Chrysler Repair Questions? Ask a Mechanic for Answers ASAP
Do both doors work intermittently.Does it sometimes open about a foot and then stop?
The most common problems with the sliders are the wiring harness at the bottom of the door track.These wiring harnesses bend and flex so much that the wires inside the harness conduit break a give several different problems.
These doors have a bunch of problems and a a couple of different bulletins to fix them.
One of the repairs for the liftgate involves "reflashing " the module which would have to be done at the dealership.
How handy are you? And how indepth do you want to go?
I would be more than willing to help any way I can.Would you like me to send you the bulletins and then you can decide what you want to do?
Reflashing the module involves hooking the dealership scanner and downloading new software into the module.
Here are the bulletins.
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-035-00
REV. A, DATED OCT. 27, 2000, WHICH SHOULD BE REMOVED FROM
YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS**
HAVE BEEN USED TO HIGHLIGHT CHANGES.
Power Mode Closes Lift Gate But Does Not Open The Lift Gate
NOTE: THIS BULLETIN SHOULD BE PERFORMED ON ALL IN STOCK VEHICLES
BUILT BEFORE NOVEMBER 13, 2000 (MDH1113XX).
This bulletin involves flashing the Power Lift Gate (PLG) module and resetting
obstacle detection values. Adjusting the lift gate striker and/or installing lift
gate overslam bumper shims may also be required.
2001 (RS) Town & Country/Caravan/Voyager
2001 (RG) Chrysler Voyager (International Markets)
The PLG functions in the power closing mode but not the opening mode. The lift gate
is not flush with the tail lights. Low seal load prevents the lift gate from "popping off"
and moving the lift gate latch out of the primary latching position.
Power operate the lift gate to open with the Remote Keyless Entry (RKE) Fob
or button in the overhead console. If the lift gate does not move out of the
primary latching position, perform Repair Procedure 1.
Inspect the lift gate for flushness to the body above and below the tail lamps. If the lift gate is
underflush to the body above the tail lamp and underflush or flush below the tail lamp, go to
Procedure 2A. If the lift gate is flush or overflush to the body above and below the tail lamp,
go to Procedure 2B. If the lift gate is flush or underflush to the body above the tail lamps and
over flush below the tail lamp AND the difference is more than 5mm, go to Procedure
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-013-01
DATED JUNE 22, 2001, WHICH SHOULD BE REMOVED FROM YOUR
FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE
BEEN USED TO HIGHLIGHT CHANGES.
Sliding Door Difficult To Open Or Close, B-Pillar Weatherstrip Missing, Deformed, Or Loose
This bulletin involves installing tape strips to the inside sliding door glass and
replacing both sliding door B-pillar weatherstrips.
One or both sliding doors may be difficult to open or close. Vehicles equipped
with power sliding door(s) may have incidents of false obstacle detection whereas
the door reverses direction during the closing cycle. Also, the sliding door B-pillar
weatherstrip may be loose, deformed, or missing.
With the sliding doors closed, inspect both B-pillar weatherstrips' position against
the front doors. If the weatherstrips are pinched or deformed between the front and
sliding door, perform the Repair Procedure. Open the sliding doors and inspect
both B-pillar weatherstrips for looseness. If either of the B-pillar weatherstrips
are loose or missing, perform the Repair Procedure.
Qty. Part No. Description
2 04717678AD Weatherstrip, Sliding Door B-Pillar
4 04278178 Tape Strip
1. Remove the existing B-pillar weatherstrip from the sliding door and clean
the surface with isopropyl alcohol.
2. Apply two tape strips to the inside front edge of the sliding door glass as shown in (Fig.
1). Position one tape strip 1/3 down from the top of the glass and the other 1/3 up from
the bottom of the glass. With backing removed and the adhesive side towards the inside
Power Sliding Door Reverses Direction During the Power Close Cycle,
False Obstacle Detection
This bulletin involves checking for contact between the power sliding door
hold-open latch and the sliding door weatherstrip, and grinding away a section
of metal from the lower B-pillar/rocker panel area.
2001 - 2002 (RS) Town & Country/Caravan/Voyager
2001 - 2002 (RG) Chrysler Voyager (International Market)
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH POWER SLIDING
DOOR(S), SALES CODES JRA (RIGHT) OR JRB (LEFT).
Near the end of the power close cycle, the power sliding door reverses direction. This
condition can be intermittent and may occur on one or both power sliding doors.
Inspect the sliding door B-pillar weatherstrip located at the front edge of the sliding door
glass. If the weatherstrip is deformed or the lip of the weatherstrip is rolled over, refer to
TSB 23-013-01 Rev. A, dated Dec. 14, 2001 before proceeding with this bulletin.
Inspect for contact between the power sliding door hold-open latch and
the sliding door weatherstrip:
1. With the sliding door open, closely examine the sliding door weatherstrip near
the B-pillar/sill area for witness marks (dull spots, scraping, or cuts) as shown
in (Fig. 1). If no witness marks are evident, proceed to step 2. If witness
marks are evident, perform the Repair Procedure.
Fig. 1 WEATHERSTRIP INSPECTION AREA
1 - INSPECT WEATHERSTIP BETWEEN PLASTIC SILL PLATE COVER AND SEAM IN ROCKER PANEL
2 - BOTTOM OF B-PILLAR
3 - PLASTIC SILL PLATE COVER
2. Use a business or index card to check the clearance between the sliding door
hold-open latch and the weatherstrip as shown in (Fig. 2). If there is clearance
between the hold-open latch and the weatherstrip using a card, refer to the 2002
RS Service Manual or MDS2, Power Sliding Door Systems for further diagnosis.
If there is no clearance using a card, perform the Repair Procedure.
Fig. 2 CLEARANCE CHECK
1 - SLIDING DOOR
2 - SLIDING DOOR HOLD OPEN LATCH
3 - CARD
4 - WEATHER STRIP
2 - BOTTOM EDGE OF B-PILLAR
AR 82300508 Corrosion Inhibitor
AR 04773774 Weatherstrip Adhesive
NPN Die Grinder
1. Open the sliding door.
2. Remove the plastic sill plate cover using a trim stick.
3. From the splice at the bottom center of the door opening, pull back weatherstrip past
B-pillar/sill area. Clean the off excessive weatherstrip adhesive from the metal.
4. Mark the area of metal at the B-pillar/rocker panel to be removed as shown in (Fig. 3)
Fig. 3 GRIND LOCATION
1 - SILL
2 - GRIND 4 MM (0.16") OF METAL
3 - SEAM IN ROCKER PANEL
4 - GRIND LOCATION BETWEEN SILL AND SEAM IN ROCKER PANEL
5. Place a fender cover or another appropriate cover over the carpet and seat.
WARNING: USE OF PROPER EYE PROTECTION IS REQUIRED FOR STEPS 6
THROUGH 8. LACK OF PROPER EYE PROTECTION MAY CAUSE PERSONAL INJURY.
6. Using a die grinder, grind away 4 mm of metal from the area marked.
Make sure to taper the ends of the cut.
7. Use a file to smooth the cut area.
8. Clean off the area using compressed air.
9. Apply corrosion inhibitor p/n 82300508 or equivalent to exposed bare metal.
10. Apply weatherstrip adhesive, p/n 04773374, to sliding door weatherstrip channel
and install insuring that the weatherstrip is properly seated.
11. Install the plastic sill plate cover.
12. Operate the power sliding door multiple times insuring proper power
door closing cycle operation.
Reimbursable within the provisions of the warranty.
23-85-04-93 Grind B-Pillar/Sill Area, One Sliding Door 0.4 Hrs.
23-85-04-94 Grind B-Pillar/Sill Area, Both Sliding Doors 0.7 Hrs.
61 Intermittent Op
You didn't think I was done did you?
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-020-07, DATED
JUNE 2, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ELECTRICAL
Power Sliding Door Adjustment And Diagnosis Aid
This bulletin involves specific procedures for checking sliding door alignment and
adjustment **and checking for correct states of Power Sliding Door Module (PSDM)
inputs.** These Repair Procedures should be followed prior to replacement of any parts.
2001 - 2007 RG Chrysler Voyager (International Markets)
2001 - 2007 RS Town & Country/Caravan/Voyager
NOTE: This bulletin applies to RG/RS vehicles equipped with Power Sliding Door(s)
(Sales code JRA or JRB)
**SPECIAL TOOLS/EQUIPMENT REQUIRED:**
CH6000A Scan Tool (DRBIII®)
CH7000A/7001A J1962 Cable with red DRBIII® connector
Power Sliding Door(s) out of adjustment **and addition of an electrical diagnostic chart**.
This Service Bulletin is being released because accurate sliding door adjustment
procedures are not currently available in DealerCONNECT > TechCONNECT at this time.
The service information will be updated soon.
**This bulletin also provides additional information and tips to assist technicians with
electrically diagnosing the Power Sliding Door.**
NOTE: **Door adjustment should be checked and corrected first then diagnose
electrical issues concerning the Power Sliding Door.**
NUMBER: 23-020-07 REV. A
DATE: September 27, 2007
ADJUSTMENT REPAIR PROCEDURE:
1. Before replacing any parts, check and adjust sliding door to vehicle body side
aperture, (spacing), margins, flushness and seal gap. Recommended tolerances to be
a. Check door height using body character lines as an up/down reference. Also use
roof contour as a reference factor. (This may vary slightly for proper striker
b. Check C-pillar and B-pillar for door spacing from door to door and door to glass or
rear quarter panel. All spacing should be 5 mm, +/- 1 mm (0.200 in +/- .040 in) and
uniform top to bottom at each pillar.
c. Sliding door at B-pillar, (to front door); sliding door sheet metal, (below glass),
should be flush to 1.5 mm, (.060 in) inboard of front door sheet metal.
d. Sliding door at C-pillar, (to rear quarter panel sheet metal); sliding door sheet metal,
(below glass), should be flush to 1.5 mm, (.060 in) outboard of rear quarter panel
e. Visually inspect the sliding door C-pillar striker alignment to latch. Striker MUST go
straight into the latching mechanism.
f. On the left door, check the fuel door blocker striker entry into latch. Striker at this
point must not affect alignment.
2. **Does the power sliding door require adjustment?
a. Yes >>> Proceed to Step #3
b. No >>> Proceed to POWER SLIDING DOOR ELECTRICAL DIAGNOSIS.**
NOTE: For the purpose of this document, the lower roller and "L" bracket assembly,
(located at the lower front corner of the sliding door), will be referenced as
the lower hinge.
NOTE: If adjustments are required, both Male Stabilizers on the front of the sliding
door and Upper Guide Roller should be loosened and remain loose during
the adjustment process so they do not influence door position, (Fig. 1).
23-020-07 REV. A -2-
Fig. 1 UPPER ROLLER AND FRONT STABILIZER
1 - Upper Guide Roller
2 - Front Stabilizer, Upper Shown, Lower Similar
NOTE: If the vehicle has a fault code 1B, ignore this until after the Repair Procedure
is completed. If the vehicle has a fault code 1C, and the sliding door is
functioning, ignore this until after the Repair Procedure is completed. If the
door is not functioning, check door alignment and fit as described below
before performing diagnosis procedure for fault code.
NOTE: IF A DOOR WILL NOT OPEN: Hold handle out, (release position) for 30
seconds. Listen for mechanism attempting to release, then push in on rear of
sliding door to unload latch. Door should open.
3. Preliminary Striker Adjustment
4. This is a preliminary adjustment of the striker. This preliminary adjustment should be
performed if the striker is influencing the door position. Final adjustment will be made
later in the Repair Procedure. Mark current location of striker perimeter, (Fig. 2), then
loosen both bolts of striker assembly, remove only 1 bolt at a time, (so that inner
threaded plate will not fall between inner and outer panels). Rotate striker out of the
way, (then snug remaining bolt). The plate with the nuts attached inside the post have
ample room to grind or file without rotating plate out of the way. Elongate the hole(s)
by grinding or filing the sheet metal and painting the raw edge to prevent rusting.
Repeat this procedure for the other striker mounting bolt hole as required. Install
striker to desired position and recheck flushness, (Fig. 3). Rear of the sliding door
should be flush to 1.5 mm, (.060 in) outboard of rear quarter panel sheet metal.
-3- 23-020-07 REV. A
Fig. 2 STRIKER, MARKED AROUND OUTSIDE
1 - Mark Perimeter of Striker for Adjustment Reference
Fig. 3 STRIKER ROTATED
1 - Striker Rotated
2 - Threaded Plate Does Not to be Rotated For Grinding Procedure.
3 - Elongate Body Sheet Metal to Position Striker as Desired.
23-020-07 REV. A -4-
NOTE: Adjust Lower Hinge for up and down adjustment. Adjust center hinge to
adjust fore and aft adjustment. Be aware that adjusting either hinge will
cause the door to rotate about the other hinges load roller.
6. Visually inspect the sliding door height by checking the alignment of the character lines
to the quarter panel and front door (Fig. 4).
a. If the sliding door height is correct, proceed to >>>Step #19.
b. If the sliding door height is incorrect at the C-pillar, proceed to >>> Step #7.
c. If the sliding door height is incorrect at B-pillar, proceed to >>>Step #10.
Fig. 4 BODY CHARACTER LINES
1 - Sliding Door Character Lines
2 - Rear Quarter Panel Character Lines
3 - Front Door Character Lines
-5- 23-020-07 REV. A
7. Open door to mid-point of travel. Note the vertical jack screw as shown in (Fig. 5).
Fig. 5 CENTER HINGE AND ADJUSTER
1 - Center Hinge On Sliding Door
2 - Hinge Mounting Bolts
3 - Center Hinge Jack Screw
8. Adjustments of the sliding door height at the C-pillar can be accomplished by turning
the center hinge jack screw. Turn the bolt clockwise to raise door and
counterclockwise to lower door (Fig. 5).
9. Verify alignment, readjust if necessary.
10. Does the sliding door height require adjustment at B-pillar?
a. Yes, proceed to >>> Step #11.
b. No, proceed to >>> Step #19
23-020-07 REV. A -6-
11. Remove access plug in the sliding door trim panel, (lower front corner) (Fig. 6).
Fig. 6 LOWER HINGE
1 - Lower Hinge Assembly
2 - Hinge Lower Mounting Bolts are Accessible Under Door Panel
3 - Remove Access Plug to Loosen Upper Mounting Bolt
CAUTION: Do not loosen the bolts attaching the L bracket to the roller arm on the
lower hinge assembly.
12. Open door to mid-point of travel.
13. Mark outline of lower hinge arm bracket on sliding door to assist in making
14. Support sliding door at the bottom with protected floor jack.
15. Loosen lower hinge arm bracket bolts.
16. Move lower hinge arm up to lower door and down to raise door.
17. Tighten lower hinge arm bracket bolts to 13 Nm, (115 in-lbs) torque.
18. Verify alignment, readjust if necessary.
19. Door Gap Adjustment - FORE/AFT:
20. Check B-pillar and C-pillar for door aperture, (spacing), gaps and door to door gaps.
All spacing should be 5 mm, +/- 1 mm (0.200 in +/- .040 in) and uniform top to bottom.
Do sliding door gaps require adjustment?
a. Yes >> go to next step.
b. No >> go to Step #35
21. If adjustment is required, mark the outline of the center hinge bracket on the door.
Loosen center hinge bolts as necessary to move center hinge forward or rearward.
Moving the hinge rearward on the door increases the gap at the C-pillar and
decreases the gap at the B-pillar. Moving the hinge forward on the door decreases the
gap at the C-pillar and increases the gap at the B-pillar.
22. Snug center hinge bolts.
23. Close door and check door alignment.
-7- 23-020-07 REV. A
24. Verify alignment, readjust if necessary.
25. Tighten center hinge bolts to 13 Nm, (115 in-lbs) torque.
26. Door Flushness:
27. Loosen both male stabilizers on the front of the sliding door and upper guide roller.
28. Check flushness of sliding door at C-pillar, (rear quarter panel sheet metal to sliding
door sheet metal); sliding door should be flush to 1.5 mm, (.060 in) outboard of rear
quarter panel. Check flushness of sliding door at B-pillar; (to front door sheet metal
and sliding door sheet metal). Sliding door should be flush to 1.5 mm, (.060 in)
inboard of front door. Which adjustment is required?
a. If the rear of the sliding door needs to be adjusted for flushness at C-pillar, go to >>
b. If the front of the sliding door needs to be adjusted for flushness at B-pillar, go to >>
c. If the sliding door does NOT need to be adjusted for flushness, go to >> Step #33.
29. Check the upper front corner of sliding door of sliding door sheet metal, (above glass),
(B-pillar) flushness to sheet metal (above front door glass). Check the upper rear
corner of sliding door of sliding door sheet metal, (above glass), (C-pillar) flushness to
sheet metal (above rear quarter glass).
NOTE: Protect surface of door as needed while making this adjustment.
30. To adjust the upper part of the sliding door at B-pillar, (above glass), use a heavy
rubber mallet on the door assembly, lightly tapping door top in or out as necessary.
31. To adjust the upper rear corner, (above glass), of the sliding door at C-pillar inboard or
outboard, use a heavy rubber mallet on the door assembly, lightly tapping door top in
or out as necessary.
NOTE: Correctly adjusting door flushness should correct Door Seal Compression.
Refer to Step #38 for procedure to check door seal compression WHILE
MAKING door adjustments.
32. Final Striker Adjustment
33. Remark current location of striker perimeter, (Fig. 2) above, then loosen both bolts of
striker assembly, remove only 1 bolt at a time, (so that inner threaded plate will not fall
between inner and outer panels). Rotate striker plate out of the way, (then snug
remaining bolt). Elongate the hole(s) by grinding or filing the sheet metal and painting
the raw edge to prevent rusting. The plate with the nuts attached inside the post have
ample room to grind or file without rotating plate out of the way. Repeat this procedure
for the other striker mounting bolt hole as required. Install striker to desired position
and recheck flushness, (Fig. 3) above. Back of sliding door should be flush to 1.5 mm,
(.060 in) outboard of rear quarter panel sheet metal.
34. Verify alignment, readjust if necessary.
35. Door Seal Compression:
36. After flush and gap adjustments have been made, door seal compression should be
correct. The only variable that can be adjusted is the top of the sliding door at B-pillar.
This can be adjusted slightly using the upper roller arm to set the top of sliding door
37. Snug the upper roller bolts loosened in step #1.
NOTE: If other areas of the sliding door need adjustment for door seal compression,
refer back to sliding door flushness adjustments to correct, Step #28.
23-020-07 REV. A -8-
38. To check the Door Seal Compression, place a piece of paper across door seal and
close door. Pull paper out of door opening. If paper tears, setting is too tight. If paper
slides through too easily, the compression is insufficient and needs to be adjusted.
Check seal compression around sliding door perimeter in the following 10 areas:
a. Mid point of upper header.
b. Top third of B-pillar, (mid way between character line and header).
c. Top third of C-pillar, (mid way between character line and header).
d. Bottom third of B-pillar, (mid way between character line and rocker panel).
e. Bottom third of C-pillar, (mid way between character line and rocker panel).
f. All 4 corners.
g. Mid point of rocker panel, bottom, center of sliding door.
39. Does the seal compression at the top of B-pillar require adjustment?
b. No >> go to Step #45
c. If seal compression is incorrect anywhere else on the sliding door, adjustments
must be made using procedures starting at Step #28 above.
40. To adjust for less seal compression at the top of the B-pillar seal, first open door to
mid-point of travel.
41. Loosen bolts attaching upper roller arm to door.
42. Install necessary 1 mm shim(s), p/n 04894494AA, to move upper corner of sliding door
at B-pillar for less seal compression.
43. Tighten upper roller bracket. Tighten bolts to 13 Nm, (115 in-lbs) torque.
44. Perform paper test in Step #38 to verify proper adjustment.
45. Stabilizer Adjustment - UPPER/LOWER:
46. Open sliding door.
47. Finger tighten the bolts, (loosened in Step #1), holding the upper and lower male
stabilizer to the front of the sliding door only enough so that the stabilizers can move,
but not too freely. Be sure compressed washer(s) are out of dimples.
48. Open and close sliding door 3 times.
49. Open sliding door just enough to reach in and hold lower stabilizer in place.
50. Tighten lower stabilizer bolts.
51. Open and close sliding door 3 times.
52. Open sliding door just enough to reach in and hold upper stabilizer in place.
53. Tighten upper stabilizer bolts.
-9- 23-020-07 REV. A
54. After all adjustments are complete, double check alignment of the fuel door striker into
the blocker latch on the left sliding door, and the latch to striker alignment at the rear of
both sliding doors. These MUST go straight into the latching mechanisms (Fig. 7) and
Fig. 7 LEFT LATCH AND FUEL DOOR BLOCKER
1 - Sliding Door Latch Mechanism
2 - Sliding Door Striker
3 - Fuel Door Blocker Latch Mechanism, LH Door Only
4 - Fuel Door Blocker Striker, LH Door Only
23-020-07 REV. A -10-
Fig. 8 LEFT REAR LATCH, VIEW FROM INSIDE VEHICLE
1 - Upper Portion of Latch Mechanism, (on Sliding Door)
2 - Striker, (on Body of Vehicle)
3 - Lower Portion of Latch Mechanism, (on Sliding Door)
-11- 23-020-07 REV. A
**POWER SLIDING DOOR ELECTRICAL DIAGNOSIS:
The Power Sliding Door (PSD) may not power open OR will power open but will not power
close when utilizing the Remote Keyless Entry (RKE) transmitter OR switches located
inside the vehicle.
NOTE: The following table provides information about normal switch states that can
be read with the DRBIII®. This information will be valuable when making
Input Normal FULL
Open Closed Closed Primary/Ajar switch, internal to
the latch. Open when latch is in
primary, Closed when latch is
out of primary.
Open Closed Closed Internal to the latch. Indicates
when the latch pawl has
secured the latch in primary or
secondary. Goes Open when
entering secondary latch
position. Closed when out of
secondary and primary.
Open Closed Open Located on lower roller.
Indicates when the door is in
the hold open latch position.
Closed when full open. Open
23-020-07 REV. A -12-
Input Normal/Not Pressed Pressed Description
Open Closed Located in latch. Normally
Open. Closed to ground
when inside or outside
handle are activated. Also
closes to ground when
the latch is in the process
of a power release.
Lock Switch Unlocked = Closed Locked = Open Located in latch. Indicates
lock status for the sliding
door. Used to inhibit
Pawl Switch - The pawl switch may behave differently depending on how hard the door is
closed. Check the switch reading by closing the latch just to the secondary position, with a
moderate slam to full closed (primary), and an aggressive slam to primary. If slamming of
the door to primary causes the pawl switch to remain closed when the latch is in primary,
Replace the latch.
Full Open Switch - If the full open switch always reads open, check the hold open latch
cable to make sure it isn't preventing the hold open latch from contacting the switch. An
easy way to check is to remove the hold open cable and then read the switch status with
the door fully open. If the cable is impacting the switch status, replace the hold open cable.
Latch Hesitating or Pausing During Cinch - Place the door in the mid point of travel.
Use a screwdriver to place the latch in the secondary position. If the latch still hesitates or
pauses during cinch, replace the latch.**
Labor Operation No: Description Amount
23-00-11-95 Door, Sliding/Side - Adjust/Align A/T
ZZ Service Action
-13- 23-020-07 REV. A
The thing I would check first is the wiring harness at the bottom of the sliding door.Get a small screw driver and take the "link" apart and pull each individual wire one at a time and see if there is a break in any of them.They can be repaired by soldering them back together.Here is a pic of the harness I'm talking about.
Yes, that is where it is at.
You have to take the "links" apart to check the wiring.This is by far the most problematic area.Take the links apart and pull each individual wire seperately.Usually one and sometime more are broken.