M/T - Poor Shift Quality/High Shift Effort
NUMBER: 21-002-03GROUP: Transmission
DATE: Feb. 14, 2003
THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL FEB. 21, 2003.
SUBJECT:
Poor Shift Quality
OVERVIEW:
This bulletin involves installing a revised transaxle selector shift lever.
MODELS:
2001 - 2003 (RG) Chrysler Voyager (International Markets)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L GAS ENGINE (SALES CODE EDZ) OR 2.5L TURBO DIESEL ENGINE (SALES CODE ENC OR EDJ) AND A T-850 MANUAL TRANSAXLE (SALES CODE DDR).
SYMPTOM/CONDITION:
Customer may describe poor shift quality, or high shift effort.
DIAGNOSIS:
If the customer's description matches the Symptom/Condition, perform Repair Procedure.
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Open the hood.
2. 2.4L gas vehicles go to step 7. 2.5L Turbo Diesel vehicles, remove battery thermal shield.
3. Remove battery hold down nut, clamp and battery.
4. Remove battery tray. Disconnect battery temperature sensor.
5. Remove coolant recovery bottle from bracket.
6. Remove coolant recovery bottle mounting bracket.
7. Disconnect crossover cable from transaxle crossover lever (Fig. 1).
8. Disconnect selector cable from transaxle selector lever (Fig. 1).
9. Using a 5.0 mm (0.196 in.) pin punch, remove the double roll pin from the selector lever.
10. Remove the lever from the shaft.
11. Place the new selector lever (p/n 05104812AA) on the shaft in the same orientation that the old lever was removed, being careful to line up the hole in the lever and shaft.
12. Install the double roll pin as follows:
a. Start the large roll pin into the lever just far enough to engage the shaft.
b. Start the small roll pin into the large roll pin.
c. Finish driving both roll pins into the lever until they are both flush with the lever.
13. Install the selector cable onto the transaxle selector lever.
14. Install the crossover cable onto the transaxle crossover lever.
15. Verify the shifter is operating properly.
16. 2.4L gas vehicles go to step 21. 2.5L Turbo Diesel vehicles, install the coolant recovery bottle mounting bracket.
17. Install the coolant recovery bottle in the bracket.
18. Connect battery temperature sensor. Install battery tray.
19. Install battery, clamp and hold down nut.
20. Install battery thermal shield.
21. Close the hood.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: