Chrysler RG Voyager. Manual — part 745
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Using a trim stick (special tool # C-4755) or
equivalent, gently pry the leading upper edge of the
B-pillar switch away from the B-pillar trim.
(3) Once the upper edge is free from B-pillar trim,
rock the switch out of the switch opening.
(4) Disconnect the B-pillar switch electrical con-
nector. First, slide the connector lock away from the
switch then, depress connector retaining tab while
pulling straight apart.
(5) Remove the B-pillar switch from the vehicle.
INSTALLATION
(1) Connect the B-pillar switch electrical connector.
Slide connector lock toward the switch to lock in place.
(2) Hook the lower edge of the B-pillar switch on
the B-pillar trim and then push the switch firmly
into position.
(3) Connect the battery negative cable.
LOWER DRIVE UNIT
DESCRIPTION
The lower drive unit is located on the power sliding
door lower hinge assembly (Fig. 11). This drive unit
is used to transfer the rotation of the flex drive
assembly into longitudinal movement via the drive
unit gear and door track rack teeth (Fig. 11).
OPERATION
During a power open or close cycle, the power drive
unit is driven by the flex drive assembly. The lower
drive units main gear engages the lower door tracks
rack teeth, this moves the power sliding door assem-
bly accordingly.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Open the appropriate sliding door and remove
the lower drive unit cover retaining screws (Fig. 12).
(3) Remove the lower drive unit retaining fasten-
ers (Fig. 13).
(4) Disconnect the flex drive assembly from the
lower drive unit. Expand the flex drive collar until
the lower drive unit can be pulled straight off.
(5) Remove the lower drive unit from the vehicle.
INSTALLATION
(1) Position the lower drive unit near the lower
hinge.
(2) Connect the flex drive assembly on the lower
drive unit. Push the flex drive collar straight on until
the it snaps in place (Fig. 14). It may be necessary
to rotate the drive unit slightly until the flex
drive seats in place.
(3) Install the lower drive unit retaining fasteners
(Fig. 15). Torque the larger allen headed center stud
Fig. 11 LOWER DRIVE UNIT
1 - LOWER DRIVE UNIT
2 - FLEX DRIVE ASSEMBLY
Fig. 12 SLIDING DOOR LOWER HINGE ASSEMBLY
1 - LOWER DRIVE UNIT COVER
2 - LOWER DRIVE UNIT COVER RETAINING SCREWS
3 - SLIDING DOOR
4 - LOWER HINGE ARM BRACKET
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POWER SLIDING DOOR SYSTEM
8N - 53
B-PILLAR SWITCH (Continued)
to 9 N·m (80 in. lbs.). Torque the smaller screw to 3
N·m (28 in. lbs.).
(4) Install the lower drive unit cover and retaining
screws (Fig. 16).
(5) Connect the battery negative cable.
Fig. 13 LOWER DRIVE UNIT RETAINING
FASTENERS
1 - LOWER DRIVE UNIT RETAINING SCREW
2 - DO NOT REMOVE
3 - LOWER DRIVE UNIT RETAINING BOLT
Fig. 14 LOWER DRIVE UNIT
1 - LOWER DRIVE UNIT
2 - FLEX DRIVE ASSEMBLY
Fig. 15 LOWER DRIVE UNIT RETAINING
FASTENERS
1 - LOWER DRIVE UNIT RETAINING SCREW
2 - DO NOT REMOVE
3 - LOWER DRIVE UNIT RETAINING BOLT
Fig. 16 SLIDING DOOR LOWER HINGE ASSEMBLY
1 - LOWER DRIVE UNIT COVER
2 - LOWER DRIVE UNIT COVER RETAINING SCREWS
3 - SLIDING DOOR
4 - LOWER HINGE ARM BRACKET
8N - 54
POWER SLIDING DOOR SYSTEM
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LOWER DRIVE UNIT (Continued)
FLEX DRIVE
DESCRIPTION
The flex drive assembly is located in the lower por-
tion of the power sliding door (Fig. 17) and is used to
connect the door motor to the lower drive unit. An
E-clip is used to secure the flex drive to the motor
assembly, while the flex drive collar is used to secure
the drive to the lower drive unit. The flex drive
assembly is basically a flexible drive shaft for the
power sliding door system. The flex drive assembly is
a replaceable component.
OPERATION
With one end of the flex drive attached to the door
motor and the other attached to the lower drive unit,
the flex drive transfers the power and torque from
the motor to the drive unit. A square shaped drive
cable, inside the flex drive assembly engages the
motor drive and rotates to move the door accordingly.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the appropriate sliding door trim
panel, (Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - REMOVAL).
(3) Position the weathershield aside to gain access
to the flex drive assembly.
(4) Remove the E-clip from the flex drive assembly
(Fig. 18).
(5) Pull the flex drive straight out of the motor
assembly.
(6) Remove the lower drive unit cover retaining
screws and remove the cover (Fig. 19).
(7) Expand the flex drive collar, next to the lower
drive unit until the flex drive can be pulled straight
off the lower drive unit.
(8) Remove the flex drive assembly from the vehi-
cle.
INSTALLATION
(1) Position the flex drive assembly in the vehicle.
(2) Install the flex drive on the lower drive unit.
Push straight on until it snaps in place. It may be
necessary to rotate drive unit gear slightly until the
flex drive seats in place.
(3) Install the lower drive unit cover and retaining
screws (Fig. 20).
(4) Install the flex drive in the motor assembly.
Line up the square shaped inner shaft and push
straight on (Fig. 21).
(5) Install the E-clip on the flex drive assembly.
Fig. 17 POWER SLIDING DOOR COMPONENTS
1 - POWER SLIDING DOOR CONTROL MODULE
2 - MODULE RETAINING SCREW
3 - MODULE ELECTRICAL CONNECTORS
4 - DOOR MOTOR ASSEMBLY
5 - FLEX DRIVE ASSEMBLY
6 - DOOR MOTOR RETAINING FASTENERS
7 - DOOR MOTOR ELECTRICAL CONNECTOR
Fig. 18 FLEX DRIVE E-CLIP
1 - FLEX DRIVE CABLE RETAINING CLIP
2 - FLEX DRIVE CABLE
3 - DOOR MOTOR ASSEMBLY
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POWER SLIDING DOOR SYSTEM
8N - 55
(6) Install the weathershield.
(7) Install the sliding door trim panel, (Refer to 23
- BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION).
(8) Connect the battery negative cable.
LOWER DRIVE UNIT TRACK &
RACK
DESCRIPTION
The door track and rack assembly provides a mat-
ing rack gear (Fig. 22) for the lower drive unit to
engage. The track also accepts the lower hinge roll-
ers, which helps support the weight of the sliding
door as well as providing a smooth surface for the
hinge rollers to move upon. The lower door track is a
replaceable component.
OPERATION
With the start of a power sliding door open cycle,
the door motor drives the flex drive assembly. The
flex drive assembly drives the lower drive unit. A
metal drive gear which is part of the lower drive
unit, meshes with the door track rack teeth and
moves the sliding door into the full open position.
The same operation repeats itself, during a power
close cycle only the system rotates in the opposite
direction.
Fig. 19 LOWER HINGE/DRIVE ASSEMBLY
1 - LOWER DRIVE UNIT COVER
2 - LOWER DRIVE UNIT COVER RETAINING SCREWS
3 - SLIDING DOOR
4 - LOWER HINGE ARM BRACKET
Fig. 20 LOWER HINGE/DRIVE ASSEMBLY
1 - LOWER DRIVE UNIT COVER
2 - LOWER DRIVE UNIT COVER RETAINING SCREWS
3 - SLIDING DOOR
4 - LOWER HINGE ARM BRACKET
Fig. 21 FLEX DRIVE CABLE
1 - DOOR MOTOR
2 - FLEX DRIVE COLLAR
3 - FLEX DRIVE INNER SHAFT
8N - 56
POWER SLIDING DOOR SYSTEM
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FLEX DRIVE (Continued)
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