test ports for above, port 1 = overdrive clutch, port 2 = torque converter off, port 3 = low/reverse clutch, port 4 = 2/4 clutch, port 5 = reverse clutch, port 6 = underdrive clutch

 

SUBJECT:
Belt-Like Squeal Sound at High Engine RPM
OVERVIEW:
This bulletin involves replacing the heater core return hose and replacing
the variable restrictor with a fixed restrictor.
MODELS:
2001 - 2002 (RS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L
ENGINE AND WITHOUT REAR HVAC (SALES CODE HBB) AND WITHOUT
AN ENGINE OIL COOLER (SALES CODE NHA).
SYMPTOM/CONDITION:
With the engine at 3000 RPM or higher, a belt-like squeal sound may be heard
from the center of the dash area. This sound is similar to the sound produced
by a worn/loose accessory drive belt or faulty generator.
DIAGNOSIS:
Start engine and apply the parking brake. Open and support the hood. From the engine
compartment, accelerate the engine to produce the sound (3000 RPM or higher). Use
pliers to pinch off the heater core return hose (top hose) between the heater core outlet
tube and the in-line restrictor. If the noise is eliminated, perform the Repair Procedure.
PARTS REQUIRED:
Qty. Part No. Description
1 05005341AA Coolant Hose, Heater Core Return
1 05072197AA Restrictor
AR 05066386AA Coolant, Engine (MS9769)
07-001-02 -2-
REPAIR PROCEDURE:
WARNING: TO PREVENT INJURY, ALLOW THE ENGINE TO COOL BEFORE
PERFORMING THIS REPAIR. WHEN THE ENGINE IS AT OPERATING TEMPERATURE,
ENGINE COOLANT IS HOT AND UNDER PRESSURE.
1. Using pliers, remove both tension clamps from the heater core return
hose (top hose to heater core) (Fig. 1).
Fig. 1 HEATER RETURN LINE & RESTRICTOR
1 - HEATER CORE OUTLET TUBE
2 - HEATER CORE RETURN HOSE AND RESTRICTOR LOCATION
2. Remove and discard the heater core return hose and restrictor.
3. Install the new restrictor into the coolant tube as shown in (Fig. 2)
Fig. 2 RESTRICTOR LOCATION
1 - COOLANT TUBE
2 - RESTRICTOR
3 - HOSE TO HEATER CORE OUTLET TUBE
4. Install the tension clamps to the new heater core return hose.
5. Install and fully seat the heater core return hose onto the coolant tube and
the heater core outlet tube. Install the tension clamps.
6. Fill the coolant recovery/reserve container to the full level using a 50/50 mix
of Mopar coolant (p/n 05066386AA) and distilled water.
7. Start the engine and check for coolant leaks.
-3- 07-001-02

 

WHEEL ALIGNMENT


NOTE: All specifications are given in degrees.

FRONT WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE
CAMBER - LEFT +0.35° −0.05° to +0.75°
CAMBER - RIGHT +0.05° −0.35° to +0.45°
Cross-Camber (Maximum side-to-side difference) +0.30° −0.20° to +0.80°
CASTER* +2.50° +1.50° to +3.50°
Cross-Caster (Maximum side-to-side difference) 0.00° −0.75° to +0.75°
TOTAL TOE** +0.26° +0.06° to +0.46°
REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE
CAMBER* −0.06° −0.46° to +0.34°
Cross-Camber (Maximum side-to-side difference) 0.00° −0.25° to +0.25°
TOTAL TOE* ** +0.10° −0.15° to +0.35°
THRUST ANGLE 0.00° −0.30° to +0.30°
Notes:
* For reference only. These are non-adjustable angles.
** TOTAL TOE is the sum of both left and right wheel toe settings. TOTAL TOE should be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is toe-in and negative toe is toe-out

 

45AutoPete
Rookie Join Date: Aug 2009
Vehicle: 2002 Durango SLT+ 4WD 4.7
Posts: 98

The Correct Way To Flush Any Transmission

I am posting this because I think that everyone here should know exactly the correct way to flush a transmission instead of taking it to the so called shops that use the machines which will do more harm than good and also because I went round and round with a moron from another forum who thinks that machine flushing is not bad on any transmission. This is for the 45RFE and 545RFE Transmissions but can also be used for other auto transmissions.
1. Drop trans. pan and clean debris off of bottom of pan and on magnet.
2. Remove old filter or filters and install new filter or filters.
3. Install cleaned pan and torque all bolts according to manufacturer's specs.
4. Add 6 quarts of trans. fluid. ATF+4
5. Before starting engine, remove return line from radiator and install fitting with a hose on it. Put that into a pan to catch the trans. fluid. I use an old gallon gas can as that is a very good visual.
6. Start engine and do not worry about tranny fluid spraying all over the place, it will be trickling out of that hose you put on. Visually watch the container that is catching the old stuff and add accordingly.
7. A person will need around 18 quarts to do this, 6 for the initial fill and 12 for the flush. There are no such thing as shortcuts in this way of doing the flush. Shortcuts are the machine flush that makes easy money for shops who do not change out the filters esp. stealerships.
For all other transmissions, look up what it would take for a complete fill and not just a fluid and filter change and that is what you will be buying in quarts of tranny fluid.

This is from a member in the durango section. This will also work on any dodge transmission.

 

Thanks for the writeup on the Transmission Flush. Would you clarify the part regarding the 1 gallon catch container? Do you use several buckets to catch the 16 or so quarts of fluid? Do you shut the engine off while changing buckets or do it on the fly?

The answer may be obvious but I thought I just might ask.

Thanks for all your help! Splitrimz

 

DIAGNOSIS AND TESTING - SELF-DIAGNOSTICS
The instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform the Self-Diagnostic Test. The self diagnostic system displays instrument cluster stored fault codes in the odometer display, sweeps the gauges to the calibration points, and bulb checks the warning indicators. When the key is in the ON position with the engine not running, the MIL will remain illuminated for regulatory purposes.

To activate the Self-Diagnostic program:
With the ignition switch in the OFF position, depress the TRIP ODOMETER RESET button.
Continue to hold the TRIP ODOMETER RESET button until Sof and a number (software version number (i.e. Sof 3.2) appears in the odometer window then release the button. If a fault code is present, the cluster will display it in the odometer display. When all fault codes have been displayed, the cluster will display “end” in the odometer display. Refer to the INSTRUMENT CLUSTER DTC'S table to determine what each trouble code means. INSTRUMENT CLUSTER DTC'S DTC DESCRIPTION
100.0 LOOP-BACK FAILURE
100.1 ABS COMMUNICATION FAULT
100.2 BCM COMMUNICATION FAULT
100.3 EATX COMMUNICATION FAULT
100.4 FCM COMMUNICATION FAULT
100.5 ORC COMMUNICATION FAULT
100.6 SBEC/DEC/MCM COMMUNICATION FAULT
200.0 AIRBAG LED SHORT
200.1 AIRBAG LED OPEN
200.2 ABS LED SHORT
200.3 ABS LED OPEN
200.6 EL INVERTER TIME-OUT
200.7 EATX MISMATCH
400.0 EEPROM READ/WRITE FAILURE
400.1 IMPROPER POWER DOWN DETECTED


CALIBRATION TEST
The CLUSTER CALIBRATION table contains the proper calibration points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If any gauge is out of calibration, replace the cluster.

CLUSTER CALIBRATION SPEEDOMETER CALIBRATION POINT
1 0 MPH (0 KM/H)
2 20 MPH (40 KM/H)
3 60 MPH (100 KM/H)
4 100 MPH (160 KM/H)
TACHOMETER
1 0 RPM
2 1000 RPM
3 3000 RPM
4 6000 RPM
FUEL GAUGE
1 EMPTY
2 1/4 FILLED
3 1/2 FILLED
4 FULL
TEMPERATURE GAUGE
1 COLD
2 1/4
3 3/4
4 HOT


ODOMETER SEGMENT TEST
If a segment in the odometer does not illuminate normally, a problem exists in the display.

ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST
If a segment in the transmission range indicator does not illuminate normally, a problem exists in the display.

 

NUMBER: 23-044-02
GROUP: Body
DATE: Oct. 14, 2002
SUBJECT:
NS Strut Tower Corrosion
OVERVIEW:
This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion
perforation condition at the top of the strut tower/s.
MODELS:
1996 - 2000 NS Town&Country/Voyager/Caravan
SYMPTOM/CONDITION:
Cosmetic corrosion or perforation at upper strut tower/s usually between the strut
and upper load path beam inner panel (inner fender).
DIAGNOSIS:
Inspect left and right strut towers for condition. If corrosion is present, perform
one of the following repair procedures.
NOTE: ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE
REPAIRS SHOULD BE OBTAINED PRIOR TO BEGINNING REPAIRS.
PARTS/MATERIALS REQUIRED:
Qty. Part No. Description
1 05080009AA Strut Cap (Left Side)
1 Kit 05086513AA NS Strut Cap Installation Kit
(Left Side).
1 05080008AA Strut Cap (Right Side)
1 Kit 05086512AA NS Strut Cap Installation Kit
(Right Side).
11/2 - 2 Cartridges
Per Side
05083855AA Mopar Structural Adhesive
EQUIPMENT REQUIRED:
W-7804R 90-degree drill motor (PSE)
W-861 High-speed air cutter (die grinder) (PSE)
23-044-02 -2-
05016570AA Adhesive dispenser (MOPAR)
W-AK175 ACH Power set rivet gun (PSE)
REPAIR DESCRIPTION:
Repair A - Cosmetic corrosion removal and the application of corrosion
resistant materials and/or primers and topcoats.
Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s.
NOTE: REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION
SHEET INCLUDED IN THE PARTS KITS.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation
No:
Description Amount
23-85-86-90 Perform Repair Procedure A- Surface
Corrosion (Rusted) - One Side
1.7 Hrs.
23-85-86-91 Perform Repair Procedure A- Surface
Corrosion (Rusted) - Both Side
2.6 Hrs.
23-85-86-92 Perform Repair Procedure B- Corrosion
Perforation(Rust Perforation) - One Side
3.9 Hrs.
23-85-86-93 Perform Repair Procedure B- Corrosion
Perforation (Rust Perforation) - Both Side
6.8 Hrs.
FAILURE CODE:
87 Rusted
P1 Rust Perforation

 

UPDATE:2008 GC SXT 3.3L Problems .......... From our member jfgator......
Took the van back to the dealer yesterday. The service writer called today to say that the problem that we have (windshield wipers going/washer fluid spraying, lights blinking, steady horn sound) replicated itself today when someone tried to use the remote to unlock it. They took it into the garage and did some inspecting. They found that the plastic container that holds the windshield washer fluid has a tiny hole in it, and the fluid was leaking onto a harness, which had corrosion on it. The harness is somehow connected to the TIP module. They are 99% sure that the fluid leaking onto that harness was causing the problem, and making the TIP module faulty. They will not replace the TIPM until they are 100% sure, but they are leaning towards replacing it and giving the van back to us. Hope that this helps someone in the future if they have the same problems...

 

INSTALLATION


NOTE: Perform Step #1 through Step #6 on each side of vehicle to complete pad set installation, then proceed to Step #7 .

CAUTION: Anytime the brake rotor or brake pads are being replaced, the rear caliper piston must be seated (bottomed) to compensate for the new brake rotor or lining. Because the parking brake self-adjuster mechanism is attached to the piston, a special seating method is required. The only acceptable method is by rotating the piston back into the bore using Retractor, Special Tool 8807, as described below. Any other seating method will damage the self-adjuster mechanism.




1. If necessary, seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3).
b. Insert the extension through Special Tool 8807–1 (2).
c. Place Special Tool 8807–2 (1) on the end of the extension.
d. Insert lugs on Special Tool 8807–2 into notches in face of caliper piston (5).
e. Thread the screw drive on 8807–1 down until it contacts the top of 8807–2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur.
f. Turn 8807–2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807–1 with 8807–2 to start the process of piston retraction.




2. Make sure abutment shims (4) are in place on both upper and lower slide abutments of caliper adapter (3).

NOTE: If the brake pads have a protective paper on the rear face of the brake pad plate, it must be removed before pad installation.
3. Place the brake pads (2, 5) in the abutment shims (3) clipped into the disc brake caliper adapter bracket (3) as shown.




CAUTION: Use care when installing the caliper (2) onto the adapter bracket to avoid damaging the guide pin boots.


4. Install the disc brake caliper (2) over the brake pads on the brake caliper adapter bracket.

CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head.


5. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper and lower caliper guide pin bolts (1). Tighten the guide pin bolts to 35 Nˇm (26 ft. lbs.).




6. Install tire and wheel assembly (1) (Refer to 22 - Tires and Wheels - Installation) . Install and tighten wheel mounting nuts (3) to 135 Nˇm (100 ft. lbs.).


7. Lower vehicle.
8. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
9. Check and adjust brake fluid level as necessary.
10. Road test vehicle and make several stops to wear off any foreign material on brakes and to seat brake pads.

 

NUMBER: 24-007-02

SUBJECT:
A/C Temperature Differential (Stratification) Between Left and Right Front Panel Outlets
OVERVIEW:
This bulletin involves diagnosing A/C temperature difference (stratification)
between the left and right front panel outlets.
MODELS:
2001 - 2002 (RS) Town & Country/Caravan/Voyager
2001 - 2002 (RG) Chrysler Voyager (International Markets)
NOTE: THIS BULLETIN APPLIES TO RS/RG VEHICLES EQUIPPED
WITH DUAL ZONE MANUAL (HAD), 3 ZONE MANUAL (HAG), OR ATC
(HAH) CLIMATE CONTROL SYSTEMS
SYMPTOM/CONDITION:
More than 12 F. warmer outlet air temperature on the left front panel outlet as compared
to the right front panel outlet when the HVAC controls are set to max cold.
DIAGNOSIS:
Set the A/C controls so that the compressor is engaged, the air within the vehicle is being
recirculated, the output air is being directed through the panel outlets, the temperature
control is in the full cool position, and the front and rear (if equipped with rear A/C) blower
motor(s) are operating at their highest speed. Use a temperature probe to measure the
front left and right panel outlet temperatures. If the difference between the two panel
outlets is greater than 12 F, perform the diagnostic procedure below.
EQUIPMENT REQUIRED:
CH6000 Scan Tool DRBIII
CH7000/7001 J1962 Cable
DIAGNOSTIC PROCEDURE:
1. Connect DRBIIIŽ and check for A/C related Diagnostic Test Codes (DTC). If DTCs
are present, repair them using appropriate body diagnostic manual (Heating
& A/C section for manual systems and Automatic Temperature Control section
for ATC systems) and clear any fault codes related to A/C.
2. Use DRBIIIŽ to perform a Heater - A/C Control Calibration as outlined in the
appropriate Service Manual (section 24, Controls - Front).
a. If calibration passes, recheck the A/C panel outlet temperature stratifiaction.
24-007-02 -2-
b. If the calibration fails: Use the DRBIIIŽ for further diagnosis of the DTC’s in the
appropriate body diagnostic manual (Heating & A/C Diagnostic section) and correct
the problem. After calibration is successful, check the A/C panel outlet stratification.
3. Use the DRBIIIŽ to perform an A/C Cool Down Test as outlined in the appropriate
service manual (section 24, Diagnosis and testing).
a. If the cool down test fails, proceed to A/C Performance Test and verify
performance against the temperature and pressure chart in the service
manual (Section 24, Diagnosis and Testing). Add refrigerant if necessary
and check the A/C panel outlet stratification.
4. Perform diagnosis and testing of expansion valve as described in the appropriate
service manual (section 24, Plumbing - Front, Expansion Valve).
a. If the expansion valve fails the test - replace the expansion valve as described
in the service manual and proceed to step 5 of this procedure.
b. If the expansion valve passes, review the warranty history for previous
compressor failures. If a compressor has previously failed and the expansion
valve and/or receiver/drier was not replaced at that time, replace both
the expansion valve and receiver/drier.
5. Compare A/C system pressures to the A/C performance chart in the appropriate
service manual and recheck for panel outlet stratification.
6. If greater than 12 F. stratification exist, replace the evaporator and receiver/drier
following procedures in the appropriate service manual