Chrysler Aspen Complete Workshop Service Repair Manual 2006

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🏷️ Basic Information Identification Make: Chrysler Model: Aspen Year: 2006 Codes Chassis Code: HG (Second Generation) Platform: Chrysler HG platform (shared with Dodge Durango) 👋 Introduction Market Position Segment: Full-size Luxury SUV Target Audience: Families, towing needs, premium SUV buyers seeking comfort and capability. Competitive Analysis Key Competitors: Chevrolet Tahoe, GMC Yukon, Ford Expedition, Toyota Sequoia, Lincoln Navigator. Key Features Vehicle Platform: Built on Chrysler's HG platform, shared with the Dodge Durango, offering robust body-on-frame construction. Interior Amenities: Offered three rows of seating, premium interior materials, advanced infotainment options for its time. 📋 Manual Details Coverage Areas Documentation Type: Complete Workshop Service Repair Manual Primary Focus: Maintenance, Troubleshooting, Repair, Diagnostics, Wiring Diagrams Page Count Estimated Pages: Over 2000 (typical for comprehensive workshop manuals of this era) Manual Type Type: Factory Authorized Service Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, engine performance, fuel system, cooling system, exhaust system, transmission (automatic), drivetrain, driveline components Chassis: Suspension (front and rear), steering system, brake system (front and rear disc), ABS, traction control Electrical: Body control module (BCM), power distribution, lighting, instrumentation, HVAC controls, power accessories, security system, diagnostic trouble codes (DTCs), wiring diagrams Body Interior: Body panels, doors, glass, interior trim, seats, airbags, HVAC system, exterior trim Procedures Included Maintenance: Scheduled maintenance, fluid checks and changes, filter replacements, lubrication Repair: Component removal, installation, adjustment, overhaul, rebuild procedures for all major systems Diagnostics: Troubleshooting guides, symptom-based diagnostics, DTC lookup and interpretation, electrical circuit testing Technical Specifications: Torque specifications, clearances, pressures, electrical parameters, test procedures Technical Depth Depth: Comprehensive: Covers everything from basic fluid changes to complete engine and transmission rebuilds, including detailed electrical diagnostics and component-level troubleshooting. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Searchable text for quick information retrieval Print Quality: High-resolution scans of original factory manuals, optimized for clarity and detail. Binding Type Binding: N/A (Digital format) Paper Type Paper: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Code And Type: EZH (4.7L SOHC V8) Displacement: 4.7 Liters (285 cubic inches) Cylinder Arrangement: V8 Valve Train: Overhead Cam (SOHC) Bore X Stroke: 3.75 in x 3.30 in (95.3 mm x 83.8 mm) Compression Ratio: 9.0:1 Horsepower: 235 hp @ 4500 rpm Torque: 305 lb-ft @ 3600 rpm Fuel Type: Unleaded Gasoline Engine Variants Optional Engine Code And Type: 8LW (5.7L HEMI OHV V8) Optional Engine Displacement: 5.7 Liters (345 cubic inches) Optional Engine Horsepower: 335 hp @ 5000 rpm Optional Engine Torque: 370 lb-ft @ 3600 rpm Fuel System Injection Type: Sequential Multi-Port Fuel Injection (MPI) Fuel Pump Pressure: 39-49 PSI (269-338 kPa) for 4.7L; 58 PSI (400 kPa) for 5.7L HEMI Recommended Octane: 87 Octane (for 4.7L); 89 Octane recommended for 5.7L HEMI for optimal performance 🔧 Transmission Standard Transmission Type: 5-Speed Automatic (45RFE/545RFE) Gear Ratios 45Rfe 545Rfe: 1st: 3.00, 2nd: 1.67, 3rd: 1.00, 4th: 0.75, 5th: 0.67, Reverse: 2.23 Transmission Fluid Type: ATF+4 (Automatic Transmission Fluid) Transmission Fluid Capacity: Approx. 11.0 quarts (10.4 liters) for 45RFE/545RFE with filter change. Optional Optional Transmission: N/A (Only 5-Speed Automatic offered for 2006 Aspen) Features Drive System: Available in 2WD (RWD) and 4WD (Full-time, 4-Mode) Tow Haul Mode: Includes a 'Tow/Haul' mode to optimize shifting for towing heavy loads. 📐 Dimensions Exterior Length: 201.0 inches (5105 mm) Width: 75.0 inches (1905 mm) Height: 72.7 inches (1847 mm) Wheelbase: 119.0 inches (3023 mm) Front Track: 63.0 inches (1600 mm) Rear Track: 63.1 inches (1603 mm) Ground Clearance: 8.3 inches (211 mm) Interior Seating Capacity: 7 or 8 passengers (depending on configuration) Front Headroom: 40.7 inches (1034 mm) Second Row Headroom: 40.1 inches (1019 mm) Third Row Headroom: 38.9 inches (988 mm) Cargo Cargo Volume Behind 3Rd Row: 17.1 cu ft (484 liters) Cargo Volume Behind 2Nd Row: 49.8 cu ft (1410 liters) Cargo Volume Behind 1St Row: 84.7 cu ft (2398 liters) Weights Curb Weight: Approx. 5,200 - 5,600 lbs (2359 - 2540 kg) Gross Vehicle Weight Rating Gvwr: Approx. 6,700 - 7,000 lbs (3039 - 3175 kg) Towing Capacity: Up to 8,950 lbs (4060 kg) (when properly equipped with the 5.7L HEMI and tow package) 🛡️ Safety Features Ratings NHTSA Front Driver Crash Test: 5 Stars (for 2006 model year, specific rating may vary slightly) NHTSA Front Passenger Crash Test: 5 Stars (for 2006 model year, specific rating may vary slightly) IIHS Front Crash Rating: Good (for 2006 model year, specific rating may vary slightly) Active Features Traction Control: Standard on all models (Electronic Traction Control) Electronic Stability Control: ESP (Electronic Stability Program) - Standard on all models. Antilock Braking System: ABS (4-wheel disc brakes with ABS) - Standard. Passive Features Airbags: Driver and front-passenger airbags, supplemental front and rear side-curtain airbags. Seatbelts: Three-point seatbelts with pretensioners in all seating positions. Child Seat Anchors: LATCH (Lower Anchors and Tethers for...

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Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Aspen

Year:

Codes

Chassis Code:

HG (Second Generation)

Platform:

Chrysler HG platform (shared with Dodge Durango)

👋 Introduction

Market Position

Segment:

Full-size Luxury SUV

Target Audience:

Families, towing needs, premium SUV buyers seeking comfort and capability.

Competitive Analysis

Key Competitors:

Chevrolet Tahoe, GMC Yukon, Ford Expedition, Toyota Sequoia, Lincoln Navigator.

Key Features

Vehicle Platform:

Built on Chrysler's HG platform, shared with the Dodge Durango, offering robust body-on-frame construction.

Interior Amenities:

Offered three rows of seating, premium interior materials, advanced infotainment options for its time.

📋 Manual Details

Coverage Areas

Documentation Type:

Complete Workshop Service Repair Manual

Primary Focus:

Maintenance, Troubleshooting, Repair, Diagnostics, Wiring Diagrams

Page Count

Estimated Pages:

Over 2000 (typical for comprehensive workshop manuals of this era)

Manual Type

Type:

Factory Authorized Service Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, engine performance, fuel system, cooling system, exhaust system, transmission (automatic), drivetrain, driveline components

Chassis:

Suspension (front and rear), steering system, brake system (front and rear disc), ABS, traction control

Electrical:

Body control module (BCM), power distribution, lighting, instrumentation, HVAC controls, power accessories, security system, diagnostic trouble codes (DTCs), wiring diagrams

Body Interior:

Body panels, doors, glass, interior trim, seats, airbags, HVAC system, exterior trim

Procedures Included

Maintenance:

Scheduled maintenance, fluid checks and changes, filter replacements, lubrication

Repair:

Component removal, installation, adjustment, overhaul, rebuild procedures for all major systems

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, DTC lookup and interpretation, electrical circuit testing

Technical Specifications:

Torque specifications, clearances, pressures, electrical parameters, test procedures

Technical Depth

Depth:

Comprehensive: Covers everything from basic fluid changes to complete engine and transmission rebuilds, including detailed electrical diagnostics and component-level troubleshooting.

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchability:

Searchable text for quick information retrieval

Print Quality:

High-resolution scans of original factory manuals, optimized for clarity and detail.

Binding Type

Binding:

N/A (Digital format)

Paper Type

Paper:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Code And Type:

EZH (4.7L SOHC V8)

Displacement:

4.7 Liters (285 cubic inches)

Cylinder Arrangement:

Valve Train:

Overhead Cam (SOHC)

Bore X Stroke:

3.75 in x 3.30 in (95.3 mm x 83.8 mm)

Compression Ratio:

9.0:1

Horsepower:

235 hp @ 4500 rpm

Torque:

305 lb-ft @ 3600 rpm

Fuel Type:

Unleaded Gasoline

Engine Variants

Optional Engine Code And Type:

8LW (5.7L HEMI OHV V8)

Optional Engine Displacement:

5.7 Liters (345 cubic inches)

Optional Engine Horsepower:

335 hp @ 5000 rpm

Optional Engine Torque:

370 lb-ft @ 3600 rpm

Fuel System

Injection Type:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Pump Pressure:

39-49 PSI (269-338 kPa) for 4.7L; 58 PSI (400 kPa) for 5.7L HEMI

Recommended Octane:

87 Octane (for 4.7L); 89 Octane recommended for 5.7L HEMI for optimal performance

🔧 Transmission

Standard

Transmission Type:

5-Speed Automatic (45RFE/545RFE)

Gear Ratios 45Rfe 545Rfe:

1st: 3.00, 2nd: 1.67, 3rd: 1.00, 4th: 0.75, 5th: 0.67, Reverse: 2.23

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid)

Transmission Fluid Capacity:

Approx. 11.0 quarts (10.4 liters) for 45RFE/545RFE with filter change.

Optional

Optional Transmission:

N/A (Only 5-Speed Automatic offered for 2006 Aspen)

Features

Drive System:

Available in 2WD (RWD) and 4WD (Full-time, 4-Mode)

Tow Haul Mode:

Includes a 'Tow/Haul' mode to optimize shifting for towing heavy loads.

📐 Dimensions

Exterior

Length:

201.0 inches (5105 mm)

Width:

75.0 inches (1905 mm)

Height:

72.7 inches (1847 mm)

Wheelbase:

119.0 inches (3023 mm)

Front Track:

63.0 inches (1600 mm)

Rear Track:

63.1 inches (1603 mm)

Ground Clearance:

8.3 inches (211 mm)

Interior

Seating Capacity:

7 or 8 passengers (depending on configuration)

Front Headroom:

40.7 inches (1034 mm)

Second Row Headroom:

40.1 inches (1019 mm)

Third Row Headroom:

38.9 inches (988 mm)

Cargo

Cargo Volume Behind 3Rd Row:

17.1 cu ft (484 liters)

Cargo Volume Behind 2Nd Row:

49.8 cu ft (1410 liters)

Cargo Volume Behind 1St Row:

84.7 cu ft (2398 liters)

Weights

Curb Weight:

Approx. 5,200 - 5,600 lbs (2359 - 2540 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 6,700 - 7,000 lbs (3039 - 3175 kg)

Towing Capacity:

Up to 8,950 lbs (4060 kg) (when properly equipped with the 5.7L HEMI and tow package)

🛡️ Safety Features

Ratings

NHTSA Front Driver Crash Test:

5 Stars (for 2006 model year, specific rating may vary slightly)

NHTSA Front Passenger Crash Test:

5 Stars (for 2006 model year, specific rating may vary slightly)

IIHS Front Crash Rating:

Good (for 2006 model year, specific rating may vary slightly)

Active Features

Traction Control:

Standard on all models (Electronic Traction Control)

Electronic Stability Control:

ESP (Electronic Stability Program) - Standard on all models.

Antilock Braking System:

ABS (4-wheel disc brakes with ABS) - Standard.

Passive Features

Airbags:

Driver and front-passenger airbags, supplemental front and rear side-curtain airbags.

Seatbelts:

Three-point seatbelts with pretensioners in all seating positions.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system.

💡 Technology Features

Infotainment

Infotainment System:

Optional AM/FM/CD/MP3 player with satellite radio capability, optional navigation system, rear-seat entertainment system.

Display Technology:

Optional touchscreen display for navigation and infotainment controls.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Parking Assist:

Optional rear parking assist sensors.

Connectivity

Auxiliary Input:

Optional auxiliary audio input jack.

Bluetooth:

Optional Uconnect Bluetooth hands-free communication system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions (consult manual for specific severe vs. normal duty recommendations).

Engine Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.

Cabin Air Filter Replacement:

Every 12,000-15,000 miles (19,000-24,000 km) or 12 months.

Spark Plug Replacement:

4.7L V8: Approx. 100,000 miles (160,000 km) with original equipment. 5.7L HEMI: Approx. 100,000 miles (160,000 km) with original equipment (e.g., platinum plugs).

Transmission Fluid Change:

Every 30,000-60,000 miles (48,000-96,000 km) or every 3 years, especially for towing. ATF+4 fluid is critical.

Fluid Specifications

Engine Oil Viscosity:

SAE 5W-20 (recommended for most conditions for both engines).

Engine Oil Spec:

API Certified SAE 5W-20 meeting Chrysler MS-6395 specification.

Coolant Type:

HOAT (Hybrid Organic Acid Technology) coolant, typically Mopar OAT Antifreeze/Coolant, or equivalent meeting Chrysler MS-9769 specification.

Power Steering Fluid:

Chrysler MS-5901 (or equivalent ATF+4 for some applications, check manual).

Brake Fluid Type:

DOT 3

Known Issues

Common Complaints Powertrain:

Early versions of the 4.7L engine could be prone to valve seat wear or oil consumption; HEMI engines generally robust but can have issues like MDS lifter noise if maintenance is neglected. Transmission fluid cooler leaks (internal to radiator) leading to coolant contamination of transmission fluid.

Common Complaints Electrical:

Intermittent electrical issues related to body control modules, power windows, and sensors can occur. HVAC blower motor resistor failure.

Common Complaints Suspension:

Wear in ball joints, tie rod ends, and sway bar links due to the vehicle's weight and typical use.

Common Complaints Body:

Rattles and squeaks from interior trim panels, particularly in the third row.

📚 Vehicle History

Brand Heritage

Chrysler Legacy:

Chrysler has a long history of producing comfortable and well-equipped vehicles, often targeting the premium segments of the market.

Model Evolution

Introduction Year:

The Chrysler Aspen was introduced for the 2007 model year, but this manual specifically covers the 2006 production run of vehicles intended for the upcoming model year, or initial early release vehicles often designated by a pre-production year. This manual's designation as '2006' implies it covers the initial launch and specifications applicable to that production period, potentially including vehicles built in late 2005 that were sold as 2006 models or pre-production units of the 2007 model year.

Platform Sharing:

The Aspen shared its chassis and many components with the second-generation Dodge Durango, both being part of Chrysler's strategy to offer a premium SUV under the Chrysler brand.

Production

Assembly Location:

Newark, Delaware, USA (shared assembly plant with Dodge Durango)

Production Years:

2007-2009 (for the actual market release, though manual covers 2006 production specs)

🏆 Awards & Recognition

Recognitions

General Reception:

The Chrysler Aspen, while a competent luxury SUV, received mixed reviews. It was praised for its comfortable ride, spacious interior, and powerful engine options (especially the HEMI), but criticized for its fuel economy and some interior material choices compared to segment leaders.

Specific Awards:

While specific major awards for the Aspen are not widely documented, its underlying platform and powertrain (particularly the HEMI) were generally well-regarded within the Chrysler lineup.