electric regulator equipped vehicles, attach the motor to the inner door panel using 3 nut & washer assemblies (P/N 6100048). B) For manual regulator equipped vehicles, attach the manual drive assembly to the inner door panel with 2 screws (P/N 6501682). 7. Using the original hardware, attach the glass to the regulator. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > Customer Interest for Window Regulator: > 232993 > Jun > 93 > Window Regulator - Inoperative > Page 6285 8. If the vehicle is electric regulator equipped, locate the wiring harness extension package (P/N K4746909). Determine which insulator in the package needs to be installed to the door harness end of the wiring harness extension (black for 1988 and prior, red for 1989 and 1990). Referring to Figure 2 for proper wire to insulator orientation, assemble the appropriate insulator to the wiring harness extension. If the red insulator is used, the wedge must be installed in the terminal end of the insulator and xmas tree fastener must be inserted into the slot on the side of the red insulator. 9. Install the wiring harness extension (P/N K4746909). Use the xmas tree fasteners of the insulators to secure the harness to the door, refer to Figure 3. At the forward attachment point, the insulator must be installed so it is inside the door cavity. At mid-door attachment, install the insulator so it is outside the door cavity. Bend the tab back into the door so the insulator becomes flush to slightly underflush with the inner door panel. 10. Verify the proper operation of the window. Adjust as necessary. Tighten the upstop screw. 11. Reinstall the door trim. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > Customer Interest for Window Regulator: > 232993 > Jun > 93 > Window Regulator - Inoperative > Page 6286 TIME ALLOWANCE: Labor Operation No. 23-34-10-96 Power Window Regulator 1.0 Hrs. 23-34-10-97 Manual Window Regulator 0.9 Hrs. FAILURE CODE: 27 - Damaged Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Regulator: > 232993 > Jun > 93 > Window Regulator Inoperative Window Regulator: All Technical Service Bulletins Window Regulator - Inoperative NO.: 23-29-93 GROUP: Body EFFECTIVE DATE: Jun 4, 1993 SUBJECT: Drum And Cable Window Regulator Retrofit Procedure MODELS: 1989-1990 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1984-1988 (S) Caravan/Grand Caravan/Voyager/Grand Voyager SYMPTOM/CONDITION: The window regulator may become inoperative due to the flex track portion of the window regulator being damaged. DIAGNOSIS: Inspect the flex track portion of the window regulator for damage or mis-positioning. PARTS REQUIRED: Each Manual Regulator Package Consists of: 1 Window Regulator 1 Screw & Washer Assembly, Upper Regulator to Door Attachment 6 Screw, Regulator to Door Attachment 1 Template, Window Regulator Retrofit 1 Instruction Sheet REPAIR PROCEDURE: This bulletin involves replacing flex track style window regulator(s) with drum and cable style window regulator(s). NOTE: WHEN REMOVING THE RIVETS ATTACHING THE REGULATOR TO THE DOOR, DO NOT USE A DRILL BIT LARGER THAN 1/4 IN. 1. Using the appropriate steps of the procedure outlined in section 23 of the applicable service manual, remove the damaged window regulator(s). Save the hardware attaching the glass to the regulator for use at reassembly. 2. Remove all debris from inside the door shell. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Regulator: > 232993 > Jun > 93 > Window Regulator Inoperative > Page 6292 3. Use the reference holes of the template (P/N K4746908) to properly position the template on the front door(s) inner panel then tape the template in place. Refer to Figure 1. 4. Center punch and drill, 7.9 mm (5/16 in.) holes identified with an * (asterisk) on the template. Four are for the regulator cable guide bar and three are for the motor attachment (if the vehicle is equipped with electric windows). NOTE: IN THE NEXT STEP, BE CAREFUL NOT TO TWIST THE CABLES OF THE WINDOW REGULATOR ASSEMBLY. 5. Position the new drum and cable window regulator in the door and attach the cable guide bar with 5 screws (4 - P/N 6501682 and 1 - P/N 6100557) which is used at the up stop position. The top screw should be left loose for now and tightened when making the final adjustment to the up-stop in step 10. 6. A) For electric regulator equipped vehicles, attach the motor to the inner door panel using 3 nut & washer assemblies (P/N 6100048). B) For manual regulator equipped vehicles, attach the manual drive assembly to the inner door panel with 2 screws (P/N 6501682). 7. Using the original hardware, attach the glass to the regulator. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Regulator: > 232993 > Jun > 93 > Window Regulator Inoperative > Page 6293 8. If the vehicle is electric regulator equipped, locate the wiring harness extension package (P/N K4746909). Determine which insulator in the package needs to be installed to the door harness end of the wiring harness extension (black for 1988 and prior, red for 1989 and 1990). Referring to Figure 2 for proper wire to insulator orientation, assemble the appropriate insulator to the wiring harness extension. If the red insulator is used, the wedge must be installed in the terminal end of the insulator and xmas tree fastener must be inserted into the slot on the side of the red insulator. 9. Install the wiring harness extension (P/N K4746909). Use the xmas tree fasteners of the insulators to secure the harness to the door, refer to Figure 3. At the forward attachment point, the insulator must be installed so it is inside the door cavity. At mid-door attachment, install the insulator so it is outside the door cavity. Bend the tab back into the door so the insulator becomes flush to slightly underflush with the inner door panel. 10. Verify the proper operation of the window. Adjust as necessary. Tighten the upstop screw. 11. Reinstall the door trim. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Regulator: > 232993 > Jun > 93 > Window Regulator Inoperative > Page 6294 TIME ALLOWANCE: Labor Operation No. 23-34-10-96 Power Window Regulator 1.0 Hrs. 23-34-10-97 Manual Window Regulator 0.9 Hrs. FAILURE CODE: 27 - Damaged Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Manual Window Regulator Replacement Window Regulator: Service and Repair Manual Window Regulator Replacement *** THIS ARTICLE HAS BEEN UPDATED BY TSB # 23-29-93 DATED JUNE 4, 1993 Power Window Regulator Assembly REMOVAL 1. Remove trim panel and door liner. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 2. Remove the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair 3. Drill out the five (5) rivets holding the power door regulator to the door. 4. Remove two (2) screws at the door sill. 5. Remove the manual window regulator by rotating it out of the door. INSTALLATION 1. Install the manual window regulator by rotating it as it is installed. 2. Install the two (2) screws at the door sill. Window Regulator Tightening Sequence 3. Install five (5) 1/4-20 X 1/2 screws in place of the rivets that were drilled out for removal. Using the sequence shown, torque the screws to 90 lb-in (11 Nm). 4. Install the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair 5. Install the door liner and door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Manual Window Regulator Replacement > Page 6297 Window Regulator: Service and Repair Power Window Regulator Replacement *** THIS ARTICLE HAS BEEN UPDATED BY TSB # 23-29-93 DATED JUNE 4, 1993 Power Window Regulator Assembly REMOVAL 1. Remove trim panel and door liner. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 2. Remove the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair 3. Drill out the five (5) rivets holding the power door regulator to the door. 4. Remove two (2) screws at the door sill. 5. Remove the power window regulator by rotating it out of the door. INSTALLATION 1. Install the power window regulator by rotating it as it is installed. 2. Install the two (2) screws at the door sill. Window Regulator Tightening Sequence 3. Install five (5) 1/4-20 X 1/2 screws in place of the rivets that were drilled out for removal. Using the sequence shown, torque the screws to 90 lb-in (11 Nm). 4. Install the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair 5. Install the door liner and door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > Customer Interest: > 232692 > Oct > 92 > Windshield Washer Nozzle - Freezes Up Check Valve: Customer Interest Windshield Washer Nozzle - Freezes Up NO.: 23-26-92 GROUP: Body DATE: Oct. 19, 1992 SUBJECT: Windshield Washer Nozzle Freeze Up MODELS: 1989 - 1992 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1989 - 1993 (AA)Spirit/Acclaim/Lebaron Sedan 1989 - 1993 (AC)Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG)Daytona 1989 - 1993 (AJ) Lebaron Coupe/Lebaron Convertible 1989 1993 (AP)Shadow/Shadow Convertible/Sundance 1990 - 1993 (AY)Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN MAY BE APPLIED TO OLDER VEHICLES WITH WIPER ARM MOUNTED NOZZLES. SYMPTOM/CONDITION: Inoperative windshield washer system when ambient temperatures are below freezing. One or all nozzles may be affected and the frozen restriction can be anywhere between the washer fluid reservoir and the nozzle(s). PARTS REQUIRED: 1 Washer fluid check valve 4740043 REPAIR PROCEDURE: This bulletin involves installing an in-line check valve in the windshield washer hose. 1. Pinch off the washer hose near the reservoir to prevent fluid from running out of the reservoir. 2. Cut a one inch section out of the hose two to three inches from the reservoir. 3. Locate the arrow molded on the check valve (P/N 4740043). Install the check valve in the hose so the arrow points away from the reservoir. 4. Verify system operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-43-10-91 ......0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 232692 > Oct > 92 > Windshield Washer Nozzle - Freezes Up Check Valve: All Technical Service Bulletins Windshield Washer Nozzle - Freezes Up NO.: 23-26-92 GROUP: Body DATE: Oct. 19, 1992 SUBJECT: Windshield Washer Nozzle Freeze Up MODELS: 1989 - 1992 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1989 - 1993 (AA)Spirit/Acclaim/Lebaron Sedan 1989 - 1993 (AC)Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG)Daytona 1989 - 1993 (AJ) Lebaron Coupe/Lebaron Convertible 1989 1993 (AP)Shadow/Shadow Convertible/Sundance 1990 - 1993 (AY)Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN MAY BE APPLIED TO OLDER VEHICLES WITH WIPER ARM MOUNTED NOZZLES. SYMPTOM/CONDITION: Inoperative windshield washer system when ambient temperatures are below freezing. One or all nozzles may be affected and the frozen restriction can be anywhere between the washer fluid reservoir and the nozzle(s). PARTS REQUIRED: 1 Washer fluid check valve 4740043 REPAIR PROCEDURE: This bulletin involves installing an in-line check valve in the windshield washer hose. 1. Pinch off the washer hose near the reservoir to prevent fluid from running out of the reservoir. 2. Cut a one inch section out of the hose two to three inches from the reservoir. 3. Locate the arrow molded on the check valve (P/N 4740043). Install the check valve in the hose so the arrow points away from the reservoir. 4. Verify system operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-43-10-91 ......0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Check Valve: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations I/P, Cowl & Steering Column Components Center Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Engine Compartment Components. LH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair Windshield Washer Switch: Service and Repair Fig. 2 Ignition lock removal. Models w/tilt column FRONT Standard Column Refer to Vehicle Lighting/Turn Signals/Turn Signal Switch/Service and Repair for washer/wiper switch replacement procedure. Tilt Column 1. If equipped, disarm airbag system. Refer to MAINTENANCE PROCEDURES. 2. Remove turn signal/hazard warning switch as described under "Turn Signal/Hazard Warning Switch, Replace." 3. Remove ignition key lamp. 4. Position ignition lock cylinder in Lock position, then insert a small diameter screwdriver into lock cylinder release holes and push inward until spring loaded lock cylinder retainers release. 5. Remove buzzer/chime switch by inserting a bent piece of stiff wire into exposed loop of wedge spring and pulling straight out. Use caution not to drop switch into steering column. 6. Remove three switch housing cover attaching screws, then the housing cover. 7. Remove washer/wiper switch. Remove washer/wiper switch pivot pin using a suitable punch, if necessary. 8. Reverse procedure to install. Rearm airbag system. REAR 1. Disconnect battery ground cable. 2. Remove switch plate bezel. 3. Remove four screws attaching switch plate to lower panel. 4. Pull switch assembly rearward, then disconnect switch electrical connectors. 5. Remove switch retaining screw. Depress locking tabs to remove switch from switch plate. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 6336 Wiper Switch: Testing and Inspection Fig. 11 Two Speed Wiper Switch Continuity Chart Fig. 12 Intermittent Wiper Switch Continuity Chart 1. Disconnect electrical connector to switch at body wiring harness connector. 2. Operate switch in all positions, and check continuity between terminals with an ohmmeter. The first (clockwise) position is the Off position. Next is the slide for the Delay wipe, with counterclockwise rotation, reducing the delay. Low is the next detent position. High is the full counterclockwise detent position. In any wiper mode, if the knob is pushed in all the way, the washer circuit will be completed. 3. If continuity is not as specified in charts, replace switch. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 6337 Wiper Switch: Service and Repair Fig. 2 Ignition lock removal. Models w/tilt column FRONT Standard Column Refer to Vehicle Lighting/Turn Signals/Turn Signal Switch/Service and Repair for washer/wiper switch replacement procedure. Tilt Column 1. If equipped, disarm airbag system. Refer to MAINTENANCE PROCEDURES. 2. Remove turn signal/hazard warning switch as described under "Turn Signal/Hazard Warning Switch, Replace." 3. Remove ignition key lamp. 4. Position ignition lock cylinder in Lock position, then insert a small diameter screwdriver into lock cylinder release holes and push inward until spring loaded lock cylinder retainers release. 5. Remove buzzer/chime switch by inserting a bent piece of stiff wire into exposed loop of wedge spring and pulling straight out. Use caution not to drop switch into steering column. 6. Remove three switch housing cover attaching screws, then the housing cover. 7. Remove washer/wiper switch. Remove washer/wiper switch pivot pin using a suitable punch, if necessary. 8. Reverse procedure to install. Rearm airbag system. REAR 1. Disconnect battery ground cable. 2. Remove switch plate bezel. 3. Remove four screws attaching switch plate to lower panel. 4. Pull switch assembly rearward, then disconnect switch electrical connectors. 5. Remove switch retaining screw. Depress locking tabs to remove switch from switch plate. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Engine Compartment Components. LH Rear Corner Of Engine Compartment Applicable to: 1989 4-153/2.5L & V6-181/3.0L Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Windshield Washer Pump: Locations Rear Body Components LH Rear Corner Of Cargo Compartment Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Technical Service Bulletins > Customer Interest: > 232692 > Oct > 92 > Windshield Washer Nozzle - Freezes Up Windshield Washer Spray Nozzle: Customer Interest Windshield Washer Nozzle - Freezes Up NO.: 23-26-92 GROUP: Body DATE: Oct. 19, 1992 SUBJECT: Windshield Washer Nozzle Freeze Up MODELS: 1989 - 1992 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1989 - 1993 (AA)Spirit/Acclaim/Lebaron Sedan 1989 - 1993 (AC)Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG)Daytona 1989 - 1993 (AJ) Lebaron Coupe/Lebaron Convertible 1989 1993 (AP)Shadow/Shadow Convertible/Sundance 1990 - 1993 (AY)Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN MAY BE APPLIED TO OLDER VEHICLES WITH WIPER ARM MOUNTED NOZZLES. SYMPTOM/CONDITION: Inoperative windshield washer system when ambient temperatures are below freezing. One or all nozzles may be affected and the frozen restriction can be anywhere between the washer fluid reservoir and the nozzle(s). PARTS REQUIRED: 1 Washer fluid check valve 4740043 REPAIR PROCEDURE: This bulletin involves installing an in-line check valve in the windshield washer hose. 1. Pinch off the washer hose near the reservoir to prevent fluid from running out of the reservoir. 2. Cut a one inch section out of the hose two to three inches from the reservoir. 3. Locate the arrow molded on the check valve (P/N 4740043). Install the check valve in the hose so the arrow points away from the reservoir. 4. Verify system operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-43-10-91 ......0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 232692 > Oct > 92 > Windshield Washer Nozzle - Freezes Up Windshield Washer Spray Nozzle: All Technical Service Bulletins Windshield Washer Nozzle Freezes Up NO.: 23-26-92 GROUP: Body DATE: Oct. 19, 1992 SUBJECT: Windshield Washer Nozzle Freeze Up MODELS: 1989 - 1992 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1989 - 1993 (AA)Spirit/Acclaim/Lebaron Sedan 1989 - 1993 (AC)Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG)Daytona 1989 - 1993 (AJ) Lebaron Coupe/Lebaron Convertible 1989 1993 (AP)Shadow/Shadow Convertible/Sundance 1990 - 1993 (AY)Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN MAY BE APPLIED TO OLDER VEHICLES WITH WIPER ARM MOUNTED NOZZLES. SYMPTOM/CONDITION: Inoperative windshield washer system when ambient temperatures are below freezing. One or all nozzles may be affected and the frozen restriction can be anywhere between the washer fluid reservoir and the nozzle(s). PARTS REQUIRED: 1 Washer fluid check valve 4740043 REPAIR PROCEDURE: This bulletin involves installing an in-line check valve in the windshield washer hose. 1. Pinch off the washer hose near the reservoir to prevent fluid from running out of the reservoir. 2. Cut a one inch section out of the hose two to three inches from the reservoir. 3. Locate the arrow molded on the check valve (P/N 4740043). Install the check valve in the hose so the arrow points away from the reservoir. 4. Verify system operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-43-10-91 ......0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield Washer Spray Nozzle: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair Windshield Washer Switch: Service and Repair Fig. 2 Ignition lock removal. Models w/tilt column FRONT Standard Column Refer to Vehicle Lighting/Turn Signals/Turn Signal Switch/Service and Repair for washer/wiper switch replacement procedure. Tilt Column 1. If equipped, disarm airbag system. Refer to MAINTENANCE PROCEDURES. 2. Remove turn signal/hazard warning switch as described under "Turn Signal/Hazard Warning Switch, Replace." 3. Remove ignition key lamp. 4. Position ignition lock cylinder in Lock position, then insert a small diameter screwdriver into lock cylinder release holes and push inward until spring loaded lock cylinder retainers release. 5. Remove buzzer/chime switch by inserting a bent piece of stiff wire into exposed loop of wedge spring and pulling straight out. Use caution not to drop switch into steering column. 6. Remove three switch housing cover attaching screws, then the housing cover. 7. Remove washer/wiper switch. Remove washer/wiper switch pivot pin using a suitable punch, if necessary. 8. Reverse procedure to install. Rearm airbag system. REAR 1. Disconnect battery ground cable. 2. Remove switch plate bezel. 3. Remove four screws attaching switch plate to lower panel. 4. Pull switch assembly rearward, then disconnect switch electrical connectors. 5. Remove switch retaining screw. Depress locking tabs to remove switch from switch plate. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > Customer Interest: > 231189 > May > 89 > Wiper Arm - Loose Wiper Arm: Customer Interest Wiper Arm - Loose Models 1989 AA, AC, AH, AP & AS Bodies Subject Wiper Arm Loose On Pivot Shaft Index BODY Date May 22, 1989 No. 23-11-89 (C23-04-9) P-1976 BODY CODE LEGEND AA - SPIRIT/ACCLAIM AC - DYNASTY/NEW YORKER/LANDAU AH - LANCER/LeBARON GTS (4-DOOR HATCHBACK) AP - SHADOW/SUNDANCE AS - CARAVAN/VOYAGER/CARAVAN C/V SYMPTOM/CONDITION Windshield wiper arm attachment to the pivot shaft may strip and loosen due to insufficient torque or excessive loading on wiper arm. Loose wiper arms which have not been otherwise damaged may be reused by removing and reinstalling, using the following procedure. This will allow the arm to re-establish a tight fit on the pivot shaft splines. If the wiper arm is cracked or damaged, a new arm must be installed following this same procedure. Figure 1 REPAIR PROCEDURE 1. Lift the wiper arm and place a 1/8" (3.5 mm) pin (Allen wrench, nail, etc.) into the arm pin hole (see Figure 1). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > Customer Interest: > 231189 > May > 89 > Wiper Arm - Loose > Page 6378 Figure 2 2. Lift the head cover and remove the wiper arm attaching nut (see Figure 2). 3. Remove wiper arm from the pivot using a rocking motion. 4. Using a wire brush, clean the wiper pivot shaft splines thoroughly to remove any metal filings. 5. Cycle the windshield wiper motor to the park position and install wiper arm as follows: - For AC, AH, AP and AA bodies position wiper arm so that blade tip is 3/4" from top of cowl screen. - For AS body, position wiper arms so that blade tips are located as follows: Left: 5.0 mm (2.0") above windshield cowl top Right: 2.5 mm (1.0") above windshield cowl top 6. Tighten the retaining nut to the torque value indicated below. - For vehicles with a 10 mm pivot shaft nut (built prior to February, 1989) torque to 120 in.lbs (14 N-m). - For vehicles with a 13 mm pivot shaft nut (built after February, 1989) torque to 175 in.lbs (20 N-m). 7. Run wiper motor to check for correct operation of wiper arms. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operations No. 23-43-60-90 . . . . . . . . . . . . . . . 0.2 Hrs. FAILURE CODE: K4 - Loose Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 231189 > May > 89 > Wiper Arm - Loose Wiper Arm: All Technical Service Bulletins Wiper Arm - Loose Models 1989 AA, AC, AH, AP & AS Bodies Subject Wiper Arm Loose On Pivot Shaft Index BODY Date May 22, 1989 No. 23-11-89 (C23-04-9) P-1976 BODY CODE LEGEND AA - SPIRIT/ACCLAIM AC - DYNASTY/NEW YORKER/LANDAU AH - LANCER/LeBARON GTS (4-DOOR HATCHBACK) AP - SHADOW/SUNDANCE AS - CARAVAN/VOYAGER/CARAVAN C/V SYMPTOM/CONDITION Windshield wiper arm attachment to the pivot shaft may strip and loosen due to insufficient torque or excessive loading on wiper arm. Loose wiper arms which have not been otherwise damaged may be reused by removing and reinstalling, using the following procedure. This will allow the arm to re-establish a tight fit on the pivot shaft splines. If the wiper arm is cracked or damaged, a new arm must be installed following this same procedure. Figure 1 REPAIR PROCEDURE 1. Lift the wiper arm and place a 1/8" (3.5 mm) pin (Allen wrench, nail, etc.) into the arm pin hole (see Figure 1). Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 231189 > May > 89 > Wiper Arm - Loose > Page 6384 Figure 2 2. Lift the head cover and remove the wiper arm attaching nut (see Figure 2). 3. Remove wiper arm from the pivot using a rocking motion. 4. Using a wire brush, clean the wiper pivot shaft splines thoroughly to remove any metal filings. 5. Cycle the windshield wiper motor to the park position and install wiper arm as follows: - For AC, AH, AP and AA bodies position wiper arm so that blade tip is 3/4" from top of cowl screen. - For AS body, position wiper arms so that blade tips are located as follows: Left: 5.0 mm (2.0") above windshield cowl top Right: 2.5 mm (1.0") above windshield cowl top 6. Tighten the retaining nut to the torque value indicated below. - For vehicles with a 10 mm pivot shaft nut (built prior to February, 1989) torque to 120 in.lbs (14 N-m). - For vehicles with a 13 mm pivot shaft nut (built after February, 1989) torque to 175 in.lbs (20 N-m). 7. Run wiper motor to check for correct operation of wiper arms. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operations No. 23-43-60-90 . . . . . . . . . . . . . . . 0.2 Hrs. FAILURE CODE: K4 - Loose Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Arm: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations I/P, Cowl & Steering Column Components Center Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations Wiper Motor: Locations Liftgate Components Center Of Liftgate Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Lower I/P Components LH Side Of I/P Dodge Grand Caravan Workshop Manual (V6-181 3.0L SOHC (1989)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 6417 Wiper Switch: Testing and Inspection Fig. 11 Two Speed Wiper Switch Continuity Chart Fig. 12 Intermittent Wiper Switch Continuity Chart 1. Disconnect electrical connector to switch at body wiring harness connector. 2. Operate switch in all positions, and check continuity between terminals with an ohmmeter. The first (clockwise) position is the Off position. Next is the slide for the Delay wipe, with counterclockwise rotation, reducing the delay. Low is the next detent position. High is the full counterclockwise detent position. In any wiper mode, if the knob is pushed in all the way, the washer circuit will be completed. 3. If continuity is not as specified in charts, replace switch.