Vehicle Segment:
Full-size Minivan
Target Audience:
Families, individuals requiring flexible passenger and cargo space
Key Competitors:
Ford Windstar, Chevrolet Venture/Pontiac Montana/Oldsmobile Silhouette, Honda Odyssey, Toyota Sienna
Vehicle Appeal:
Spacious interior, versatile seating arrangements, comfortable ride, optional all-wheel drive (on some models/years)
Cost Savings:
Enables DIY repairs and maintenance, saving significant costs compared to professional labor rates.
Diy Savings Potential:
Hundreds to thousands of dollars in potential savings on repair bills.
Primary Coverage:
All Models, Engines, Trim Levels, and Transmission Types for Chrysler Grand Voyager 1996-2005
Specific Coverage Areas:
General Maintenance, Troubleshooting, Engine Service/Repair, Transmission Service/Repair, Brake System, Wiring Diagrams, Electrical System, Suspension, Periodic Lubrication, Steering, Cooling System, Fuel Injection/Fuel System, Emission System, Heater/Air Conditioning, Engine Control System, Chassis/Body, Restraint System, Interior, Differential/Drive, Axle
Estimated Page Count:
Hundreds (specific count not provided, typical for comprehensive workshop manuals)
Type:
Workshop Repair Service Manual
Source Quality:
Professional, original workshop manual quality, same used by local service/repair shops.
Powertrain:
Engine (service, repair, troubleshooting), Transmission (service, repair, troubleshooting), Fuel System (injection, components), Cooling System, Emission Control System, Exhaust System
Chassis:
Brake System (including ABS), Suspension System (front and rear), Steering System, Drive Axles, Differential, Wheel Alignment
Electrical:
Complete Electrical System Diagnosis, Wiring Diagrams, Engine Control System (ECU), Lighting, Instruments, Audio System, HVAC Controls, Power Accessories (windows, locks, mirrors), Restraint System (Airbags, Seatbelts)
Body:
Chassis and Body Repair, Interior Components, Exterior Body Panels, Doors, Hood, Tailgate, HVAC System (Heating and Air Conditioning)
Interior Comfort:
Heater/Air Conditioning System (HVAC) coverage
Powertrain Accessories:
Engine Control System diagnostics and repair.
Maintenance:
Scheduled Maintenance (oil changes, filter replacements, fluid checks), Periodic Lubrication, Belt Replacement, Spark Plug Replacement, Air Filter Replacement, Brake Pad/Rotor Replacement, Cooling System Flush, Battery Maintenance
Repair:
Engine Component Rebuilds (cylinder heads, pistons), Transmission Overhaul, Brake System Component Replacement (calipers, lines), Suspension Component Replacement (shocks, struts, control arms), Steering Component Replacement (tie rods, power steering pump), Electrical Component Diagnosis and Replacement, HVAC System Component Replacement, Body Panel Repair and Replacement, Interior Trim Repair
Diagnostics:
Troubleshooting Guides for Common and Specific Issues, Diagnostic Trouble Codes (DTCs) interpretation, Electrical System Diagnostics, Fuel System Diagnostics, Engine Performance Diagnostics, Transmission Performance Diagnostics
Diagnostics Electrical:
Combined troubleshooting and electrical service procedures with detailed wiring diagrams for ease of use.
Depth:
Comprehensive, Professional Technician Level. Includes detailed substeps, notes, cautions, warnings, and numbered instructions for all repair procedures. Offers detailed illustrations, drawings, and photos.
Diagrams Illustrations:
Hundreds of detailed illustrations, drawings, and photos for procedures; includes wiring diagrams.
Instruction Format:
Numbered instructions, detailed substeps, notes, cautions, and warnings for critical information.
Oil Change Interval:
Every 3,000-5,000 miles or 6 months, or as per vehicle's specific oil change indicator, using synthetic blend or full synthetic oil.
Transmission Fluid Change:
Every 30,000-60,000 miles, depending on driving conditions. ATF+4 fluid is typically specified.
Coolant Change:
Every 30,000-60,000 miles or 2-4 years for HOAT coolant.
Spark Plugs:
Recommended replacement every 60,000-100,000 miles depending on plug type (platinum/iridium).
Engine Oil Viscosity:
Typically 5W-30, but consult owner's manual for specific engine
Power Steering Fluid:
ATF+4 or specific Mopar power steering fluid
Brake Fluid:
DOT 3 or DOT 4 (check cap or manual)
Common Problem 1:
Transmission internal failures, particularly in earlier 42LE transmissions, often related to solenoid pack issues or torque converter clutch wear.
Common Problem 2:
Engine oil leaks from valve cover gaskets, oil pan gaskets, and crankshaft seals, especially on the 3.8L V6.
Common Problem 3:
Cooling system leaks from radiator, hoses, and water pump.
Common Problem 4:
Power sliding door mechanism issues (sticking, not operating).
Common Problem 5:
Heater core leaks, leading to coolant smell inside the cabin and defrosted windows.
Common Problem 6:
Wheel bearing wear, particularly on front wheels, leading to humming or grinding noises.
Brand Focus:
Chrysler has a long history in the minivan segment, pioneering the concept with the original Dodge Caravan/Plymouth Voyager.
Generation Notes:
This period (1996-2005) covers the second and third generations of the Chrysler minivan platform, with significant updates and redesigns.
Platform Designation:
This period aligns with the NS (North American) platform, evolving from its initial introduction.
Assembly Locations:
Primarily Windsor, Ontario, Canada
