Transmission A604 PDF

A604 -41 TE
automecanico.com
AUTOMATIC
TRANSMISSION
EXPLODED - DIAGNOSTIC!
REPAIR
JA TRANSAXLE 21 - 45
TRANSAXLE 41TE
INDEX
page
DESCRIPTION AND OPERATION (Continued)......52

DIAGNOSIS AND VERIFICATION (Continued).....62
SERVICE PROCEDURES (Continued).....................68
DISASSEMBLY AND INSTALLATION (Continued)73
SHIFT POSITION INDICATOR .................................. 60
ROAD TEST ................................................................ 55
twenty-one -46 TRANSAXLE JA

DISASSEMBLY AND ASSEMBLY (Continued).....86
DISASSEMBLY AND ASSEMBLY (Continued)...100
DISASSEMBLY E AND ASSEMBLY E (Continued)113
TRANSAXLE—ASSEMBLY..................................116

CLEANING THE VALVE BODY...........................132
ADJUSTMENT OF THE GEAR SHIFT LINKAGE132
AUTOSTICK.............................................................132
SETTINGS (Continued)............................................133
ADJUSTING THE INTERLOCK SYSTEM............133
v4.................................................................................92
OFF ON.......................................................................92
sw.................................................................................92
sw.................................................................................92
0-5................................................................................92
=xxE-a..........................................................................92
N...................................................................................94
_k.................................................................................94
NMS.............................................................................95
DC................................................................................96
LR_CC.........................................................................96
LUBRICATION..........................................................96
33*33333.....................................................................98
2442-4}........................................................................98
SCHEMES AND DIAGRAMS (Continued).............142
SCHEMES AND DIAGRAMS (Continued).............143
45-80..........................................................................102
AUTOMATIC TRANSAXLE41TE..........................148
SPECIFICATIONS (Continued)...............................152
41TE TRANSAXLE DETORSION SPECIFICATIONS 152
AUTOMATIC TRANSAXLE41TE..........................152
SPECIAL TOOLS (Continued).................................153
• Valve body assembly
• Solenoid assembly
GENERAL INFORMATION •
Transmission position sensor (TRS)
Drive speed sensor
41TE TRANSAXLE IDENTIFICATION
•
• Transmission speed sensor

The 41TE transaxle identification code is a series of digits • transfer gears
printed on a bar code label attached to the transaxle case, as To inform yourself about the procedures, you must See
shown in (Fig. 1). Removal and Installation in this group.
For example, the identification code K 821 1125 1316 can be LIQUID REQUIREMENTS
decomposed as follows:
• K = Kokomo Transmission Plant NOTE: To learn about the procedures check fluid levels, with
• 821 = Last three digits of transaxle part number See Service Procedures in this group.
• 1 125 = Manufacturing date
NOTE: The transmission manifold and differential have a

• 1316 = Manufacturing sequence number common oil pan with an aber ture between the two.
TRANSMISSION AND DIFFERENTIAL

Transmission fluid is required on this transaxle. ATF+3
Automatic Transm ission Type 7 176 Mopar ® , ATF+3 Automatic
Transm ission F luid-Type 7 1 76, by Mopar ® .
Substitute fluids may cause torque converter clutch shaking.
AD A I p T a IV rt O e S d D e E la LI t Q in U t I u D r O a S
fluorescent leak detection fluid, it is not recommended to use any
fluid additives. two (transmission or differential) on this transaxle.
DESCRIPTION AND OPERATION

TRANSAXLE 41TE
Fig. 1 Transaxle identification label The 41TE is a four-speed transaxle consisting of a hydraulic and
If the label is not legible or missing, reference can be made to mechanical assembly with conventional with adaptive electronic
the “PK” number (stamped on the transaxle box) for identification. controls and monitors. Adaptive electronic controls take into
This number differs slightly in that it contains the entire transaxle consideration transmission wear and driver habits to provide
part number instead of the last three digits. consistent shifting throughout the life of the transaxle. It is used It
uses a set of drive clutches that includes the low, overdrive and
SERVICE ON BOARD sea clutches. cha back. It also uses separate holding clutches: 2nd
Servicing of the following components can be performed on and speed: L/R (first and reverse). The transmission output is
4th
board the vehicle without the need for disassembly. mount the directed to an integrated differential via a gear system. transfer
transaxle: rates according to the following input-to-output relationships:
DESCRIPTION AND OPERATION (Continued) 52


DIAGNOSIS AND VERIFICATION (Continued) 62
SERVICE PROCEDURES (Continued) 68
DISASSEMBLY AND ASSEMBLY (Continued) 86

TRANSAXLE—ASSEMBLY 116

CLEANING THE VALVE BODY 132
AUTOSTICK 132
SETTINGS (Continued) 133
ADJUSTING THE INTERLOCK SYSTEM 133
v4 92
OFF ON 92
sw 92
sw 92
0-5 92
=xxE-a 92
N 94
_k 94
NMS 95
DC 96
LR_CC 96
LUBRICATION 96
33*33333 98
2442-4} 98
SCHEMES AND DIAGRAMS (Continued) 142
45-80 102
AUTOMATIC TRANSAXLE41TE 148
SPECIFICATIONS (Continued) 152
SPECIAL TOOLS (Continued) 153
The final transmission ratio depends on the
engine option to be selected:


DISASSEMBLY AND INSTALLATION (Continued) 73

DISASSEMBLY E AND ASSEMBLY E (Continued) 113
TRANSAXLE—ASSEMBLY 116

CLEANING THE VALVE BODY 132
ADJUSTMENT OF THE GEAR SHIFT LINKAGE 132
AUTOSTICK 132
SETTINGS (Continued) 133
ADJUSTING THE INTERLOCK SYSTEM 133
v4 92
OFF ON 92
sw 92
sw 92
0-5 92
=xxE-a 92
N 94
_k 94
NMS 95
DC 96
LR_CC 96
LUBRICATION 96
33*33333 98
2442-4} 98
45-80 102
SPECIFICATIONS (Continued) 152
2.4
DESCRIPTION AND OPERATION (Continued)
HYDRAULIC SYSTEM OPERATION OF THE SYSTEM AND THE
The hydraulic part of the transaxle consists of the transaxle
fluid, fluid passages, valves hydraulics and various operating
TRANSMISSION CONTROL MODULE
pressure control components.
DESCRIPTION
The hydraulic control system design (without electronic The Transmission Control Module (TCM) is located on the
assistance) provides the transmission with PARK, REVERSE, left (driver's) side of the engine compartment, next to the timing
NEU shift positions TRAL and S ECOND, based on the driver's belt. tension control (PDC) (Fig. 2).
choice of gear lever only mind. This design allows the vehicle to
be driven (in a “failure” mode) in the event of a failure of the
electronic control system or in situations that the transmission
control module (TCM) recognizes as potentially damaging to the
transaxle.
MECHANIC SYSTEM
The primary mechanical components of the transaxle are as
follows:
• Three multi-disc drive clutches
• Two multi-plate holding clutches
• Four hydraulic accumulators
• Two planetary gear trains
• hydraulic oil pump
• valve body
• Solenoid assembly
ELECTRONIC SYSTEM
Control of the transaxle is carried out by a sys Fully
customizable electronic theme. The program Optimum shifting
is achieved through continuous feedback information from the Fig. 2 Transmission Control Module Location — Feature
sensors. real-time res that is supplied to the Transmission
Control Module (TCM). FUNCTIONING
The TCM is the “heart” or “brain” of the electronic control
The TCM is the unit that controls all the operations electronic
system. The TCM is based on information tion coming from
transaxle tions. The TCM receives information information
various direct and indicative inputs lines (sensors, switches, regarding vehicle operation from direct and indirect inputs and
etc.) to determine driver demand and operating conditions selects the transaxle operating mode. The direct inputs are
vehicle control. With this information, the TCM can calculate wired to the TCM, which uses them specifically mind. Indirect
and make timely and quality changes. ity through various output inputs originate from other components and modules and are
or control devices (solenoid assembly, transmission control shared with the TCM via the PCI bus.
relay, etc.). Some examples of direct inputs to the TCM are:
• Battery voltage (B+)
The TCM also performs certain diagnostic functions.
automatic diagnostics and provides information (sensor data,
DTCs, etc.) which is useful for proper diagnosis and repair. T • Ignition voltage “ON”
his information can be viewed with the DRB III scan tool.
• Transmission control relay (B + switch tada)
• Throttle position sensor
• Crankshaft position sensor (CKP)
• Transmission position sensor (TRS)
• Pressure Switches (L/R, 2/4, OD)
• Transmission temperature sensor grade to TRS)

• Drive shaft speed sensor
• Transmission shaft speed sensor

• TRS Hall Effect Switch (Autostick)
Some examples of indirect inputs to the TCM are:
• Engine and body identification
• Manifold pressure
• Specification Idle
• Torque reduction confirmation
•
Speed control activation switch
• Engine coolant temperature
• Ambient and battery and deactivation of
temperature the
• Brake switch status
• DRB tool communication TCM
Based on the information received from these various inputs,
the TCM determines the appropriate programming and shift
points, based on current operating conditions and vehicle
demands. driver. This is possible by controlling the various
direct and indirect outputs.
Some examples of direct TCM outputs are:
• Transmission control relay
• Solenoids (L/R, 2/4, OD and UD)
• Vehicle speed (at PCM)
• Torque reduction request (to PCM)
Some examples of indirect TCM outputs are:
• Transmission temperature (to PCM)
• PRNDL position (to BCM)
• Autostick indication (to BCM)
In addition to the verification of entries and the con controlling
the outputs, the TCM has other important functions and
responsibilities:
• Storage and maintenance of clutch volume indices (CVI)
• Storing and selecting appropriate shift programs
• Automatic system diagnosis Fig. 3 Example of CVI calculation
• Diagnostic capabilities (with DRB III scan tool)
Gear ratios can be determined by using the DRB III scan tool
NOTE: If the TCM has been replaced, the “Quick Learn and reading the drive and transmission speed sensor values on
Procedure” must be performed. For information See “Quick the “Monitors” screen. The gear ratio can be obtained ner by
Learn Procedure” in Service Procedures in this group. dividing the value of the drive speed sensor by that of the
transmission speed sensor Zion.
For example, if the drive shaft is rotating at 1,000 rpm and
CLUTCH VOLUME RATES the drive shaft is rotating at 500 rpm, the TCM may determine
An important function of the TCM is monitoring the Clutch
that the gear ratio is 2:1. In direct (third gear), the gear ratio
Volume Indices (CVI). CVIs represent the volume of fluid
changes to 1:1. The gear ratio changes when the clutches are
needed to compress a clutch assembly.
applied and disengaged. By monitoring the time it takes to
The TCM monitors gear ratio changes by checking the drive
change the gear ratio in response to a shift request, the TCM
and transmission speed sensors. The impeller or turbine speed
can determine the volume of fluid used to apply or release a
sensor sends an electrical signal to the TCM that represents the
friction element.
drive shaft rpm. The Sen The transmission speed sensor
The volume of transmission fluid needed to apply the friction
provides the TCM with information about the speed of the
elements is continually updated for the adaptive controls. As the
output shaft.
friction material wears, the volume of fluid needed to apply the
By comparing the two inputs, the TCM can determine the
element increases.
position of the transaxle gears. This is important for calculating
CVIs, since the TCM determines CVIs by
dd e monitoring the time it takes for a change to occur (Fig. 3).
TCM MEASURES TIME

THAT DELAYS IN COM-
PRIME THE SET OF
CLUTCH TO CHANGE
THE GEAR RATIO
NAJES
Certain internal mechanical problems with the input clutch CLUTCH VOLUMES
assembly (broken return springs, out-of-position spring rings, Proper clutch
excessive clutch assembly clearance, incorrect assembly, etc.) Update time volume
Clutch
can cause inadequate element volumes. broken or out of scale.
Likewise, if the sensors
Change
drive and transmission speed or wiring is defective, these
conditions may occur. nes. The following table identifies the L/R dreosdcaednudrea 35 to 83
appropriate clutch volumes and when they are monitored or nltiebr e n 2-1 or 3-
updated: 1
2/4 Change 1-2 20 to 77
SCHEDULING OF CHANGES O.D. Change 2-3 48 to 150
As mentioned above, the TCM has a programming capability
that allows you to select tion a variety of cam settings bios. YOU 24 to 70
change 4-3 or 4-2
Selection of the shift schedule depends on the following:
• Gear lever position
• Throttle position • Software level
• engine load When driving conditions change, the TCM appropriately
• Liquid temperature adjusts the shift schedule. Depending on driving conditions,
refer to the following table to determine the correct intended
operation.
Programming Condition Planned operation

Extreme cold Start-up oil temperature below -27° C (-16° F)
PARK, REVERSE, NEUTRAL and 2nd only gear
(prevents shifts that can cause a clutch to fail

with frequent shifts)
Cold Start-up oil temperature greater than -27° C (- – 2-3 delayed upshift (approximately 35-49
12° F) and less than 2° C (36° F) km/h or 22-32 mph)
– 3-4 delayed upshift (72-85 km/h or 45-53
mph)
– Early 4-3 freewheeling downshift
(approximately 48 km/h or 30 mph)
– Early 3-2 freewheeling downshift
(approximately 27 km/h or 17 mph)
– Shifts are prevented with high speed
retraction 4-2, 3-2 and 2-1
– Without EMCC
Warm Oil temperature at start-up greater than 2° C – Normal operation (upshift, freewheeling
(36° F) and less than 27° C retreats and downshifts)
(80°F) – Without EMCC
Programming Condition Planned operation

Hot Start-up oil temperature greater than 27° C (80° – Normal operation (upshift, freewheeling
F) retreats and downshifts)
– Total EMCC, without PEMCC except for
caecrorpaldaar
FaEvMelCocCid(aedxecsepstuopceorinoraeds
maisión 112-133 km/h or 70-83 mph)
Overheating Oil temperature greater than 115° C (240° F) or – 2-3 delayed upshift (40-50 km/h or 25-32
engine coolant temperature greater than 118° C mph)
(244° F)
– 3-4 delayed upshift (65-80 km/h or 41-48
mph)
– FEMCC in 3 speed from 48-80 km/h (30-48
at
mph)
– PEMCC in 3 speed from 43-50 km/h (27-31
at
mph)
Overheating Oil temperature greater than 127° C (260° F) – All programming features for “Overheat”
changes apply.
– PEMCC in 2nd gear
over 35 km/h (22 mph)
– Above 35 km/h (22 mph), the torque converter
does not unlock unless the intake is closed or a
PEMCC wide-open throttle recall is performed
at 2 1.
to
information regarding pressure switches, see “Pressure

SOLENOID ASSEMBLY
PRESSURE
AND SWITCHES Switches” in this group.
DESCRIPTION
The solenoid and pressure switch assembly sion is external
to the transaxle and is mounted on the next to the valve body.
The assembly consists of four solenoids that control the
hydraulic pressure applied to four of the five friction elements
(transaxle clutches) and the converter clutch. torque dor. The
solenoid assembly also has has pressure switches that supply
information to the TCM.
FUNCTIONING
The internal solenoids of the assembly are powered with the
voltage supplied by the transmission control relay. The
solenoids are energized when the TCM grounds the required
solenoid return wire. Pressure switches simply tell the TCM
whether or not pressure exists in a circuit. clutch problem. For
BATTERY POWER (TCM) fault diagnosis (DTC).

For continuous power, a direct battery feed to the TCM TRANSMISSION CONTROL RELAY
protec is used. fused by fuse. The battery power is connected The transmission control relay is located in the power
and is also applied on the drive side. transmission control relay distribution center (PDC), on the left side of the engine
contacts. This has Battery power is necessary to retain adaptive compartment (Fig. 4). The relay receives fused B (+) voltage
learned values in the TCM RAM (Random Access Memory). and is energized from the TCM. It is used to supply food
When the battery is disconnected, B (+), this memory is lost. mentation to the solenoid assembly when the trans My mission
When the battery is restored, B (+), the TCM detects this loss. is in normal operating mode. When the relay is OFF, no power
Memory is checked and a Diagnostic Code is set. is supplied to the solenoid assembly and
The transmission is in “failure” mode. After a controller reset AB A I B E IE A C B E IE R R R CE A R B R IE
(ignition key set to the “run” position or after cranking the 2D RT R O TO T A O DO ARDTOO
engine), the TCM energizes the relay. Before this, the TCM O.D. OPEN CLOSED CLOSED
verifies that all contacts are open, such as checking that there is
no voltage at the switched battery terminals. After this
verification, the voltage of the pre-switches is checked. sion of 2 speed and 2/4 at 3 ). The test simply verifies that they are
at speed
the solenoid assembly. After the excitement tion of the relay, the in operation, looking for the closing state when the
TCM checks the terminals to verify that the voltage is above 3 corresponding element is applied. Immediately after a cam bio
volts uncles. at 1 , 2 or 3 gear with the engine speed above 1,000 rpm, the
a a, a
TCM activates momenta the pressure element of the 2/4 and/or

OD clutch circuits to identify that they are
closed the correct switch. If it doesn't close, try it again. If the
switch does not close the second time, the appropriate
Diagnostic Trouble Code (DTC) will be set.
DRIVE AND TRANSMISSION SPEED

SENSORS
DESCRIPTION
Drive and transmission speed sensors are bifilar magnetic
pickup devices that generate AC signals when rotation occurs.
They are threaded to the transaxle case and are considered
primary inputs to the Transmission Control Module (TCM).
FUNCTIONING
The drive speed sensor provides information about the
speed at which the drive shaft rotates. When the teeth of the
drive clutch hub pass the sen coil sor, an AC voltage is
Fig. 4 Lo t rcaanliszmac i sió ió nnd ( eclarrealcé t edre í sc t o i generated and sent to the TCM. The TCM interprets this
cnat ) role of the information as the drive shaft rpm.
The transmission speed sensor generates a
PRESSURE SWITCHES
The pressure switches are located within the solenoid AC signal in a similar manner, although its coil is excited by the
assembly and service is performed only ly by replacing the rotation of the rear planetary box parking pawl lugs . The TCM
assembly. interprets this information as driveshaft rpm.
The TCM compares the drive and transmission speed
The TCM relies on three pressure switches to check fluid
signals to determine the following:
pressure in the L/R, 2/4, and OD hydraulic circuits. The primary
Transmission gear ratio
purpose of these switches is to help the TCM detect when
•
Speed ratio error detection

clutch hydraulic circuit failures occur. Switches close at 159 kPa
•
• CVI calculation
(
p 2 le 3 mpesn it ) e y ssie eax birseten ao 7 n 6 o kP pare ( s 1 i 1
onp. sE i) l eT i nC d M i cavnersi i fimca - constantly correct
states (opening or cie rre) of the switches in each change, as
indicated in the following table:
If the TCM detects any switch open or closed at the incorrect
time for a given shift, a Diagnostic Trouble Code (DTC) will be
set.
The TCM also tests the pressure switches. sion of 2/4 and
OD when normally deactivated fords (OD and 2/4 are tested at
1 , OD at
speed
CHANGE L/R 2/4 O.D.
R OPEN OPEN OPEN

P/N CLOSED OPEN OPEN
1 to
CLOSED OPEN OPEN
The TCM also compares the drive speed signal and the should use. If the thermistor circuit fails, the TCM will revert to
engine speed signal to determine the following: using the calculated oil temperature.
• Torque converter clutch slipping
• Speed ratio of the elements of the con
TEMPERATURE SENSOR
TRANSMISSION
torque pourer DESCRIPTION
THROTTLE POSITION SENSOR, The transmission temperature sensor is a thermistor
THROTTLE integrated into the Transmission Position Sensor (TRS). Service
The Transmission Control Module (TCM) receives the throttle can only be performed by replacing the TRS.
position signal. radiator and its mass from the Throttle Position
Sensor (TPS). The TPS has a ten 5 volt activation voltage
FUNCTIONING
supplied by the motor controller. The TCM verifies that the The TCM uses the transmission temperature sensor to
throttle signal is not out of range or intermittent (excessive detect the temperature of the manifold fluid. Since fluid
signal changes). temperature can affect transmission shift quality and converter
lockup, the TCM requires this information to determine what
shift schedule it should operate on.
TRANSMISSION POSITION SENSOR
tur E a l P a C f M in v d e e rif e in ca er t g a iz m a br ié l n o e v st e on s ti d
DESCRIPTION la a d t o r s es de d t e em in p f e r r i a - - vehicle operation when a
The Transmission Position Sensor (TRS) is mounted on the
transmission “overheating” condition occurs.
top of the valve body inside the transaxle and can be serviced
only by removing the valve body. The electrical connector Calculated temperature
extends through the transaxle case. A failure of the temperature sensor or circuit will result in the
The Transmission Position Sensor (TRS) has four switch actual temperature being replaced by the calculated
contacts that perform the following functions: temperature. The calculated temperature is a predicted liquid
• Determine the position of the shift lever temperature, calculated from a combination of inputs:
• Battery temperature (ambient)
•
S qu u m e i e n n is P tr A ar
arran RK m y as N a E p U a T r R aAeLúr n
e lé cam de el nt m e. otor of
i
• Engine coolant temperature
• Supply ground for sea lights relay go back to REVERSE
only. • Running time at speed from start
The TRS also has an integrated temperature sensor
(thermistor) that communicates transaxle temperature to the SOLENOIDS
TCM and PCM.
DESCRIPTION
FUNCTIONING Solenoids are used to control the ele friction modes of L/R
The Transmission Position Sensor (TRS) communicates the (First and Reverse), 2/4, OD (Overdrive) and UD (Low). The
shift lever position to the TCM as a combination of open reverse clutch is controlled by operating pressure. operation
switches. cough and closed. Each shift lever position bios is coming from the manual valve in the valve body. The solenoids
assigned a combination of switch states (open and closed) that are located
the TCM receives from the four sense circuits. The TCM
interprets this information and determines the transmission's
gear position and appropriate shift timing.
Since there are four switches, there are 16 possible
combinations of open and closed switches (codes). Seven of
these codes are related tioned to the shift position and three are
recognized as “between shift” codes. As a result, six codes are
obtained that should never be produced.
These codes are called “invalid”. An invalid code will produce a
DTC and the TCM will then determine the shift lever position
based on data from the pressure switches. This per Prevents
normal operation of the transmission in the event of TRS failure.
The TRS has an integrated thermistor that the TCM uses to

control the transmission manifold temperature. This temperature
is used to determine determine what shift schedule the TCM
within the solenoid and pressure switch assembly and cannot the SSV is in the downshift position and therefore directs fluid to
be serviced separately. rado. They can only be repaired by the L/R clutch circuit. In 2nd , 3rd , and 4th , it is in the
gear gear gear
replacing the with together. upshift position and directs fluid to the Torque Converter Clutch
(TCC) circuit.
FUNCTIONING When shifting to 1st , the uses a special hydraulic
gear
sequence to ensure movement of the SSV to the shifting

The solenoids receive power from the transmission control
position. cedent The L/R pressure switch is controlled to confirm
relay through a single wire. The TCM energizes or activates the
SSV movement. If the move is not confirmed (the L/R pressure
solenoids individually by grounding the required solenoid return
switch does not close), 1st is replaced by gear
. After making 2nd gear
wire. When a solenoid is energized, the solenoid valve moves

and a liquid passage is opened or closed (vented or applied), three unsuccessful attempts to get into 1st on a given key gear
depending on its default operating state. The result is the start, a DTC sets.
application or return of an ele frictional ment.
2/4 and UD solenoids vent normally to allow operation of the ELECTRONICALLY MODULATED
transaxle in failure mode (P, R, N, 2) in the event of an electrical CONVERTER CLUTCH
failure. The TCM controls the operation of the torque converter
Solenoids and circuits are tested for continuity periodically. clutch (TCC) through the solenoid and pressure switch
Each solenoid is activated or deactivated depending on its assembly and the valve body. When the transaxle is in , or 2nd 3rd
current state. The TCM should detect an inductive discharge 4th ity, the TCC can be excited when certain conditions are
gear
point during this test. Otherwise, the circuit is tested again. met.
carefully to verify the fault. In addition to periodic testing, the To reduce heat buildup in the transmission and insulate the
solenoid circuits are checked ban if a gear ratio or pressure transmission system from torsional vibrations, the TCM can
switch error occurs. produce a solenoid duty cycle of L/R-CC to achieve uniform
clutch application. torque pourer. This function, called
VEHICLE SPEED SIGN electronically modulated torque converter clutch (EMCC), can
The vehicle speed signal is taken from the sen transmission occur at various times depending on the following variables:
speed sensor. The TCM converts this signal into a pulse per • Gear lever position
mile and sends it to the PCM. The PCM, in turn, sends the
vehicle speed message to the BCM over the PCI bus. The BCM
• Current shift position
sends this signal to the dashboard instrument cluster to mos
bring the speed of the vehicle to the driver. The vehicle speed
signal pulse is approx. approximately 8,000 pulses per mile. • Transmission fluid temperature
GEAR POSITION INDICATOR • Engine coolant temperature
DESCRIPTION
The gear position indicator is located on the • Drive speed
gd dashboard instrument cluster. Indicates

manual valve lever by illuminating the
the position of the
LED located below the P, R, N, D, 3 or L shift symbols.
FUNCTIONING
The transmission position sensor (TRS) sends a signal to the
transmission control module (TCM) about the position of the
valve lever. manual valve. The TCM converts this signal into
shift lever position (SLP) information and sends it to the BCM
(body control module) and the dashboard instrument cluster.
Pair to replace the cam position indicator bio, see group 8E,
Instrument Cluster and Gauges.
SWITCHING SOLENOID VALVE

DESCRIPTION
The Solenoid Switch Valve (SSV) is located in the valve body
and controls the direction of the transmission fluid when the L/T-
TCC solenoid is energized.
FUNCTIONING
The Switching Solenoid Valve (SSV) with Controls the
operating pressure coming from the LR-TCC solenoid. In 1st , gear
• butterfly angle AUTOSTICK
• Engine speed
The TCM controls the torque converter through internal logic FUNCTIONING
software. Software programming provides the TCM with fine Autostick is a driver-interactive feature of the transaxle that
control of the L/R-DC solenoid. There are four logical states of provides manual shifting capability. When he changes dor is
placed in the Autostick position, the transaxle per It remains at
sal id S a i qnu E e M se CC can be applied as follows:
•
the speed you were using before activating Autostick,
regardless of that speed. Movement of the shifter to the left
• partial EMCC
• total EMCC (towards the driver) produces a downshift and the movement
• Gradual to without EMCC ment to the right (towards the passenger) produces a m n in c a a
r m á b l i a o v as e c lo e c n i d da ed nte s . the E e l c g i r o u n p a d o
WITHOUT EMCC a d . e E i l ns v t e ru h m ícu e l no to p s u i e l d u e - put yourself in
Under S IN EMCC conditions, the L/R solenoid is Autostick mode from , 2nd 1st or
speed city while in Autostick
3rd
deactivated. There are various conditions that can produce mode. The speed control can be operated in Autostick mode
operation in EMCC-FREE mode. This NO EMCC mode may be from 3rd to
speed. Cruise control will disengage if the transaxle
4th
initiated due to a transaxle failure or because the TCM does not is placed in 2nd . Shifting to the OD position cancels Autostick
gear
detect the need for EMCC under the current driving conditions. mode and tran seje resets the overdrive shift programming.
PARTIAL EMCC AUTOMATIC NEUTRALIZATIONS
Partial EMCC mode operation modulates the L/R (duty cycle)
For safety, durability and driving reasons tion, some changes
solenoid to obtain partial application of the clutch clutch. torque
are automatically executed or prevented mathematically.
pourer. Partial EMCC operation is maintained until full EMCC
mode is requested and activated. During partial EMCC
operation, some slippage occurs. Partial EMCC mode normally
occurs at low speeds, low load and acceleration situations. light
ration.
EMCC TOTAL
During Full EMMC mode operation, the TCM increases the
duty cycle of the L/R solenoid to fully activate after the Partial
EMCC control brings the engine speed to the desired speed slip
range. transmission drive speed in relation to engine rpm.
GRADUAL TO NO EMCC
Operation in this mode is intended to ity smooth the change
from full or partial EMCC to Non-EMCC mode. This is done with
medium acceleration by decreasing the duty cycle of the L/R
solenoid.
SHIFT AND IGNITION INTERLOCK

The ignition interlock system connects the automatic
transmission shifter and the ignition lock system. With the
ignition key in the LOCK or ACCESS ORY positions, the
interlock system prevents the transmission from moving out of
the park position. When the key is in the OFF or RUN positions,
the shifter is unlocked and can be moved to any shift position.
The system also prevents the operator from Turn the ignition
key to the LOCK or ACCESSORY positions.
NOTE: If the vehicle has column shifts, install a new interlock

cassette (column shifts) when replacing the ignition lock
cylinder. Adjust the system after replacing the cassette. See
the procedure ment in this group.
NOTE: If the vehicle has ground shifts, adjust the interlock

cable after replacing position the lock cylinder.
TRANSAXLE 21 -
65
AUTOMATIC CHANGES WILL OCCUR UNDER THE FOLLOWING CONDITIONS
EXCHANGE RATE APPROXIMATE SPEED
Freewheeling downshift 4-3 21 km/h (13 mph)

Upshift 1-2 Engine at 6,300 rpm
Upshift 2-3 Engine at 6,300 rpm
Change with retreat 4-3 21-75 km/h (13-47 mph) with sufficient intake
MANUAL CHANGES ARE NOT ALLOWED UNDER THE FOLLOWING CONDITIONS
EXCHANGE RATE APPROXIMATE CHANGE POINT

Upshift 3-4 Less than 24 km/h (15 mph)
3-2 downshift More than 118 km/h (74 mph) with closed intake or 112 km/h
(70 mph) in other conditions
2-1 downshift More than 65 km/h (41 mph) with closed intake or 60 km/h
(38 mph) in other conditions
DIAGNOSIS AND VERIFICATION poor acceleration, the torque converter freewheel coupling may
be slipping. If acceleration is normal, but large throttle openings
GENERAL DIAGNOSIS OF THE 41TE are required to maintain speed, the torque converter clutch may
have stuck. Both stator defects require replacement of the
TRANSAXLE torque converter and a complete cleaning of the transaxle.
CAUTION: Before attempting any repair For the 41TE four- An engine failure can be attributed to a cracked control plate.
speed automatic transaxle, check the diagnostic trouble A cracked drive plate can cause the camshaft position sensor
codes with the DRBIII scan tool. Always use the Powertrain and crankshaft position sensor signals to be out of sync. That
Diagnostic Test Procedures Manual. circumstance may cause a failed start condition.
A slipping clutch can set a DTC and can be determined by
The following general conditions can cause transaxle failure: observing the operation. ing the transaxle in all shift lever
• Poor engine performance positions and comparing which internal units are applied in
• Incorrect settings these positions. The Table of Elements Used provides a basis
for road test analysis.
• Hydraulic failures
• mechanical failures
• Electronic failures
The diagnosis of these problems should always begin by

verifying the easily accessible variables: fluid level and condition
and adjustment of the gear shift cable. Then perform a road test
to determine if the problem has been corrected or additional
diagnosis is required. If the problem persists after completing
the tests and correction preliminary tests, pretests should be
performed hydraulic sion.
ROAD TEST
Before performing the road test, verify that the fluid level and
condition and joint adjustments have been checked.
During the road test, the transaxle must be operated in each
position to verify that there is no slippage or shifting variations.
If the vehicle operates correctly at highway speeds, but has
DIAGNOSIS AND VERIFICATION (Continued)
Gear lever position starter lock parking
CLUTCHES
space I lie
UD (Low) OD (About Reverse 2/4
March)
Low and
Reverse (First
and reverse)
AND AND AND
- x x
R - REV ERSE
N - NEU TRAL x x
OD - OVERDRIVE
First x x
Second x x
Direct x x
Overdrive x x
D - DRIVE*
First
x x
Second x x
Direct x x
x x
L - LOW* First Second x x
Second Direct x x
Fig. 5 ELEMENTS USED IN EACH POSITION OF THE SHIFT LEVER
To detect slipping units and confirm mar the correct operation

of units in good condition an elimination procedure can be used
My nation. Road test analysis can normally diagnose slipping
units. However, the actual cause of the malfunction may not be
detected. Leaking hydraulic circuits or stuck valves can cause
virtually any condition.
HYDRAULIC PRESSURE TESTS

Pressure testing is a very important step tant in the
diagnostic procedure. These tests bas usually reveal the cause
of most hydraulic transaxle problems.
Before performing pressure tests, ensure that the fluid level
and condition and control cable settings have been verified and
approved. The liquid must be at operating temperature
temperature between 65.5 and 93.3° C (150 and 200° F).
Install an engine tachometer, raise the vehicle on a lift that Fig. 6 pressure spigots
allows the front wheels to turn, and position the tachometer so it
can be read. TEST ONE-SELECTOR SHIFT ON
Connect 1 .034 kP to (1 50 psi) gauges into the required FIRST LOW SPEED
holes for the tests to be performed. A 2069 kPa (300 psi) gauge (1) Connect the pressure gauge to the low/reverse clutch
(C-3293) is required for the reverse pressure test. spigot.
Test hole positions are shown tran in (Fig. 6).
(2) Move the gear selector lever to the (L) position. TRANSMISSION (D IN CIRCLE), OVERDRIVE
(3 ) Allow the vehicle wheels to rotate and increase the
GEAR
throttle opening to achieve an indicated vehicle speed of 32
(8) ) Connect the pressure gauge to the 2/4 clutch nipple.
km/h (20 mph).
(2) Move the selector lever to position D (in a circle).
ma(4rc) h Laaa t lre á cstu d rea b edeseprr d esió 7 n deal 9 e (3) Allow the front wheels of the vehicle to rotate and
93 9
increase the throttle opening to achieve an indicated vehicle
m 8 b k r P agau ( e 11 d 5 e ab 1 a 4 ja 5 / psi). speed of 48 km/h (30 mph).
(5) This test verifies the pump output, pressure regulation (4) The 2/4 clutch pressure reading should be 517 to 655
and the condition of the hydraulic circuit low/reverse clutch and kPa (75 to 95 psi).
shift pattern. (5) This test checks the 2/4 clutch hydraulic circuit.
TRY TWO-GEAR SELECTOR IN 2ND. TEST FIVE-TRANSMISSION SHIFT SELECTOR

TRANSMISSION SPEED (D IN CIRCLE), OVERDRIVE
(6) ) Connect the pressure gauge to the converter clutch
NOTE: This test verifies the hydraulic circuit of the disengagement pressure tap. torque dor.
submultiplication clutch as well as the shift diagram.
(3) Allow the front wheels of the vehicle to rotate and
(1) Connect the indicator to the submultiplication clutch increase the throttle opening to achieve an indicated vehicle
spigot. speed of 80 km/h (50 mph).
(2) Move the selector lever to position 3.
(3 ) Allow the vehicle wheels to rotate and increase the CAUTION: Both wheels must rotate at the same speed.
km/h (30 mph). (4) The torque converter clutch release pressure must be
(4) In second gear, the underdrive clutch pressure reading less than 35 kPa (5 psi).
should be 758 to 1,000 kPa (110 to 145 psi). (5) This test checks the torque converter hydraulic circuit.
TEST SIX-REVERSE SHIFT SELECTOR

TEST 2A–SELECTOR IN OVERDRIVE
(6) ) Connect the pressure gauge to the low/reverse clutch
NOTE: This test verifies the hydraulic circuit of the spigot.
submultiplication clutch as well as the shift diagram.
(1) Connect the pressure gauge to the underdrive clutch

spigot.
(2) Move the selector lever to the OD position.
(3 ) Allow the wheels to spin freely and increase the throttle
opening to achieve an indicated vehicle speed of 64 km/h (40
mph).
(4) Sub clutch pressure reading multiplication must be less
than 35 kPa (5 psi). Otherwise, this indicates that there is a fault
in the con together with solenoids or the TCM.
TEST THREE-OVERDRIVE CLUTCH CHECK

(1) Connect the pressure gauge to the overdrive clutch
spigot.
(3) ) Allow the vehicle wheels to rotate and increase the
km/h (20 mph).
(4) Clutch pressure reading speed should be 510 to 655
kPa (74 to 95 psi).
(5) Move the selector lever to position (3) and increase the
vehicle speed display to 48 km/h (30 mph).
(6) The vehicle must be in second gear and the overdrive
clutch pressure must be less than 35 kPa (5 psi).
(7) This test verifies the overdrive clutch hydraulic circuit as
well as the shift pattern.
TEST FOUR-SHIFT SELECTOR IN

(2) Move the selector lever to the reverse position. correctly.
(3) Read the reverse clutch pressure with the transmission (2) Low pressure in all positions indicates a faulty pump, a
stationary (foot on the brake) and the mari Open the throttle to clogged filter, or a valve. Stuck pressure regulator valve.
obtain 1500 rpm. (3) If the pressures are not within the specified pressure
(4) Clutch pressure reading low/ 2 m 3 to 5 rcphsa i). rear range, this indicates leaks in the clutch circuit.
must be between 1 1 3 8 and 1 620 kPa ( 1 65 and
(4) If the overdrive clutch pressure is greater than 35 kPa (5
(5) ) This test checks the reverse clutch hydraulic circuit. psi) in step 4 of test 3, the overdrive clutch reaction shaft
retainer ring is worn or the solenoid assembly is defective.
(5) If the clutch pressure is too low tion is greater than 35
INDICATIONS OF TEST RESULTS
kPa (5 psi) in Step 4 of Test 2A, the cause is a defective
(6) ) If the correct operating pressure values are measured
solenoid assembly or TCM.
in all tests, the pump and pressure regulator are working
ALL SPECIFICATIONS ARE IN KPA (PSI IN PARENTHESES)

(on lift, with wheels free to rotate)
Gear selector position Royal march PRESSURE SPITCHES

Submulti envelope reverse clutch 2/4 clutch Low/
clutch clutch March Conver Reverse
application clutch off Clutch
torque
switch
tivated
* PARK 0-14 (0-2) 0-35 (0-5) 0-14 (0-2)

414-758 (60- 793-1000
PARK 0 km/h (mph) 110) 0-14 (0-2) (115-145)
REVERSE 0 km/h (mph) * REVERSE 0-14 ( 0-2) 0-48 (0-7) 1138-1620 345-690 0-14 (0-2)
(165-235) (50-100)
11381620
(165-235)
* NEUTRAL (DEAD POINT) 0-14 (0-2) 0-35 (0-5) 0-14 (0-2)
NEUTRAL (NEUTRAL) 0 km/h 414-758 (60- 793-1000
(mph) 110) 0-14 (0-2) (115-145)
# FIRST 0-35 (0-5) 0-14 (0-2)
L (LOW) 758-1000 414-758 (60- 793-1000
32 km/h (20 mph) (110-145) 110) 0-14 (0-2) (115-145)
3 # SECOND 758-1000 0-35 (0-5) 0-14 (0-2) 414-758 (60- 0-14 (0-2)
48 km/h (30 mph) (110-145) 110)
793-1000
(115145)
# DIRECT 0-14 (0-2) 0-14 (0-2)
3 517-655 (75- 517-655 414-620 (60-
72 km/h (45 mph) 95) (75-95) 90) 0-14 (0-2)
# OVERDRIVE 0-14 (0-2) 0-14 (0-2) 0-14 (0-2)
OD (OVERDRIVE) 48 km/h (30 517-655 414-620 (60- 517-655
mph) (75-95) 90) (75-95)
OD (OVERDRIVE) 80 km/h (50 # OVERDRIVE WITH 0-14 (0-2) 5 17-655 0 -14 (0-2) 0 -3 5 (0-5) 517-655 0-14 (0-2)
mph) CLUTCH (75-95) (75-95)
TORQUE CONVERTER
# V P e R lo E c C i A da U d C d IO e N lm : L o a to s r d a o 1 s .5 ru 0 e 0 d r a ps m d . front wheels must be moving at the same speed.
PRESSURE CHECK SPECIFICATIONS

CLUTCH TESTS WITH AIR PRESSURE back and forth moves forward. The piston should return to its
Clutches that do not work can be located can be used using initial position when the air pressure is removed.
a series of tests that replace liquid pressure with air pressure
(Fig. 7) (Fig. 8). Clutches can be tested by applying air pressure REVERSE CLUTCH
Apply air pressure to the reverse clutch apply passage and
to their respective passages after Assemble the valve body. To
watch for the reciprocating piston to move rearward. The piston
perform this test, install special tool 605 6. To perform air
should return to its initial position when the air pressure is
pressure tests, proceed as follows:
removed.
NOTE: The compressed air supply must be free of any dirt
or moisture. Use a pressure of 207 kPa (30 psi).
2/4 CLUTCH
Apply air pressure to the feed hole located in the 2/4 clutch
Remove the oil pan and valve body. retainer. Observe the area where the 2/4 piston contacts the
See Valve Body Removal. first separator plate and watch carefully to see if the 2/4 piston
moves rearward. The piston should return to its initial position
when the pre is removed. air sion.
LOW/REVERSE CLUTCH
Apply air pressure to the low/reverse clutch feed hole (on the
rear It will be from the box, between 2 bolt holes). Next, look at
the area where the low/reverse piston contacts the first
separator plate and watch carefully to see if the piston moves
forward. lante. The piston should return to its original position
when the air pressure is removed.
SUBMULTIPLICATION CLUTCH
Since this clutch piston cannot be seen, its operation is
verified by checking its function. Air pressure is applied to the
2/4 or low/reverse clutches. This locks the drive shaft. Use a
piece of rubber hose wrapped around the drive shaft and a pair
of pliers to rotate the drive shaft. Then apply air pressure to the
sub-multiplier clutch. The drive shaft must not rotate with
manual torque. Download the pre sion and confirm that the
drive shaft can rotate.
FCUOGNAVEDRETLIDIQOURI D OE-
PAARREA OF THE COVER OF THE
(6) ) Investigate the source of the leak.
(2)
Fluid leaks from the torque converter area can originate
from an engine oil leak. The area should be examined carefully.
The liquid installed at the factory is red and can therefore be
distinguished from the engine oil.
(3)
Before removing the transaxle, perform the following
These verifications:
Fig. 8 Reverse Clutch Test OVERDRIVE CLUTCH

Apply air pressure to the overdrive clutch apply passage and
observe if the piston
(4)
When it is determined that the leak originates in the ALL PRND3L SCOPE LIGHTS Check wiring and connectors
transaxle, before removing the transaxle and converter torque COME ON IN THE PYN
regulator, check the fluid level. DRIVING POSITIONS
(5)
) A high fluid level can cause oil leaks from the breather
on the manual axle. If the fluid level is too high, adjust it to the
level Transmission position sensor
defective
(6) rr
6 e ) c D to e . After performing this operation, check for Defective manual lever
leaks. If the leak persists, perform the following operation on the ALL VISOR LIGHTS COME Check wiring and connectors
vehicle to determine if you are leaking the torque converter or ON IN ALL GEAR POSITIONS
transaxle.
TORQUE CONVERTER LEAKS Transmission position sensor

Possible sources of torque converter leaks are:
defective
(1) Leakage from the external (peripheral) welding of the
Defective manual lever
torque converter. CCD communications
malfunction
(2) Torque converter hub welding.
ALL THE LIGHTS OF THE Normal transitional condition
DISPLAY OFF between gear positions PR and
RN
v N i O if T b A le : . L Nao isnot l e d nat d euroreapa d rear l laa.
Rmeaezma pelasc i ene t the torque converter.
Check the shift lever linkage
Body control module
malfunction
CHECKING THE OPERATION OF THE
INTERLOCK SYSTEM
cV o e n ri e fi c q t u o e re e s l
If the interlock system operates in a manner other than
wiring and the
described below, system repair is required.
Defective instrument cluster
(3) ) Place the shifter in the PARK position with the gate and
the ignition key in the LOCK or ACCESSORY positions. The
ALL VISOR LIGHTS OFF, CCD communications
changer MUST NOT be able to be removed from the park
ALONG WITH A 'NO BUS ' malfunction
position with com door. MESSAGE
(2) Turn the ignition key to the OFF or RUN/ON positions.
The shifter MUST be able to move to ANY derailleur position. VISOR LIGHTS OUT OF Check wiring and connectors
(3) Place the shifter in the DRIVE position. The ignition key SEQUENCE WITH SHIFT
MUST NOT be able to turn to the positions LOCK or LEVER
ACCESSORY functions. Transmission position sensor
defective
SHIFT POSITION INDICATOR
The transmission position sensor (located on the valve body) Defective manual lever
sends a signal to the TCM relative to CCD communications
malfunction
t
d i e v latara l nasepjoes. i cE i l ó Tn C d Me l raepcaib l aenlcaas
de
eeña l al d v e á l lv c u o l nammuatand u oar l and processes AUTOSTICK
the data. The TCM sends the Shift Lever Position (SLP) The Autostick function will be disabled if one of the following
information to the BCM via the CCD bus. The BCM then conditions occurs:
illuminates the appropriate shifter position indicator in the • DTC P0705, Shifter Signal Check, normally accompanied
instrument cluster. by all PRNDL lights turning on in PARK and NEUTRAL. This
If a problem occurs with the shift position indicator, refer to condition will produce a DTC P0705 if these three errors
the diagnostic information in the chart below. If the defect
cannot be corrected using the chart, consult the diagnostic
manual. appropriate ethics.
Pair to replace the cam position indicator biador, see group
8E, Instrument Cluster and Gauges.
CONDITION POSSIBLE CAUSE

res are detected after any movement of the key to the ON position.
• DTC P 1796, Autostick Input Circuit
• DTC P1797, Manual Transmission Overheat (Transmission

Oil Temperature > 135° C (>275° F) or Engine Coolant
Temperature
>124° C (>255° F)).

To reactivate Autostick mode after a high temperature fault, a
temperature must be obtained. Acceptable Transmission System
Perature:
• Transmission oil temperature < 124° C (255° F)
• Engine coolant temperature < 1 15° C (240° F)
SERVICE if it is in the HOT zone

(checkered area) of the dipstick
PROCEDURES
(Fig. 9). At a liquid temperature of
21°C (70°F), the level should be
VERIFICATION OF approximately 6 mm (one-quarter
LEVEL AND STATUS inch) above the bottom hole of
OF THE the dipstick.
LIQUID
NOTE: The transmission and
differential use the same fluid
pan, which requires ATF+3
Type 7176, ATF+3/Type 7176
automatic transmission fluid.
NOTE: The transmission fluid

level should be inspected at
least every six months.
LIQUID LEVEL CHECK

cad E o l r c aol p e a c tro o a r v d e er l i
a fic t a ra r ns e m l i as s c i e ó in te t ,
ie s n i e m u il n a a r v a ari l l a la d i
e n d l i a - most automatic
transmissions. It is located on the

left side of the engine. Segu Be
sure to clean any dirt from the
dipstick handle before removing
it.
The torque converter fills in the
PARK (P) and neutral NEU
positions. TRAL (N). To ensure
that the fluid level check is
correct, place the shift lever in
PARK (P). The engine should run
at idle speed for at least one
minute, with the vehicle on a level
surface. At normal operating
temperature, approximately 82° C
(180° F), the fluid level is correct
80004ec2
Fig. 9 Liquid level indicator

markings
CHECKING THE LIQUID
LEVEL WITH THE
DRB TOOL
NOTE: To perform this
procedure, the engine and
transaxle must be at operating
temperature. normal training.
(1) 1) Start the engine and

apply the parking brake ning.
(2) Connect the DRB III scan
tool and select transmission.
(3) Select sensors.
(4) Read the transmission
temperature value Zion.
co(n5 )e l Cco u ma d praor . e the

temperature value of the liquid
(6) Adjust the transmission

fluid level shown on the dipstick
according to the Dr.
(7) Check the transmission
for leaks.
The low fluid level can cause a
diversion. ity of conditions
because it allows the pump to
suck in air along with the liquid.
As in any hydraulic system, air
bubbles make the liquid spongy
and therefore the pressures
result. so low and establish
slowly.
Incorrect filling can also raise
excess the liquid level. When the
transaxle has too much fluid, the
gears foam and produce the
same conditions as low fluid.
In both cases, air bubbles can
cause overheating, oxidation and
varnish formation. These factors
can interfere with the functioning
normal operation of valves,
clutches and servos. Foaming
can also cause or a fluid leak
from the transaxle oil level
indicator, which can be confused
with a leak.
SERVICE PROCEDURES (Continued)
80a0141b
Transmission fluid temperature chart

In addition to the fluid level, it is important to check the state of the fluid. When the liquid smells dry and dry.
fqrsmudged and dirty with metal particles or friction materials, it

will be necessary to carry out a (RECOMMENDED)
general transaxle repair. Be sure to examine Thoroughly drain (1) 1) Raise the vehicle on a lift (see group 0, Lubrication
the liquid from the dipstick. If there is any doubt about its and maintenance). Place a large-mouth drain pan under the
condition, remove a sample for double checking. transaxle oil pan.
After checking the liquid, seat completely Use the dipstick to (2) Loosen the manifold bolts and tap lightly Use a corner of
seal the system against water and dirt. the collector to loosen it and allow the fluid to drain. Next,
remove the oil pan.
FLUID AND FILTER SERVICE— (3) ) Install a new filter and O-ring on the bottom of the valve
TRANSMISSION body and tighten the retaining screws to 5 N·m (40 lbs. in.).
(4) Clean the oil pan and magnet. Reinstall the manifold
NOTE: To find out about maintenance intervals (fluid and using new Mopar ® RTV Silicone Adhesive Sealant. Tighten the
filter change) we recommend given for this transaxle, refer to oil pan bolts with a torque sion of 19 N·m (165 lbs. in.).
group 0, Lubrication and maintenance or the owner's (5) Pour 3.785 liters (four quarts) of ATF+3 automatic
manual. owner of the vehicle. transmission fluid into
NOTE: Only label type liquids should be used. Used as

Mopar® Type 7176 ATF+3 Automatic Transmission Fluid
. At the time of changing
the transmission oil, the filter change must be done. The
magnet (internal of the collector
NOTE: If the transaxle is disassembled for any reason, the

fluid and filter must be changed.
FLUID AND FILTER SERVICE

Type 7176, from Mopar ® METHOD OF SUCKING LIQUID FROM THE INDICATOR
through the opening of the oil level DIPSTICK TUBE
dipstick (1) 1) When performing the fluid suction method, make
(6) Start the engine and allow it to idle for at least one sure the transaxle is at full operating temperature.
minute. Then, with the parking and service brakes applied, (2) To perform the method of sucking liquid from the dipstick
momentarily move the shift lever to each position , ) teorm N i E na U n tube, use a device tive liquid suction (Vacula ®
T d R o A en L l ( app u ons t oicimón u edre t oP ) A . RK (station- or some
equivalent).
(7) Check the transaxle fluid level and add Add an
(3) Insert the liquid suction line into the dipstick tube.
appropriate amount to bring the fluid level to 3 mm (1/8 in.)
below the “ADD” mark on the dipstick (Fig. 10). NOTE: Verify that the suction line is inserted into the lowest
(8) Check the fluid level again until the transaxle reaches point of the transaxle oil pan. This will ensure complete
operating temperature. normal temperature of 82° C (180° F.). evacuation of the liquid in the collector.
(9) To prevent dirt from entering the transaxle, make sure
the dipstick seats in the dipstick opening. (4) Follow the manufacturer's recommended procedure. sing
and drain the transaxle fluid.
(5) Remove the suction line from the dipstick tube.
(6) Add 4 quarts (3.785 liters) of Mopar ® ATF Plus 3
Automatic Transmission Fluid Type 7176, ATF+3
through the opening for the dipstick.
(7) Start the engine and allow it to idle for at least one
minute. Then, with the parking brake applied, press the service
brake with your foot and shift the transaxle from the position
parking position to all gear positions, ending in the PARK or
NEUTRAL position.
(8) Check the transmission fluid level and add
Fig. 10 Liquid level indicator markings
lgiuqeuiduonadectarna t n i s d eaj de e easpter oap i 3a d mamp
(a1r/a8 pquuleg.) e l putr i vdee el b a d jeo de la marking “ADD”
UMNEITCOADMOESNTD E ) ALTERNATIVE de la rod indicator (Fig. 10).
SERVICE (LIQUID (9) Check the fluid level again until the transaxle reaches
operating temperature. normal temperature of 82° C (180° F.).
TRANSAXLE FLUID EXCHANGER METHOD (10) To prevent dirt from entering the transaxle, make sure
the dipstick seats in the dipstick opening.
CAUTION: It is not recommended to use exchange fluid
diverters that introduce additives into the transaxle.
(1) To carry out the transfer fluid exchange sexle, the

transaxle must be at operating temperature ning. Drive the
vehicle until it reaches full operating temperature.
sej ( e 2) ad O e b c t ueandgoa yunve i rni t feiqrcuaemq b u i ea d

eol rd d epeó l s í iqtuo id esoté d eli t mrapnio - and dry.
(3) Fill the tank to the recommended fill capacity with Mopar
® ATF+3 Type 7 176 (ATF+3 Type 7176).
(4) Couple the vehicle to the machine following the
manufacturer's instructions. Perform the exchange procedure
according to the instructions provided with the machine.
(5) ) Once the machine has completed the fluid exchange,
check the fluid level and condition and fill to the proper level
with Mopar ® Type 7176 ATF+3
. For the correct filling
procedure, see Verifi cation of the level and state of the liquid in
this group.
NOTE: Verify transaxle cooler tubes are torqued to

specifications. correct nes. The cooler tube torque
specification is 2 N m (18 lbs. in.).
•
(7)
REPAIR OF ALUMINUM THREADS (7th) d Een E c N ie T n R da A l D a A bo d me l beanp f ro i ra
d
Damaged or worn threads on the aluminum transaxle doors . or three minutes to wash the coolers and tubes. Control
housing and valve body can be repaired using Heli-Coil or readings pressure gauges and transparent return tubes.
equivalent. This repair consists of drilling the threads worn or Pressure readings should stabilize below 1 38 kP a (20 psi) on
damaged, tapping the hole with a Heli-Coil tap or equivalent and vehicles with a single cooler installed and 207 kPa (30 psi) on
installing a Heli-Coil insert or equivalent in the hole. This vehicles with dual coolers. If the flow is intermittent tempt or
restores the original thread size of the hole. exceed these pressures, replace the coolant dor.
Heli-Coil and equiva inserts and tools lenses are available in (8) Turn off the pump.
most pro automobile spare parts suppliers. (9) Disconnect the TRANSPA suction tube RENT of the tank
on the closing plate. Disconnect the CLEAR return tube at the
WASHING COOLERS AND TUBES closure plate and place it in a drain pan.
When a transaxle failure fouls the fluid, the oil coolers should (10) Turn on the pump for 30 seconds to purge wash
be flushed. The cooler bypass valve needs to be replaced. The solution from the cooler and tubes. Turn off the pump.
with torque converter should also be replaced with an (11) 11) Place the CLEAR suction tube in a quart (950 ml)
container of ATF PLUS 3 Type 7176 Mopar ® Automatic
aftermarket unit. This will ensure that metal particles or oil Transmission Fluid.
sludge are not transferred back to the rehabbed (or replaced) (12) Turn the pump on until all transmission fluid is removed
transaxle. from the 950 mL container and tubing. This purges any residual
The recommended procedure for flushing the cooler is to use cleaning solvent from the transmission cooler and tubes. Turn
tool 6906A, Cooler Washer. off the pump.
(13) ) Disconnect the connection clips from the battery.
WARNING: WEAR PROTECTIVE GOGGLES THAT MEET
Reconnect the washer tubes to the closure plate and remove
THE REQUIREMENTS OF THE OSHA AGENCY AND ANSI
the washer adapters from the cooler tubes.
STANDARD Z87.1–1968. USE STANDARD INDUSTRIAL
USE RUBBER GLOVES.
KEEP LIT CIGARETTES, SPARKS, FLAMES AND
OIL PUMP VOLUME CHECK
After installing the new transmission and repair and fill it with
OTHER SURVEYS AWAY FROM THE AREA. IGNITION
the correct level of Mopar ATF PLUS 3 automatic transmission
TESTS, IN ORDER TO PREVENT IGNITION DIDO OF
fluid (Type
COMBUSTIBLE LIQUIDS AND GASES. HAVE A CLASS (B)
FIRE EXTINGUISHER ON HAND IN THE AREA WHERE
YOU WILL USE THE WASHER.
KEEP THE AREA WELL VENTILATED.
DO NOT ALLOW WASHING SOLVENT TO CONTACT
YOUR EYES OR SKIN: IF IT GETS INTO YOUR EYES,
WASH THEM WITH WATER FOR 15 TO 20 SECONDS.
REMOVE DIRTY CLOTHES AND WASH AFFECTED SKIN
WITH
WATER AND SOAP. REQUEST MEDICAL ATTENTION.
FLUSHING THE COOLERS WITH TOOL 6906A

(1)
Remove the filler cap from the closure plate of tool
6906A. Fill the tank half or 3/4 full with fresh washing solution.
Flushing solvents are petroleum-based solutions typically used
to clean automatic transmission components. DO NOT USE
solvents that contain acids, water, gasoline or any other want
another corrosive liquid.
(2)
Reinstall the fill plug on tool 6906A.
(3)
Verify that the pump power switch is OFF. Connect the
red connection clip to the positive (+) terminal of the battery.
Connect the black (-) connection clip to a good ground.
(4)
Disconnect the transmission cooler tubes.
NOTE: When flushing coolers and transmission pipes,

ALWAYS flush in reverse.
(5)
Connect the BLUE pressure tube to the OUTLET tube of
the cooler.
(6)
Connect the CLEAR return tube to the
7 176), the volume must be verified using the following The position of the gear lever must shift into overdrive
procedure: after the overdrive shift request, until the DRBIII indicates that
the procedure is complete.
(1) Disconnect the tube coming from the cooler at the
(10) The calculated oil temperature must be greater than
transmission and place a collection container tion under the
60° and less than 200°
disconnected tube.
(11) ) Plug the DRBIII scan tool into the data link connector.
CAUTION: With the liquid stabilized at the proper level, the The connector is located under the instrument panel.
liquid collection should not exceed 950 ml (1/4 gallon). In (2) Continue to the TRANSMISSION screen.
case against rio, internal damage to the transaxle may (3) Continue to the MISCELLANEOUS screen.
occur. mission. (4) Select QUICK LEARN PROCEDURE (pro rapid learning
procedure). Follow the instructions tions of the DRBIII to
(2) Run the engine at idle idle speed, with the gear selector execute the relevant procedure.
in the NEUTRAL tion.
(3) ) If the fluid flow is intermittent or takes more than 20 PINION FACTOR PROCEDURE
seconds to collect 950 ml (1/4 gallon) of ATF fluid, disconnect Speedometer vehicle speed readings are taken from the
the tube to the cooler in the transaxle. transmission speed sensor. The TCM must be calibrated for the
different combinations tions of equipment available. A
cor (4 re ) s V po un e d lv e a y a v ll u e en la v r a e alt v r e a rn if s i e ca je procedure called Pinion Factor has been developed. Allows the
r h e a l st v a ol e u l m n e inve d l e qu l e a bomb. technician to set the transmission control module's initial
settings so that the speedometer readings are correct.
(5) If the flow is determined to be within acceptable limits,
Failure to perform this procedure may cause Inoperative
replace the cooler. Then fill the transmission to the proper level
Speedometer condition occurs. I lie.
with Mopar ATF PLUS 3 Automatic Transmission Fluid (Type
This procedure must be executed if it has been replaced
7176).
position the transmission control module.
(6) If the fluid flow still appears not to be adequate When,
To correctly read or reset the Pinion Factor, it is necessary to
check the operating pressure used. Using the Transmission
use a DRBIII scan tool. Perform the following steps with the
Hydraulic Pressure Test procedure.
DRBIII scan tool to read or reset the Pinion Factor:
(7) Check the cooler for dirt on the external surfaces. Clean
(5) ) Plug the DRBIII scan tool t aal bl ceornoec d teor i nds t er
if necessary.
u emnelanc t eosd . e data located below the
TRANSAXLE QUICK LEARN (2) Select the Transmission menu.

(3) Select the Miscellaneous menu.
PROCEDURE (4) Select Pinion Factor. Then follow the instructions on the
The quick learn procedure requires the use of the DRBIII
tool screen DRBIII exploration tool.
scan tool.
This program allows the transaxle electronics to recalibrate DISASSEMBLY AND INSTALLATION
itself. In this way, optimal operation of the transmission will be
achieved. seje. The quick learn procedure must be performed if SHIFT LEVER CABLE
any of the following procedures are executed:
(1) Transaxle Assembly Replacement DISASSEMBLY
(1) Place the transaxle in PARK.
(2) Replacing the transmission control module Zion (2) Disconnect the negative battery cable at the left pillar
tower.
(3) Solenoid Assembly Replacement (3) Remove the air cleaner assembly.
(4) Remove the positive battery cable.
(5) Remove the transmission control module (TCM)
(4) Replacing the clutch plate and/or gasket
connector. Remove the TCM.
(6) Remove the power distribution center (PDC) by pulling
(5) Valve body replacement or rehabilitation the up and out of the way.
(7) Using a pliers, pry up on the manual valve lever cable
To execute the quick learning procedure, the following
and remove the lever cable (Fig. 1 1).
conditions must be met:
(8) Remove the screw from the cable bracket on the
(6) The brakes must be applied
transaxle (Fig. 1 1).
(7) Engine speed must be greater than 500 rpm

(8) Throttle angle (TPS) must be less than 3 degrees
(9) The position of the gear lever must give until requested to
shift to overdrive
•
Fig. 11 Transaxle shift lever cable Fig. 13 Shift lever cable on floor shifter
(9) Remove the adjusting screw from the shift lever and
(15) Raise the vehicle. See group 0, Lubri cation and
knob.
maintenance.
(10) Remove the rear half of the floor console.
(16) Remove the rubber grommet from the cable from the
C floor area of the body (Fig. 14).
o(n1 s 1 u ) lt Reeeti l regr u lapom 2 i 3 ta , d C adrreloacnetre í ar (17) 7) Carefully remove the cable from the underbody by
.
a from the floor console. See group 23, Bodywork. unfolding the cable retaining collar (Fig. 14) as you go.
(11) 2) Loosen the shift lever cable adjusting lever nut (Fig.
12). FACILITY
(12) 3) Using a flat blade plier, remove the core end of the (18) ) Install the cable assembly into the tunnel hole of the
shifter cable from the gear lever knob (Fig. 13). body floor and fix the rubber washer. If necessary, use a
(13) 4) Using a flat-bladed pry bar, pry up on the cable synthetic-based lubricant to assist in installing the rubber
conduit collar to remove it from the shifter bracket. washer.
Fig. 12 Shifter cable adjustment lever nut

Pull the cable conduit up and out of the bracket (Fig. 13).
DISASSEMBLY AND INSTALLATION (Continued)
Fig. 14 Shift lever cable routing Fig. 15 Shift lever cable on the
floor changer assembly
(2) Place the cable in the retaining collar (Fig. 14) and
tighten the collar to secure the cable.
(3) Install the cable into the transaxle and tighten the
torque ring with a torque of 14 N·m (125 lbs. in.) (Fig. 11).
(4) Install the cable on the transaxle shift lever (Fig. 1 1).
(5) Lower the vehicle.
(6) Connect the cable to the shifter duct bracket and shifter
pin. Install the collar
de
(7 re ) te V n e c r i i ó fin qu d e qu a e bl e a ( p F a ig la . n 1 c 3 a ). of
tram changes seat and floor shift lever are in the PARK position.
(8) Tighten the cable adjuster nut (Fig. 12).
(9) Reinstall the front and rear floor consoles be.
(10) Install the shift lever handle.
CHANGE MECHANISM
DISASSEMBLY
(1) Disconnect the battery and insulate the cable.
(2) Remove the adjusting screw from the shift knob and
Fig. 16 Interlock cable on floor changer assembly
knob. (7) Remove the nuts from the base of the shift mechanism
(3) Remove the console assembly. See group 23, (Fig. 17). Remove the shifter assembly and cable assembly.
Bodywork.
(4) Using a flat blade plier, remove the end of the shifter
cable from the cam pin. bio (Fig. 15).
(5) Pry the retaining collar up and out to remove it from the
shift mechanism. Remove the shift lever cable from the shift
mechanism (Fig. 15).
(6) Pry up the adjuster lock on the shift-ignition interlock
cable (Fig. 1 6). Disengage the connection at the end of the shift
and ignition interlock cable from the cam mechanism groove.
bios.
SHIFT AND IGNITION INTERLOCK
CABLE
DISASSEMBLY
(1) 1) Disconnect and isolate the negative (-) cable from
the vehicle battery, located on the left pillar tower.
(2) Remove the gear shift knob adjusting screw and knob.
(3) Remove the console assembly. See group 23,
Bodywork.
(4) Remove the interlock cable from the shifter housing.
Slide the cable out of the slot in the interlock lever. (Fig. 18).
Fig. 17 Shift mechanism

FACILITY
(1) ) Install the shifter and bracket assembly (Fig. 1 7) .
Tighten the nuts to a torque of 1 7 N·m (150 lbs. in.).
(2) Install the shifter cable into the duct bracket and shift
pin. Ins remove the retaining collar (Fig. 15).
(3) Slide the core wire of the inter cable lock in the groove of
the interlock adjustment lever. Make sure the ear of the interlock
cable fits into the groove (Fig. 16).
(4) Slide the conduit end connection of the interlock cable
into the base and snap it into place (Fig. 16).
(5) Adjust the shift lever and interlock cables. See Settings
in this group.
NOTE: The shifter and interlock cables MUST be adjusted.

Consult the procedures correct settings in the Settings
section of this group. Fig. 18 Shift and Ignition Interlock Cable
(6) If the vehicle has Autostick installed, connect the (5) Pull the cable up to remove it from the gear shift
Autostick connector. mechanism.
(7) Install the console assembly. See group 23, Bodywork, (6) Remove the fuse panel cover from the left end of the
for correct procedures. instrument panel. Remove the screw securing the end of the
(8) ) Install the shift lever knob and instrument panel top cover (Fig. 19).
(7) Remove the central frame (Fig. 20).
tighten the adjusting screw. (8) Remove the screws securing the top cover.
(9) Connect the negative battery cable.
traio b r l edroe l (F ta i gb . le 2 r 1 o ). of instruments to the center of
AUTOSTICK said
The autostick switch mechanism is incorporated within the
gear shift mechanism. If the switch needs to be replaced, the (9) Pull the top cover of the dashboard ments upward
gear shift mechanism will need to be replaced. To replace the enough to gain access to the knee protector screws (Fig. 22).
car switch tick, see Replacing the Gear Shift Mechanism in this (10) 10) Remove the lower screws of the knee protector and
section. remove it.
(11) ) Remove the screws from the lower steering column
cover (Fig. 23).
(12) Pull the bottom cover to reveal open ignition key
cylinder (Fig. 24).
FUSE BOARD TOP COVER
COVER SCREW
POSITIONS OF THE TOR-

PROTECTOR'S KNIGHTS
KNEE BELOW
TOP DECK
TOR POSITIONS LOWER

NILLS 8Üaf15B3
Fig. 19 Instrument panel upper cover – Left Fig. 22 Knee Protector Attachment Points
side
SCREW POSITIONS
LOTS OF THE LOWER SHEATH
OF THE STEERING COLUMN
80att584
Fig. 23 Steering column lower cover screw positions

Fig. 20 Center frame
Fig. 21 Dashboard top cover Fig. 24

instruments–Center
Disassembly of the lower cylinder cover
of the ignition key
(13) Hold down the steering wheel tilt lever and slide the
bottom cover forward to remove it from the column (Fig. 25).
Fig. 27 Interlock cable and connector

(1) Route the interlock cable into the lower dome plate.
Fig. 25 Removal of the lower cover (2) Place the ignition switch in the ON/RUN position (Fig.
26).
(14) 4) Tilt the steering wheel to the position bottom end
(3) Install the interlock cable into the steering column cable
cover and remove the upper cover from it.
cover (Fig. 28). Verify that the cable comes under pressure into
(15) 5) Turn the ignition key to the ONRUN position (Fig. 26)
the cover.
. Take the collar and interlock cable connector. Remove the
cable from the interlock system housing (Fig. 27).
Fig. 26 Positions of the ignition switch and key

(16) Disengage the cable retaining collar located along the Fig. 28 Interlock cable on cover
cable cover. (4) Install the interlock cable into the guide collar located
(1 7) Remove the interlock cable from the bottom of the along the cable jacket.
instrument panel. (5) Route the interlock cable toward the alone.
(6) Snap the connection on the end of the shift and ignition
FACILITY interlock cable into the recess in the gear shift mechanism (Fig.
18).
CAUTION: When installing the interlock cable assembly, you
(7) Adjust the shift and ignition interlock system. See
must be careful not to bend the cable and the exposed cable
Interbloc System Adjustment queo, in this section of the service
lug at the shifter end of the cable.
manual.
NOTE: The interlock cable MUST be tightened. See Interlock Fig. 29 Interlock Mechanism
System Adjustment in this group.
MANUAL VALVE LEVER
(8) Install the console assembly. See group 23, Bodywork.
(9) Install the cam knob adjusting screw gear bio and knob. CHANGES)
(10) 0) Tilt the steering wheel to the extreme lower position DISASSEMBLY
and install the steering column upper cover. (4) ) Remove the shift cable from the lever.
(11) 1) Hold down the steering wheel tilt lever and place the (2) Loosen the lever mounting bolt. Do not remove the bolt
lower cover on the column. (not necessary).
(12) Install the steering column lower cover screws. (3) Pull up on the lever and remove it.
(13) Install the lower knee guard screws and the knee
guard. FACILITY
(14) Install the screws that secure the bottom cover. front of (4) ) For installation, reverse the disassembly procedure.
the instrument panel to the center of said dashboard.
(15) Install the center frame. SOLENOID ASSY-REPLACEMENT
(16) Install the screw that supports the end of the instrument
panel lower cover. Install the fuse panel cover from the right
end. from the instrument panel.
(17) Reconnect the negative (-) cable to the vehicle battery.
INTERLOCK MECHANISM
DISASSEMBLY
(1) Remove the lower spine covers, knee protector and
covers. See Interlock Cable Replacement.
(2) Firmly grasp the interlock cable and connector. Remove
the interlock cable.
(3) Remove the two interlock mechanism installation screws
on the steering column (Fig. 29). Remove the interblo system
cover Queo.
Fig. 30 Disassembly of the discharge speed sensor
FACILITY
(1) Install the interbloc system cover Queo on the steering To install the solenoid assembly, reverse the removal
column. Install the two tor interlock mechanism installation bolts procedure. Tighten the screws to a torque of 12 N • m (105 lbs.
on the steering column. Tighten the screws to a torque of 3 N·m in.).
(21 lbs. in.).
(2) Snap the interlock cable into the cover.
(3) Install the lower spine covers, covers and knee
protector. See Reem interlock cable term.
DISASSEMBLY
(1) 1) Disconnect the negative battery cable.
(2) Remove the engine air cleaner and tube.
(3) Remove the gear shift cable.

(4) Remove the manual valve lever.
(5) Disconnect the transmission position sensor connector.
(6) Raise the vehicle.
(7) Carefully remove the transaxle oil pan and drain the
fluid.
(8) Remove the transaxle oil filter. Allow the transaxle oil to
drain completely.
(9) Remove the valve body retaining bolts.
(10) 0) Remove the parking rod from the guide clamp and
remove the valve body from the transaxle.
(11) ) Place the valve body on the work bench (Fig. 34).
(12) 2) Remove the TRS retaining screw (Fig. 35).
Fig. 31 Removing the noise cover
(13) Remove the manual shaft seal (Fig. 36).
(14) 14) Slide the transmission position sensor up the
manual shaft and remove (Fig. 37).
FACILITY
(15) ) For installation, reverse the disassembly procedure.
Tighten the retaining screw to 5 N·m (45 lbs.) in.). Reseal the
transaxle oil pan using RTV.
SPEED-DRIVE SENSOR
Fig. 32 Removal of the fixing screws
80Dnod4i
Fig. 34 Valve body with TRS
CAUTION: When disconnecting the speed sensor connector,

make sure the protection Weather protection does not fall or
remain on the old sensor.
Fig. 33 Disassembly of the solenoid assembly

TRANSMISSION POSITION SENSOR
The transmission position sensor is located inside the
transaxle. To remove the TRS, the transaxle oil pan and valve
body must be removed.
TRANSAXLE 21 -
85
Fig. 35 Removal of retaining screw Fig. 38 Output speed sensor (turbine) SPEED
SENSOR-TRANSMISSION
CAUTION: When disconnecting the speed sensor connector,
make sure the protection tion does not fall or remain on the
sensor being removed.
The transmission speed sensor is located to the right of the

manual shift lever (Fig. 39).
Fig. 36 Disassembly of the manual shaft seal
TRANSMISSIO
N POSITION
SENSOR
MISSION
Fig. 39 Transmission speed sensor TRANSMISSION
CONTROL MODULE
Do not exchange Transmission Control Modules with those
from previous years. If a TCM from another vehicle of the same
800c6c4f
year is used, the following procedures must be carried out:
• Quick learning procedure
Fig. 37 Transmission position sensor removal
• Electronic pinion factor procedure

The drive speed sensor is located to the left of the manual The transmission control module is located next to the
shift lever (Fig. 38). battery on the left side of the vehicle ass, in the engine
compartment. It is held in place by three installation screws.
NOTE: If you replaced the transmission control module, you VALVE BODY must perform the following
procedures ments:
• Quick Learn Procedure: This procedure This function will

allow the transmission control module to learn the characteristics
of the vehicle.
• Electronic Pinion Factor Procedure: This procedure will
reprogram the TCM to compensate for different tire sizes and final
traction reduction.
2.4 LITER ENGINE

DISASSEMBLY
(1) Disconnect the negative battery cable from the left pillar
tower.
(2) Remove the air cleaner clamps and the air cleaner.
(3) Remove the 60-way connector from the TCM.
(4) Remove the three installation screws.
(5) Remove the TCM (Fig. 40).
Fig. 41 Removing the oil pan bolts
Fig. 40 Transmission control module Fig. 42 Removing the oil pan

FACILITY CAUTION: If the valve body becomes visible Polished
(6) ) For installation, reverse the disassembly procedure. incorrectly or dropped, its manual shaft guide may become
deformed and jam the manual valve.
2.5 LITER ENGINE
DISASSEMBLY NOTE: To facilitate valve body installation, turn the manual
(1) Disconnect the negative battery cable from the left pillar valve lever counterclockwise. completely to the right.
tower.
(2) Remove the 60-way connector from the TCM.
(3) Remove the three installation screws.
(4) Remove the TCM.
FACILITY
(5) ) For installation, reverse the disassembly procedure.
NOTE: To facilitate valve body disassembly, turn the manual
valve lever completely to the right.
INS P T ar A a LA in C s I t O al N ar the valve body,

reverse the pro dismantling procedure.
Fig. 43 Removing the oil filter Fig. 46 Valve body disassembly

moving the control.
Fig. 44 Disassembly of the valve body fixing bolts

Fig. 47 Valve body removed along with manual lever out of the
installation position.
TRANSAXLE
DISASSEMBLY
To remove the transaxle, disassembly is NOT required.
engine rating.
Transaxle and torque converter must be removed taken
together. Otherwise, the torque converter drive plate, pump
bushing or oil seal may be damaged. The control board does
not support loads; For this reason, all or part of the vehicle's
weight should not be allowed to rest on the plate during
disassembly.
(1) 1) Disconnect the negative battery cable from the left
Fig. 45 Removing the Parking Rod Rollers from the Guide pillar tower (Fig. 48).
Bracket (2) Remove the air cleaner duct.
(3) Remove the Transmission Control Module (TCM) and
Guide the parking rod rollers in the guide bracket, while wiring (Fig. 49).
Fig. 51 Transaxle Cooler Pipes

(7) Remove the shift cable from the shift lever and clamp
from the transaxle (Fig. 52) (Fig. 53).
Fig. 49 Transmission control module

(4) Remove the solenoid assembly connector (Fig. 50).
Fig. 52 Shift cable on the lever
Fig. 50 Solenoid assembly connector

(5) Remove the dipstick tube.
Fig. 53 Shift cable clamp
Fig. 56 Bottom Splash Guards

(1 3) Remove the remaining bolts from the left upper support
Fig. 54 Engine support accessory (characteristic) (Fig. 57).
(9) Remove the top bolts from the top bracket left rear of the TOP SUPPORT
TRANSAXLE
transaxle (Fig. 55).
Fig. 57 Left bracket bolts

(14) 14) Remove the engine oil filter.
Fig. 55 Upper transaxle support (15) 5) Remove the starter motor and wiring (Fig. 58).
(16) 6) Remove the front engine mount bracket.
(1 0) Raise the vehicle. Remove the front wheels ras. To
(17) Remove the rear bracket through bolt.
remove the wheel hub nuts and both drive axles, see group 2,
(18) 8) Remove the center member bolts.
Suspension.
(1 1) Remove the right and left side splash guards (Fig. 56). (19) 9) Remove the rear support bracket bolts and remove
the bracket.
(20) Remove the lower radiator grille.
CAUTION: The exhaust pipe flexible joint must be (21) Remove the side curved strut brackets (front and rear).
disconnected from the exhaust manifold whenever the
vehicle is lowered. If the vehicle is lowered butt with the hose NOTE: The 2.4L engine has an oil pan collar bracket
connected, damage will occur. attached to the transaxle converter cover. For the
appropriate procedure Removal and installation instructions
(1 2) Remove the bolts securing the exhaust pipe flexible refer to group 9, Engine.
joint to the exhaust manifold pipe. Disconnect the exhaust pipe
from the manifold. (22) Remove the flex plate cover.
Fig. 58 Starter motor Fig. 60 Converter Bolts

(23) Rotate the motor clockwise to align the converter bolts
(Fig. 59). Remove the converter bolts (Fig. 60). Sea than the
converter to facilitate reassembly.
8Üal1595
Fig. 61 Steering Gear and K Frame Bolts
Fig. 59 Turn the motor clockwise

(24) Remove the crankshaft position sensor (if equipped).
(25) Remove the transaxle wiring.
(26) Loosen the bolts on the right side of the mechanism.
n d i e s l m b o as d t e i l do di r re K c . tion. Loosen the bolts on the

right side
(27) Remove the bolts from the left side of the mecha nism
of direction. Remove the bolts from the left side of the K frame
(Fig. 61).
(28) Remove the stabilizer bar brackets (Fig. 62).
Fig. 62 Stabilizer bar mounts
(29) Place a transmission jack under the transaxle and
support it with a safety chain (Fig. 63). (31) Move the K-frame rearward and carefully lower the
(30) Remove the top and bottom bolts from the transaxle assembly from the vehicle.
transaxle converter cover.
FACILITY
Fig. 63 Transmission jack
INSTALLATION Fig. 65 Installing the oil pump gasket

ce d (1 i m) i Peanr t ao laani t nesr i toarl . ation of the DISASSEMBLY AND ASSEMBLY
transmission, reverse the
(2) Check and/or adjust the gear shift cable.
REHABILITATION OF THE VALVE BODY
(3) Fill the transaxle with MOPAR ® ATF 3 PLUS (automatic
transmission fluid) type 7 176.
OIL PUMP GASKET

DISASSEMBLY
BÜil'E5
Fig. 66 Transmission position sensor screw
Fig. 64 Disassembly of the oil pump gasket

DISASSEMBLY AND ASSEMBLY (Continued)
RETAINING
SPRING
POSITION SENSOR
TION OF THE
TRANSMISSION
PARKING SHOCK
ROD I LIE COCKSCO RETAINER SPRINGS
MB PLATE
2–4 ACCUMULATOR PISTON
RETAINING
SCREW
8086769
Fig. 67 Transmission position sensor removed Fig. 70 TRS, Manual axle and 2-4 accumulator
Fig. 71 Valve body screws

Fig. 68 Manual shaft and cockscomb
OVERSIDE CLUTCH CHECK
BALL CHA (N°5)
SEPARATOR PLATE
Fig. 72 Valve body and transfer plate

Fig. 69 2-4 Accumulator Plate
Fig. 73 Transfer plate and separator plate
BALL LOCATION
LOW AND DRIVE SWITCH VALVE RETENTION (No. 3)

BACK
80a62420
Fig. 74 Location of check ball

TRANSAXLE—DISASSEMBLY
NOTE: Label all clutch assemblies as you remove them to
facilitate identification for reassembly.
CAUTION: Do not mix clutch discs and plates, as failure

may occur.
1) 1) Remove the drive and transmission speed sensors.

2) Remove the transaxle solenoid assembly (Fig. 78).
Fig. 75 Removal or installation of dual retainer plate
Fig. 78 Solenoid Assembly Removal
80a773Hc
Fig. 76 Location of springs and valves
Fig. 79 Removal of oil pan bolts
NOTE: To facilitate valve body disassembly, rotate the entire

manual valve mind to the right.
Fig. 77 Low and reverse switch valve and torque
converter limit valve
CAUTION: Do not handle the valve body from the manual
valve, as damage may occur.
Fig. 80 Removing the oil pan Fig. 83 Parking pushrod rollers from guide bracket
Fig. 84 Valve body disassembly
Fig. 82 Disassembly of the valve body fixing bolts

Fig. 85 Valve body removed
NOTE: Depending on the engine application, some acu disassembling, mark the location of the accumulator spring
Mulators have two springs while others have only one. to facilitate assembly.
Springs are color coded by application and year. When
Fig. 86 Disassembly of batteries Fig. 89 Removing the low and reverse

accumulator spring ring
Fig. 87 Accumulator (submultiplication)

Fig. 90 Removal of the low and reverse accumulator plug
(cover)
Fig. 88 Accumulator (overdrive)

Measure the drive shaft end play with the transaxle in the
upright position. This ensures that the measurement is Fig. 91 Removal of the low and reverse accumulator
accurate. plunger
Fig. 92 Disassembly of the low and reverse Fig. 94 Disassembling the pump fixing bolts
accumulator
Measuring the drive shaft end play prior to disassembly will
generally indicate when a No. 4 thrust plate replacement is
required. This thrust plate is located behind the overdrive clutch
hub.
Place a dial indicator on the transaxle converter cover with its
plunger seated against the end of the drive shaft (Fig. 93).
Fig. 95 Installing Tool C-3752

CAUTION: Make sure you have removed the sen discharge
speed sensor before removing the oil pump.
Fig. 93 Drive shaft end play measurement

Move the drive shaft in and out to obtain the end play
reading. End play specifications are 0.13 to 0.64 mm (0.005 to
0.025 in.).
Record the gauge reading for reference when reassembling
the transmission. seje.
Fig. 96 Disassembly of the oil pump

21 - 98
TRANSAXLE
OIL PUMP PUMP GEARS BODY OF
Fig. 100 Measurement from external gear to bore
Fig. 97 Oil pump removed When disassembling the transaxle, it is necessary to install
Check if the oil pump is worn or damaged.
(1) ) Remove the reaction shaft bracket bolts. tion.
(2) Remove the reaction shaft support from the pump body
(Fig. 99).
(3) Remove the pump gears and check for wear or damage.
(4) Install the gears and check the clearances.
(5) Measure the clearance between the external gear and
the pump cavity (Fig. 100). The clearance should be 0.045-
0.141 mm (0.0018-0.0056 in.).
(6) Place an appropriate piece of scrap gauge ble on both
gears.
(7) Align the disposable gauge with a flat area on the
reaction shaft body.
Fig. 98 Disassembly of the fuel pump seal

oil
OIL PUMP INSPECTION
21 - 99
TRANSAXLESHAFT SUPPORT
REACTION
Fig. 99 Reaction shaft support
(8) Install the reaction shaft into the pump body. Tighten the
bolts to a torque of 27 N·m (20 lbs. foot).
(9) Remove the bolts and carefully separate the bodies.
Measure the disposable gauge following the instructions
EENXGTRE
instructions supplied. A R N N A O JE
(10) The clearance between the outer gear side and the
reaction shaft support should be 0.020 to 0.046 mm (0.008 to
0.0018 in.). The clearance between the internal gear side and
the reaction shaft support should be 0.020 to 0.046 mm (0.008
to 0.0018 in.).
CAUTION: The coolant bypass valve dor must be replaced if

transaxle failure occurs. Do not reuse the old valve or
attempt to clean it. When installing the deri valve vation,
insert it with the end of the O-ring toward the rear of the
crankcase.
ADJUSTMENT PLATE N° 4
Fig. 101 Disassembly of the bypass valve Fig. 104 Push plate #4
Fig. 102 Caged Needle Bearing Disassembly Fig. 105 Disassembly of the front sun gear
Fig. 106 Disassembly of the front carrier and rear ring

Fig. 103 Drive Clutch Assembly Disassembly assembly
NOTE: Verify that the Miller 5058 tool is properly centered
on the 2/4 clutch retainer before depressing the tool.
CLUTCH
BEARING SEAL
NEEDLES N° 7
SOLAR GEAR 2/4 CLUTCH RETURN

TRA SERO SPRING
Fig. 107 Rear sun gear disassembly Fig. 110 2/4 clutch retainer
Fig. 108 2/4 clutch retainer snap ring removal Fig. 111 Removal of the 2/4 clutch return spring
Fig. 109 Disassembly of the 2/4 clutch seal Fig. 112 Disassembly of the clutch assembly
2/4
NOTE: Label the 2/4 clutch assembly for reference
identification when reassembling.
REAC PLATE SCREWDRIVER
LOW AND
REVERSE CLUTCH
TION SPRING RING
LOW AND CONICAL
REVERSE GEAR (LATE
LONG TAB RAL CONICAL TOWARDS
ABOVE)
FACE OF
THE
COLLECTO
R OIL TOR
BQaf603
Fig. 114 Disassembly of the low and reverse reaction plate
Fig. 116 Removing the low and reverse reaction plate spring
ring
Fig. 115 Disassembly of a single disk

Fig. 117 Disassembly of the low and reverse clutch

assembly
NOTE: Label the low and reverse clutch assembly for
reference identification when reassembling.
Fig. 118 Rear cover bolt removal

3 MM (1/8 INCH) BEAD OF MOPAR SILICONE SPECIAL TOOL L-4407–6 TRANSFER SHAFT
RUBBER ADHESIVE SEALANT AS SHOWN GEAR RENCE
L-4407
Fig. 119 Removing the rear cover Fig. 122 Transfer Shaft Gear Disassembly
Fig. 120 Transfer Shaft Gear Nut Removal

Fig. 123 Disassembly of transfer shaft gear and
spacer (selective)
8Qaf6216
Fig. 121 Drive shaft gear nut

transfer and conical washer Fig. 124 Bearing cup retainer removal
NOTE: 5049-A screw on transfer shaft.
Remove the transfer shaft.
Fig. 125 Transfer Gear Bearing Cone Disassembly
Fig. 128 Disassembly of the transfer shaft
Fig. 126 Transfer Shaft Bearing Cup Removal

Fig. 129 Bearing cup removed
Fig. 127 Transfer shaft bearing snap ring removal Fig. 130 Transfer shaft bearing cone removal
NOTE: Remove the drive gear bracket and strap bolts.
All transaxles use a retaining bracket and strap that attaches

to the drive gear. The step prevents the output gear retaining
bolt from rotating out of the rear carrier. The strap is used to
hold the bracket on the drive gear and prevent the drive gear
retaining bolts from coming out.
Fig. 133 Disassembly of the footboard strap
Fig. 131 Loosening the footboard strap bolts
Fig. 132 Disassembly of the strap bolts
Fig. 135 Disassembling the output gear bolt

Fig. 136 Drive gear bolt and washer Fig. 139 Bearing cone disassembly
Fig. 137 Transmission gear disassembly Fig. 140 Rear Carrier Assembly Removal
Fig. 138 Drive gear and spacer (selective)

Fig. 141 Rear Carrier Bearing Cone Disassembly
Fig. 142 Low and reverse spring compressor Fig. 145 Low and reverse piston return spring
RETAIL SPRING
Fig. 143 Compressor in use Fig. 146 Removing the anchor shaft
SPRING RING OPENING SHOULD BRACKET ANCHOR
BE BETWEEN SPRING LEVERS ANI PLIERS DOCK SHAFT
(AS SHOWN) LENS
ANCHOR
SHAFT CAP
Fig. 144 Disassembly of the snap ring split sleeve touch the rear of the transaxle crankcase.
CAUTION: When installing, make sure the guide bracket and Fig. 147 Disassembly of the anchor shaft and plug
TRANSAXLE 21 -
109
Fig. 148 Guide Bracket Pivot Shaft Disassembly Fig. 151 Guide support disassembled
Fig. 152 Disassembly of the low and reverse clutch

Fig. 149 Pivot Shaft and Guide Bracket piston
Fig. 150 Guide support Fig. 153 Removal of the piston seal fixing screws
TOOL
LOW AND REVERSE LIE 6062
CLUTCH Plunger Seal
BOARD üata18? BÜafb118
Fig. 154 Disassembly of the piston seal Fig. 157 Disassembly of the outer shell of the
transmitter bearing
This concludes the transaxle centerline disassembly. To
disassemble the drive clutch assembly, see Drive Clutch
Rehabilitation.
DRIVE CLUTCHES AND

REHABILITATION
DISASSEMBLY
PUSH PLATE NO. 4

(SELECTIVE)
Fig. 155 Removal of the piston seal gasket

REAC PLATE
REVERSE CLUTCH
TION
KNOCK DOWN THE REVERSE

CLUTCH REACTION PLATE
TO REMOVE OR INSTALL THE
SPRING RING
DRIVE SHAFT CLUTCH SEAL

ASSY
BDfbF4a
Fig. 158 Blows on the reaction plate
Fig. 156 Disassembly of the internal tank of the

transmitter bearing
CAUTION: Rotate the bearing cup all the way around.
REVERSE SEA CLUTCH DISC CHA
CLUTCH PLATE BACK
CAUTION: LABEL AND

IDENTIFY THAT GET
THEM TOGETHER
COUGH THE CLUTCH
TO ENSURE THE
ORIGINAL POSITION.
80afb64d
Fig. 162 Reverse clutch assembly

Fig. 159 Reverse clutch spring ring
NOTE: Label the reverse clutch assembly for reference
identification.
PRESSURE PLATE
Fig. 160 Pry the reverse clutch reaction plate

Fig. 163 Overdrive and reverse pressure plate spring ring
REVERSE CLUTCH OVERDRIVE

REACTION PLATE (INSTA AND REVERSE
LEAVE THE FLAT SIDE (SCALE SIDE-
DOWN) SWIM DOWN)
BDafbF4f
Fig. 164 Overdrive and gear pressure plate

BDafbF4c:
back
Fig. 161 Reverse clutch reaction plate
OVERSEAS CLUTCH WAVY SPRING
RING CHA AND REVERSE
SET OF
OVER-AXLE
MARCH
Fig. 165 Wave spring ring Fig. 168 Overdrive shaft assembly
Fig. 166 Overdrive Clutch Assembly Removal Fig. 169 Submultiplication shaft assembly
OVERDRIVE
CAUTION: LABEL AND
CLUTCH PLATE
IDENTIFY ASSEMBLIES
CLUTCH TOS TO SECURE
PLACE ORIGINAL LIE
OVERDRIVE
CLUTCH DISC
SHAFT ASSEMBLY
OVERDRIVE
BDafbF4#
Fig. 170 Needle bearing #2
Fig. 167 Overdrive clutch assembly
NOTE: Label the clutch assembly march in order to have a reference
identification cia for when you reassemble.
NOTE: The overdrive and sub drive reaction plate
multiplication, the spring rings and the seal of the drive
clutches are not interchangeable ble with components from
the previous year's 41TE. The spring rings are thicker and
the serrations of the spring rings have changed
Fig. 173 Disassembly of a submultiplication clutch disc

CAUTION
CION: DO
NOT GO
AGAIN
U A T N IL IL IZ L
AORDEEL
DOCK
CONICAL
Fig. 171 Overdrive and underdrive reaction plate conical

spring ring
NOTE: The reaction plate of the overdrive and underdrive
clutches has a lon on both sides. Install the tapered side of
the reaction plate of these clutches facing up.
REACTION PLATE
OF THE OVERDRIVE AND
SUB CLUTCH
MULTIPLICATION
(STAGED SIDE DOWN)
Fig. 174 Sub-speed clutch flat spring ring
A CLUTCH DISC
SUBMULTIPLICATION
PLATE
CLUTCH
DISC OF
CLUTCH
CAUTION:
LABEL AND IDENTIFY
THAT GET THEM
Fig. 172 Overdrive and underdrive reaction plate TOGETHER
COUGH OF
CLUTCH FOR
SECURE THE
POSITION
ORIGINAL TION
#afh59n
Fig. 175 Clutch assembly

submultiplication
NOTE: Label the submultiplication clutch assembly so that
you have a reference identification for when reassembling.
CAUTION: Compress the recoil spring only enough to

remove or install the ani dock lock.
Fig. 178 Submultiplication clutch plunger
Fig. 176 Sub-gear spring retaining spring ring
Fig. 179 Drive hub tapered spring ring
DRIVE SHAFT
AND HUB
ASSEMBLY
Fig. 177 Submultiplication retainer and return

spring
Bafb5ar
Fig. 180 Blows on the drive hub

TRANSAXLE 21 -
116
Fig. 181 Drive hub removed Fig. 184 Spring ring and recoil spring
ENVELOPE Plunger
GEAR AND REVERSE
RETAINING
Fig. 185 Disassembling the shaft snap ring

AXLE PRESS Plunger (COMPRESS driving
THE RETURN SPRING ONLY
ENOUGH CUSTOMER TO
WITHDRAW OR INSTALL LAR THE RING
SPRING RING) RING
RETAIL
SPRING
TOOL-
LIE
SPECIAL
OVERDRIVE AND
REVERSE Plunger
Fig. 183 Disassembly of spring ring

Fig. 186 Drive Shaft Disassembly
ASSEMBLY
Use petrolatum on all joints to facilitate assembly of
components.
Fig. 189 Recoil spring and snap ring

PRESS Plunger
SCREWDRIVER
FOR AXLES (COMPRESS THE
RETAIL SPRING
JUST ENOUGH TO DAENM
Fig. 187 Drive Shaft Installation REMOVE OR INSTALL THE ILL
U O E-
SPRING RING) LLE
DOCK
RECOIL
TOOL-
LIE
SPECIAL
6057
Plunger
OVERDRIVE AND
REVERSE
8Oafb581
Fig. 190 Installing the snap ring
Fig. 188 Drive Shaft Snap Ring Installation
NOTE: The overdrive and sub drive reaction plate

multiplication, the spring rings and the seal of the drive
clutches are not interchangeable bles with components from
the previous year's 41TE. The spring rings are thicker and
the splines on the spring rings have changed position.
Fig. 191 Installing the overdrive piston and

reverse
Fig. 195 Joint Compressor, Special Tool

Fig. 192 Installing Drive Shaft Hub Assembly 5067
Fig. 196 Recoil spring and submultiplication

Fig. 193 Installing the conical spring ring retainer
the driving hub
PLUNGER
Fig. 197 Installing the sub-gear spring retainer and snap

Fig. 194 Submultiplication clutch plunger ring
CAUTION: Compress the recoil spring only enough to remove or install the snap ring.
A DISC OF
CLUTCH
SUBMULTIPLY-
CION
PLATE
CLUTCH
CAUTION:
LABEL AND IDENTIFY
THAT GET THEM
TOGETHER
CLUTCH COUGH
TO ENSURE
THE ORIGINAL
POSITION
NAL
#afh59e
Fig. 198 Sub-speed clutch assembly Fig. 201 Overdrive and underdrive reaction plate
The reaction plate of the envelope clutches gear and

FLAT SPRING RING
OF THE REACTION PLATE
submultiplication have a step on both sides. Install the stepped
CLUTCH TION side in the shape of
SUBMULTIPLICATION
cone of the reaction plate of these clutches facing upward.
CONICAL SPRING RING OF

THE EMBRA REACTION PLATE
OVERDRIVE AND
UNDERDRIVE GUIDES
SCREWDRIVER (NOT
SCRATCH THE REACTION
PLATE
CION)
Fig. 199 Sub-speed clutch flat spring ring
Fig. 202 Conical spring ring

NOTE: The snap ring ends should be located approximately
one finger width from the drive clutch hub. Make sure that
i l l d ued l l i t
the adno l o oc oen mel e estaosrn eilnla
l t tu , un jánla -
edocropmapra e ianmtreond uec irelmo pe
groove for the ring around its entire circumference Inc.
Fig. 200 Installing the last clutch disc

submultiplication
DISASSEMBLY E AND ASSEMBLY ETHICKNESS
(Continued)OF THE REACTION PLATE
SUBMULTIPLICATION
Sub clutch assembly clearance multiplication should be 0.91
6.03 mm (0.237 in)
to 1.47 mm (0.036 to 0.058 in.). Select the appropriate reaction
6.34 mm (0.250
plate in)
ordered to meet specifications:
6.65 mm (0.262 in)
Fig. 203 How to seat the conical spring ring
SELECT PLATE
TOOL
REACTION TO OBTAIN
THE CORRECT CLUTCH ESP 63 E 1 C 1 IAL
CLEARANCE OF THE SUB-
CLUTCH
MULTIPLICATION
INDI GAME
CADOR OF
QUADRANT
C-3339
80af6633
Fig. 206 Installing Overdrive Clutch Assembly

COMPRESS THE CON-
NEXT TO THE
CLUTCH WITH
HAND TO PUT
ZERO THE INDICATOR
80afb631
QUADRANT
Fig. 204 Dial indicator arrangement for clutch clearance

measurement
Fig. 207 Installing the wave snap ring
Fig. 205 Using the hook tool

to lift a clutch disc
DISASSEMBLY E AND ASSEMBLY E (Continued)
Fig. 211 Overdrive clutch assembly clearance check

Fig. 208 Overdrive and reverse pressure plate
specifications, the clutch was not assembled correctly.
REACTION PLATE teamm b ernagte u .e d Neosoe b xriesmtearca h juas . stops you

the slack
Fig. 209 Pressure plate installed

AXLE PRESS TOOL
Plunger LIE Fig. 212 Reverse Clutch Assembly Installation
5059A
REAC PLATE
REVERSE CLUTCH
TION (FLAT SIDE
DOWN)
SPRING
RING
CAUTION: PRESS FLAT
DOWN ONLY
ENOUGH FOR THE
BRACE TO BE
VISIBLE ANI
BARKING DOCK LLO
Fig. 210 Installing the flat snap ring

Overdrive clutch assembly (OD) clearance is 1.355 to 3.188
mm (0.053 to 0.125 in.). If it is not within the Fig. 213 Installation of the reaction plate
in.). Select the appropriate reverse clutch spring ring to meet
the specifications:
1.80 mm (0.071 in)

THICKNES
S
1.56 mm (0.061 in)
2.05 mm (0.081 in)
2.30 mm (0.090 in)
SPRING RING PICTURE

REVERSE CLUTCH
Thus, all clutch clearances in the drive clutch retainer have
been checked and approved.
To complete the drive clutch retainer assembly, the reverse
and overdrive clutches must be removed from the retainer.
Fig. 214 Reverse clutch snap ring installation CAUTION: Do not mix embra parts gues. Keep them in exactly
the same order.
Now proceed to the next phase of assembly. blah:
Fig. 215 How to seat the snap ring to determine the

reverse clutch clearance
COMPRESS THE CLUTCH

ASSEMBLY BY HAND TO
ZERO THE INDICATOR
Fig. 217 Installing No. 2 Needle Bearing
SPECIAL TOOL
6311
TOOL HOOK
LIE
Fig. 216 Reverse clutch assembly clearance check

Sea clutch assembly clearance back is 0.76 to 1.24 mm (0.030 to 0.049
Fig. 218 Installing the submultiplier shaft

assembly Fig. 221 Installing Overdrive Shaft Assembly
Fig. 219 Installing Thrust Washer #3

SET
Fig. 222 Drive Clutch Assembly
flush with these clutches as they were previously adjusted and

approved.
TRANSAXLE—ASSEMBLY
To assemble the transaxle centerline, with follow the
following procedures:
Fig. 220 Push Plate #3 Installation

Reinstall the overdrive clutch and reverse clutch as shown. tra It is not necessary to check the clearances again.
DISASSEMBLY AND ASSEMBLY (Continued o action)
r
KEYS LOW AND REVERSE SCREWDRIVER
TRANSMITTER CLUTCH Plunger Seal
BEARING CUP
TOOL 5050
#Qab4FO TORX-LOC SCREWS #Qaf4Fü
Fig. 223 Installing both transmitter bearing cups Fig. 226 Installing the retainer fixing screws
Fig. 224 Installing the piston seal gasket Fig. 227 Low and Reverse Clutch Plunger Installation
Fig. 225 Plunger seal installation

Fig. 228 Guide bracket disassembled
EÜbB2910
Fig. 229 Guide support

CAUTION: During installation, ensure that the guide bracket
and split sleeve
touch the rear of the transaxle case. RETRO SPRING
cessation of the plunger
Fig. 230 Pivot Shaft and Guide Bracket
Fig. 233 Installing the low and reverse piston return

spring
Fig. 231 Guide Bracket Pivot Shaft Installation
Fig. 234 Low and reverse spring compressor

LOW AND REVERSE CLUTCH SET
RETAIN SPRING OF THE
SPRING RING (INSTA- HOLDER REAR
DOR
LIE 5058–3
6057
Fig. 235 Compressor in use Fig. 238 Rear Carrier Assembly Installation
a0afa173
Fig. 236 Installing the snap ring
Fig. 239 Installing the output gear bearing cone
DRIVE GEAR BEARING ADJUSTMENT

(1) With the transmission gear removed: ins Install a 4.50
mm (0.1 77 in.) calibration spacer into the hub of the rear carrier
assembly, using grease to hold the spacer in place.
en ( g 2 r ) an C aojne t l raa h nsemrriasmor i eyn t caoj 6 i 2 ne 59 te

, i
. nA s p t rai l eetee l ccoonn j u u nna t oto d re- sion of 271 N·m
(200 lbs. foot).
Fig. 237 Installing the bearing cone

rear carrier
To measure bearing end play:
(3) Place tool L-4432 on the gear.
(4) Push and pull the gear while rotating it back and forth to
ensure seating of the bearing rollers.
(5) With a dial indicator installed on the
transaxle case, measure the end play of the output gear (Fig.
240).
(6) For information on the spacer required to obtain the
proper bearing rating, refer to the Output Bearing Spacer Chart.
Fig. 240 Checking the end play of the output gear

bearings
DRIVE GEAR BEARING SPACER BOX
longitudinal play Necessary spacer Part number Longitudinal play Necessary spacer Part number
0.05 mm (0.002
4412830 4412818
in) 4.42 mm (0.174 in) 0.53 mm (0.021 in) 3.94 mm (0.155 in)
0.08 mm (0.003 4412829 4412817
in) 4.38 mm (0.172 in) 0.56 mm (0.022 in) 3.90 mm (0.154 in)
(0 0 ,0 ,1 0 0 4 m (0 4 ,1 ,3 7 8 2 m pu m 4412829 (0 0 .0 .5 2 8 3 m (0 3 ,1 ,9 5 0 4 m pu m 4412817
pu m lg.) lg.) m
pu lg.) lg.)
0.13 mm (0.005
4412828 4412816
in) 4.34 mm (0.171 in) 0.61 mm (0.024 in) 3.86 mm (0.152 in)
0.15 mm (0.006 4412827 4412815
in) 4.30 mm (0.169 in) 0.64 mm (0.025 in) 3.82 mm (0.150 in)
0.18 mm (0.007
4412827 4412815
in) 4.30 mm (0.169 in) 0.66 mm (0.026 in) 3.82 mm (0.150 in)
0.20 mm (0.008
4412826 4412814
in) 4.26 m (0.168 in) 0.69 mm (0.027 in) 3.78 mm (0.149 in)
0.23mm 4.22mm 0.71mm 3.74mm
4412825 4412813
(0 0 ,0 ,2 09 5 (0 4 ,1 ,2 66 2 (0 0 ,0 ,7 2 4 8 (0 3 ,1 ,7 4 4 7
mpumlg.) mpumlg.) 4412825 mpumlg.) mpumlg.) 4412813
0.28 mm (0.011 4412824 4412812

in) 4.18 mm (0.165 in) 0.76 mm (0.030 in) 3.70 mm (0.146 in)
0.30 mm (0.012
4412823 4412811
in.) 4.14 mm (0.163 in) 0.79 mm (0.031 in) 3.66 mm (0.144 in)
0.33 mm (0.013
4412823 4412811
in) 4.14 mm (0.163 in) 0.81 mm (0.032 in) 3.66 mm (0.144 in)
Longitudinal play Necessary spacer Part number Longitudinal play Necessary spacer Part number
0.36 mm (0.014
4412822 4412810
in.) 4.10 mm (0.161 in) 0.84 mm (0.033 in) 3.62 mm (0.143 in)
0.38mm 4.10mm 0.86mm 3.62mm
4412822 4412810
(0 0 .0 .4 15 1 (0 4 ,1 ,0 6 6 1 (0 0 ,0 ,8 3 9 4 (0 3 ,1 ,5 4 8 3
mpumlg.) mpumlg.) 4412821 mpumlg.) mpumlg.) 4412809
0.43 mm (0.017 4412820 4412808

in) 4.02 mm (0.158 in) 0.91 mm (0.036 in) 3.54 mm (0.139 in)
0.46 mm (0.018
4412820 4412808
in) 4.02 mm (0.158 in) 0.94 mm (0.037 in) 3.54 mm (0.139 in)
0.48 mm (0.019
4412819 4412807
in) 3.98 mm (0.157 in) 0.97 mm (0.038 in) 3.50 mm (0.138 in)
0.51 mm (0.020 4412818
in) 3.94 mm (0.155 in)
(7) Use tool 6259 to remove the retaining bolt and washer.
To remove the gear transmitter assembly, use tool L-4407.
(8) Remove the calibration spacer and install the appropriate
spacer (Fig. 241). Use grease to hold the spacer in place. Install
the with transmission gear and bearing together (Fig. 242).
CAUTION: Always use a new retaining bolt. The old one
cannot be used again.
Fig. 242 Drive Gear Installation

TRANSMITTER GEAR
Fig. 241 Transmitter gear and spacer (selective)
(9) Install the new retaining bolt and washer (Fig. 243).
Tighten to 271 N·m (200 lbs.) foot) (Fig. 244).
(10) 0) With a tension wrench of lbs. pu lg., check than the
torsion (Fig. 245). The torque should be between 0.34 and 0.90
N·m (3 and 8 lbs. in.).
If the rotation torque is too high, install a 0.04 mm (0.0016 in.)
thicker spacer. If the rotation torque is too low, install a spacer. 80af621e
Fig. 243 Drive Gear Bolt and Washer Installation

Fig. 244 Tighten the drive gear to 271 N·m (200 lbs.) Fig. 246 Bracket on Drive Gear Retaining Bolt (Serrated
foot) Side Outward)
Fig. 245 Checking the rotation torque of the output gear Fig. 247 Caliper Strap (Align strap holes with tapped holes
bearings in gear)
0.04 mm (0.0016 in.) thinner. Repeat the operation until the proper
rotational force is 0.34 to 0.90 N·m (3 to 8 lbs. in.).
NOTE: Install bolts for the yoke and drive gear strap.
All transaxles have a bracket and a retaining strap that attaches

to the transmission gear. The footboard prevents the gear retaining
bolt from rotating out of the rear carrier. The strap is used to hold
the yoke on the drive gear and prevent the yoke retaining bolts from
coming out.
Fig. 248 Strap Bolt Installation

Fig. 249 Rotate the bracket clockwise against the flats of

the output gear retaining bolt. Fig. 252 Transfer Shaft Bearing Cone Installation
Fig. 250 Tighten the footboard strap bolts to 23 N·m (200

Fig. 253 Installing the bearing cup to the shaft
lbs.) in.)
TABS
RETAINING
NOTE: Screw tool 5049-A onto the transfer shaft. Install the
STRAPPING transfer shaft.
Fig. 251 Bending of the tabs on the strap up against the

flat surfaces of the bolts
Fig. 254 Transfer Shaft Installation

TRANSAXL
E
PLIERS FOR ANI- SPRING RING

PIER LLOS- SHAFT BEARING PLUNGER
TOOL 6051 TRANSFER OF THE
PRESS
FOR AXLES
NEW CONE OF
BEARING
TRANSFER
SHAFT GEAR
RENCE
Fig. 255 Transfer Shaft Bearing Snap Ring Installation Fig. 258 Bearing Cone Installation
transfer
TRANSFER SHAFT BEARING
Plunger (1) Install a 4.66 mm (0.184 in.) calibration spacer on the
PRESS FOR
AXLES transfer shaft.
(2) Install the transfer shaft gear and bearing assembly and
tighten the nut with a torque. sion of 271 N·m (200 lbs. foot).
TOOL 6061 To measure bearing end play:
• Place tool L-4432 on the transfer gear.
• Install a greased steel ball on the end of the transfer shaft.
• Push and pull the gear while rotating it back and forth to
ensure seating of the bearing rollers.
USE THE BUCKET
DISASSEMBLED BEARING RETAINER
OF THE SUPPORT CUSHION BUCKET
• Using a dial indicator, measure the end play of the transfer
RETAINER SHAFT NETE
TRANSFER
shaft.
80af620f
Fig. 256 Axle Bearing Cup Installation

transfer in retainer
ALIGN THE REFERENCE
TAB WITH
THE NOTCH
BUCKET RETAINER
BEARING 80at5214
Fig. 257 Bearing Cup Retainer Installation

TRANSFER BEARING SPACERS CHART
Part number Part number

Longitudinal play Necessary spacer Longitudinal play Necessary spacer
4.66 mm (0.183 in) 4505588 0.76 mm (0.030 in) 3.94 mm (0.155 in.) 4412818
0.05 mm (0.002 in)
4.62 mm (0.182 in) 4412835 0.79 mm (0.031 in) 3.90 mm (0.154 in) 4412817
0.08 mm (0.003 in)
0.10 mm (0.004 in) 441 2834 0 81 mm (0 032 in) 441281 7

4.58 mm (0.180 in) 4412834 0.84 mm (0.033 in) 3.86 mm (0.152 in) 4412816
0.13 mm (0.005 in)
4.54 mm (0.178 in) 4412833 0.86 mm (0.034 in) 3.82 mm (0.150 in) 4412815
0.15 mm (0.006 in)
4.50 mm (0.177 in) 4412832 0.89 mm (0.035 in) 3.82 mm (0.150 in) 4412815
0.18 mm (0.007 in)
4.50 mm (0.177 in) 4412832 0.91 mm (0.036 in) 3.78 mm (0.149 in) 4412814
0.20 mm (0.008 in)
4.46 mm (0.175 in) 4412831 0.94 mm (0.037 in) 3.74 mm (0.147 in) 4412813
0.23 mm (0.009 in)
4.46 mm (0.175 in) 4412831 0.97 mm (0.038 in) 3.74 mm (0.147 in) 4412813
0.25 mm (0.010 in.)
4.42 mm (0.174 in) 4412830 0.99 mm (0.039 in) 3.70 mm (0.146 in) 4412812
0.28 mm (0.011 in)
4.38 mm (0.172 in) 4412829 1.02 mm (0.040 in.) 3.66 mm (0.144 in) 4412811
0.30 mm (0.012 in.)
4.38 mm (0.172 in) 4412829 1.04 mm (0.041 in) 3.66 mm (0.144 in) 4412811
0.33 mm (0.013 in)
0.36 mm (0.014 in.) 4.34 mm (0.171 in) 4412828 1.07 mm (0.042 in) 3.62 mm (0.143 in) 4412810
0.38 mm (0.015 in) 4.30 mm (0.169 in) 4412827 1.08 mm (0.043 in.) 3.62 mm (0.143 in) 4412810
0.41 mm (0.016 in) 4.30 mm (0.169 in) 4412827 1.12 mm (0.044 in) 3.58 mm (0.141 in) 4412809
0.43 mm (0.017 in) 4.26 mm (0.168 in) 4412826 1 .1 4 mm (0.045 in.) 3.54 mm (0.139 in) 4412808
0.50 mm (0.020 in) 4.1 8 mm (0.165 in) 4412824 1.22 mm (0.048 in) 3.46 mm (0.136 in) 4412806
0.53 mm (0.021 in) 4.1 8 mm (0.165 in) 4412824 1.24 mm (0.049 in) 3.46 mm (0.136 in) 4412806
3.94 mm (0.155 in) 4412818 1.47 mm (0.058 in) 2.22 mm (0.127 in) 4505570
0.74 mm (0.029 in)
(1)) For correct bearing adjustment, refer to the Transfer Shaft

Bearing Spacer Chart for the required spacer combination.
(4) Use tool 6259 to remove the retaining nut and washer.
Remove the gear from the
transfer shaft using tool L-4407.
(5) Remove the calibration spacer and install the correct
spacer (Fig. 259). Install the transfer shaft gear and bearing
assembly. (Fig. 260).
Fig. 259 Transfer Shaft Gear and Spacer

(Selective)
TRANSAXLE JA
3 MM (1/8 INCH) BEAD OF MOPAR SILICONE

RUBBER ADHESIVE SEALANT AS SHOWN
Fig. 260 Transfer Shaft Gear Installation Fig. 262 Installing the rear cover
TRANSFER SHAFT GEAR-
CAUTION: The original retaining nut cannot be used again.

Always use a new retaining nut for reassembly.
(6) Install the new retaining nut and washer and tighten to
271 N·m (200 lbs.) foot) (Fig. 261). Measure the end play of the
transfer shaft. This should be 0.05 to 0.10 mm (0.002 to 0.004
in.).
Fig. 263 Installing the rear cover bolts
Fig. 261 Tighten the nut to a torque of 271 N m (200 lbs.

•
foot)
(7) Measure the bearing end play as explained in step 3. End mm (0.0016 in.) thicker spacer. Repeat until 0.05 to 0.1025
play should be 0.05 to 0.10 mm (0.002 to 0.004 in.). mm (0.002 to 0.004 in.) end play is obtained.
NOTE: If the end play is too high, install a 0.04 mm (0.0016 Fig. 264 Installing the clutch assembly
in.) thinner spacer. If the end play is too low, install a 0.04
TRANSAXLE JA
down and reverse
NOTE: Install the stepped side of the low and reverse
reaction plate facing up.
TRANSAXLE 21 -
119
Fig. 265 Low and Reverse Clutch Reaction Plate Snap

Ring Installation
Fig. 269 Low and reverse clutch clearance check

VIEW FROM CONVERTER COVER
CONICAL SPRING RING
CONICAL SPRING RING
ENDS BETWEEN 9:00
AND 10:00 Press down on the clutch assembly by hand and reset the
dial indicator to zero. The low and reverse clutch assembly
ANI EXTREME FLAT
DOCK LOCK clearance is 0.89 to 1.04 (0.035 to 0.042 in.).
BETWEEN 2:00 AND
3:00 S elect the low and reverse reaction plate to meet the
specifications:
TABLE OF THE REACTION PLATE
REACTION PLATE
LOW AND
REVERSE
DOWN AND REVERSE

START HERE
TO PLACE
PRESSING ON PART NUMBER THICKNESS
THE GROOVE
4799846 5.88 mm (0.232 in)
4799847 6.14 mm (0.242 in)
4799848 6.40 mm (0.252 in)
SEQUENCE
DO NOT USE THE
INSTALLATION
FROM A TO H SPRING RING 4799849 6.66 mm (0.262 in)
4799855 6.92 mm (0.273 in)
TRANSAXLE CRANKCASE OIL PAN FACE
80añ620a
Fig. 267 Tapered Snap Ring Instructions

Fig. 270 2/4 Clutch Assembly Installation Fig. 272 2/4 Clutch Return Spring Installation
NOTE: When installing 2 to 4 clutch plates and discs, they

must be oriented alternately. nothing so that the guide plates
of the adjacent plates do not align; Consult with (Fig. 271).
Fig. 273 Proper orientation of 2/4 clutch spring and

retainer
Fig. 271 Wobble of 2/4 clutch plate plates
NOTE: Verify that the Miller 5058 tool is centered on the

clutch retainer.
2/4 before depressing the tool.
Fig. 274 2/4 Clutch Retainer Installation

Fig. 277 Rear Sun Gear Installation
Fig. 278 Installing Front Carrier and Rear Ring

Fig. 276 2/4 clutch clearance check Assembly
Press down on the clutch assembly by hand and reset the

dial indicator to zero. The 2/4 clutch assembly clearance is 0.76
to 2.64 mm (0.030 to 0.104 in.). If specifications are not met, the
clutch has not been assembled correctly. There is no
adjustment for the 2/4 clutch clearance.
DETERMINATION OF THE THICKNESS OF

THRUST NO. 4—LONGITUDINAL SHAFT
THE PLATE
PLAY
DRIVING
To determine the correct thickness of the #4 thrust plate,
select the #4 thrust plate plus
slim. With petrolatum (Fig. 280) to hold the thrust plate in place,
PUSH #4
install the drive shaft assembly. Make sure this assembly is
securely Fig. 279 Installing the Front Sun Gear Assembly
perfectly seated (Fig. 281).
Fig. 282 Oil pump O-ring disassembly
Remove the oil pump O-ring (Fig. 282).
Pmo u d y rá fá icn i s l tmaleanr t ey preatriarasrel l aecbco i
omnabra d l ae pa l caeciate d yelaemjupn u t j ae n° 4 correct.
NOTE: Use screwed or unscrewed dowels star head screws

to align the pump to the crankcase.
CAUTION: Be sure to reinstall the O-ring on the oil pump

after selecting tion the correct #4 thrust plate.
Measure the drive shaft end play with the transaxle in the
vertical position. This ensures that the measurement is
accurate.
slim
Fig. 280 Push plate selection #4 more
IMPULSION SPEED SENSOR

HOLE (TURBINE)
OIL COOLER FITTINGS
DRIVE CLUTCH
SEAL
Fig. 281 View through discharge speed sensor hole
CAUTION: If the view through the drive speed sensor hole is

not as shown above, the drive clutch assembly is not sealed
properly.
Fig. 283 Drive Shaft End Play Measurement

NOTE: Drive shaft end play should be 0.13 to 0.6 mm (0.005
to 0.025 in.).
For example, if the end play reading is 1.4 mm (0.055 in.),
select the No. 4 thrust plate, whose thickness is 1.8 to 1.88 mm
(0.071 to 0.074 in.). This will achieve a drive shaft end play
reading of 0.5 mm (0.020 in.) that is within specifications.
To select the appropriate No. 4 push plate please see the
chart below.
FRAME OF THRUST PLATE N°4
PART NUMBER THICKNESS

4431662 0.91 mm (0.036 in)
4431663 1.14 mm (0.045 in)
4431664 1.37 mm (0.054 in)
4431665 1.60 mm (0.063 in) Fig. 284 Installing Drive Clutch Assembly
3836237 1.73 mm (0.068 in)
4431666 1.80 mm (0.071 in)
3836238 1.96 mm (0.077 in)
4431667 2.03 mm (0.080 in)
3836239 2.16 mm (0.085 in)

4431668 2.24 mm (0.088 in)
3836240 2.39 mm (0.094 in)

4431669 2.46 mm (0.097 in)
3836241 2.62 mm (0.103 in)
4446670 2.67 mm (0.105 in)
4446671 2.90 mm (0.114 in)
44444466667021 3 3 , , 1 3 5 8 mmmm ( ( 0
0 , , 1 1 2 3 4 3 ppu u l l gg. . ) )
Fig. 285 Caged Needle Roller Bearing
Installation
Reinstall the drive clutch assembly sensors with the push
plate selected.
CAUTION: The cooler bypass valve must be replaced if

transaxle failure occurs. Do not reuse the old valve or
attempt to clean it. When installing the deri valve vation,
insert it with the end of the O-ring toward the rear of the
crankcase.
Fig. 286 Bypass Valve Installation

Plunger
BOARD OF RETAINING
ACCUMULATOR
THE RINGS
BOMB
(REGISTER THE
NOTCH)
RETAIL
SPRINGS
BQafBlef
Fig. 287 Installing the oil pump gasket Fig. 290 Installing the low and reverse accumulator
Fig. 288 Oil pump installation Fig. 291 Installing the low and reverse accumulator plug
(cover)
Fig. 289 Installing the pump fixing bolts

Fig. 292 Installation of the spring ring of the
low and reverse accumulator
aüarei!5
NOTE: Depending on the engine application, some acu
Mulators will have two springs while others will have only
one. Springs are color coded by application and year.
Fig. 295 Installation of accumulators
Fig. 293 Accumulator (Submultiplication)
Fig. 296 Valve body installation
Fig. 294 Accumulator (Overdrive)

NOTE: To facilitate valve body installation, rotate the manual
valve fully clockwise.
CAUTION: Do not handle the valve body from the manual

valve, as damage may occur.
Fig. 297 Installing the valve body fixing bolts

(1) Install the transaxle solenoid assembly (Fig. 301).
Fig. 301 Solenoid Assembly Installation

(2) Install the drive and transmission speed sensors.
This concludes the transaxle centerline assembly.
DIFFERENTIAL REPAIR
NOTE: The differential is repaired as an assembly. The only
serviceable parts inside the differential are the differential
bearing cups and cones. If a fault occurs in which If you
want another part, you must replace the differential
assembly along with the transfer shaft.
Fig. 299 Oil Pan Installation DISASSEMBLY

To repair the differential, the transfer shaft must be removed
and the bearing rotation torque checked.
(1) Remove the differential cover and bolts (Fig. 302) (Fig.
303).
Fig. 300 Manifold Bolt Installation
Fig. 302 Differential Cover Bolts

(3) Using a plastic hammer, dismantle the seal rear bearing
housing and adapter plate located on the right side of the
transaxle.
WARNING: HOLD THE DIFFERENTIAL ASSEMBLY TO

PREVENT IT FROM ROLLING OFF THE COVER.
(4) Use Miller Special Tool 5048, Collars 5048-3, and Button
L-4539-2 to remove the differential bearing cone on the side of
the seal. rear bearing assembly.
(5) Use Miller Special Tool 5048, Collets 5048-4, and Button
L-4539-2 to remove the differential bearing cone located on the
side of the bearing retainer (Fig. 306) (Fig. 307) (Fig. 308).
Fig. 303 Differential cover removal

(2) Remove the retainer and differential bearing bolts.
rencial (Fig. 304) (Fig. 305).
Fig. 306 Location of button and collars on differential

and bearing (crown side)
Fig. 304 Differential retaining bolts
Fig. 307 Locating tool 5048 on top of button and collars on

differential bearing (ring gear side)
Fig. 305 Bearing seal disassembly

(6) Using Miller Special Tool L-451 8, remove the differential
bearing race from the rear bearing retainer.
Fig. 308 Differential bearing cone disassembly Fig. 310 Bearing Cup Removal DIFFERENTIAL
(crown side) SERVICE TOOLS
(7) Using Miller Special Tool 6062A, remove the differential
bearing race from the bearing retainer (Fig. 309) (Fig. 310).
COMPONENT EXTRACTOR INSTALLER
Differential bearing 5048, collars 5052, C-4171
on the side of the 5048-4, button L-
seal 4539-2
5048, collars L-4410, C-4171
Differential bearing 5048-3, button L-
on the side of the 4539-2
rear bearing
retainer
Guide to the 6062-A 6061, C-4171
d it f e real nd ci
l a e r al
e a l l r e en t e in l
L-4518 L-4520, C-4171
8052474
Differential guide
on side of rear
Fig. 309 Location of the bearing cup extractor in the seal
bearing retainer
Percussion L-4520, C-4171
Rear bearing hammer 7794-A,
retainer gasket C-637
Bearing retainer percussion L-4520, C-4171
gasket hammer
794-A, C-637
CHECKING THE LONGITUDINAL CLEARANCE
OF THE
SIDE GEAR
Check the side gear end play whenever you remove the
80524e77
Fig. 313 Location of the bearing cone on the differential
0.33 mm (0.001 and 0.013 in.).

(2) Using Miller Special Tool 5052 and C-4 1 71, install the
differential bearing into the differential. rential (side of the
Fig. 311 Side Gear End Play Check (Rear Bearing bearing retainer).
Retainer Side) (3) Using Miller Special Tool 606 1 and C-4171, install the
differential bearing guide into the bearing retainer (Fig. 314).
differential for repair.
CUSHION BUCKET
NET OF DIFFERENCES
NOTE: Side gear end play should be BETWEEN 0.02 and RENTIAL
BEARING SEAL
DIFFERENTIAL
Fig. 314 Differential bearing retainer

(4) Using Miller Special Tool L–4520 and C-4171, install the
differential bearing into the retainer.
rear bearing dor.
PRE-ADJUSTMENT OF THE DIFFERENTIAL
BEARING
(1) Using Miller Special Tool L-4410 and C-4171, install the
differential bearing into the differential. ential (side of rear
8052473
bearing retainer) (Fig. 313).

NOTE: Perform all pre-fit measurements saw the differential
without the transfer shaft and gear installed.
Fig. 312 Side gear end play check (bearing retainer
side) ASSEMBLY PRE-ADJUSTMENT OF DIFFERENTIAL BEARING USING
THE EXISTING SPACER
(1) Position the transaxle assembly as seen tical on the
NOTE: Use Silicone Rubber Adhesive Sealant or
Mopar®
support stand, with the side of the
equivalent on rear bearing retainer and retainer and adapter
plate to seal to case.
differential bearing retainer facing up.
(2) Install tool L-4436A on the differential cial and on the
geared pinion shaft (Fig. 315).
Fig. 316 Checking the rotational effort of the differential

bearings
spacer thicker than 0.05 mm (0.002 in.). Repeat until a
Fig. 315 L-4436 Tool and Tension Wrench rotational effort of 0.56 to 2.03 N·m (5 to 18 lbs.) is achieved.
(3) ) Rotate the differential at least one full revolution to in.).
ensure that it cushions the conical roller tees are perfectly When spacer selection is made, it is not necessary to
seated. install the oil deflector.
(4) Using tool L-4436A and a lbs. tension wrench. in., check
the differential rotation effort (Fig. 316). This effort must be (7)
between 0.56 and 2.03 N·m (5 and 18 lbs. in.). (a) Install the correct spacer under the bearing cup. Make
(5) If rotational effort is within specifications, remove tools. It sure the oil deflector is properly installed in the bearing
is com completed the installation. retainer, under the spacer and bearing cup. nete.
(b) Install the differential bearing retainer using tools 5052
(6) If the rotational effort is not within specifications,
continue with the following steps. and C-4171. Seal retainer to cover with MOPAR ® adhesive
(a) Remove the differential bearing retainer from the sealant
transaxle case. and tighten
(b) Remove the bearing cup from the bearing retainer bolts with a torque of 28 N·m (250 lbs. in.)
Remove the differential, with tool 6062A (8) Using tool L-4436A and a lbs. tension wrench. in.,
(c) Remove the existing spacer from the bottom of the recheck the differential rotational effort (Fig. 3 1 6). This effort
bucket. must be between 0.56 and 2.03 N·m (5 and 18 lbs. in.).
(d) Measure the existing spacer. The spacer thickness should only be determined if any of the
following parts are replaced:
NOTE: If the rotational stress is too high when measuring, • transaxle case
install a spacer thinner than 0.05 mm (0.002 in.). If the
rotational effort is too low, install a
• differential carrier
•
Differential bearing retainer
• Rear bearing retainer
• Differential bearing cups and cones
DIFFERENTIAL BEARING SPACER CHART
PART NUMBER SPACER THICKNESS

MM INCHES
4659257 0,980 0,0386

4659258 1 0° 0 0402
4659259 , 1,06 0,0418
4659260 1,10 0,0434
4659261 1,14 0,0449

4659262 1,18 0,0465
4659263 1,22 0,0481
4659264 1,26 0,0497
4659265 1,30 0,0512

4659266 1,34 0,0528
4659267 1,38 0,0544
4659268 1,42 0,0560

4659269 1,46 0,0575
4659270 1,50 0,0591
4659271 1,54 0,0607
4659272 1,58 0,0623

4659273 1,62 0,0638
4659274 1,66 0,0654
4659275 1,70 0,0670
4659283 2,02 0,0796

4659284 2,06 0,0812
PREVISION ADJUSTMENT WITHOUT SPACER (9) Using the end play measurement determined, add 0.18
(1) Remove bearing cup from differential bearing retainer mm (0.007 in.). The result must be between 0.56 and 2.03 N·m
using Miller Special Tool 6062A. (5 and 18 lbs. in.) bearing pre-adjustment. To determine To
(2) Remove the existing spacer from under the bearing cup. determine which spacer to use, refer to the Differential Bearing
(3 ) Reinstall bearing cup into retainer using Miller Special Spacer Chart.
Tool 606 1 and C-4171. (1 0) Remove the differential bearing retainer. Remove the
bearing cup.
NOTE: When calculating the spacer it is not necessary to (11) Install the oil deflector. Install the combi Correct spacer
placement under bearing cup.
install the oil deflector.
(1 2) Install the differential bearing retainer. Seal the retainer
(4) Install bearing retainer into housing. Tighten the bolts to a to the cover with Adhesive Sealant.
torque of 28 N • m (250 lbs. in.).
(5) Position the transaxle assembly as seen tical on the
support stand and install the tool Miller L-4436-A special seat in
the bearing retainer.
(6) Rotate the differential at least one full revolution to ensure
that it cushions the conical roller tees are perfectly seated.
(7 ) Fix a dial indicator on the case and set it to zero. Place
the tip on the end of the special tool L-4436-A.
(8) Place a large screwdriver on each side of the crown and
pry it up. Check the dial indicator for the amount of end play.
CAUTION: Do not damage the transaxle case and/or the

sealing surface of the differential retainer.
Mopar ® silicone rubber (6) Loosen the cam cable adjuster nut. gear shift in the
. Tighten the bolts to a torque of shifter assembly (Fig. 317).
28 N • m (250 lbs. in.).
(13) Using the Miller L-4436-A special tool and a lbs tension
wrench. in., check the differential rotation effort (Fig. 3 16). This
effort must be between 0.56 and 2.03 N·m (5 and 18 lbs.
in.).
NOTE: If the rotational stress is too high, install a spacer
thinner than 0.05 mm (0.002 in.). If the rotational effort is too
low, install a spacer thicker than 0.05 mm (0.002 in.). Repeat
until a rotational stress of 0.56 to 2.03 N·m (5 to 18 lbs.) is
achieved. in.).
CLEANING AND INSPECTION
CLEANING THE VALVE BODY Fig. 317 Shift cable adjustment lever nut
Before removing any part from the transaxle, plug all
openings and clean the unit, preferably mind with steam. (7) Move the gear shift lever on the transaxle to the PARK
Cleanliness should not be neglected throughout disassembly position.
and assembly. When disassembling, each piece should be (8) Check that the shift lever and transmission seje are in
washed with a solvent Vent properly and then dry with the park position. Tighten the sea shift cable adjuster nut chas
compressed air. Do not scrub parts with shop cloths. All on the shifter assembly. Now, the articles The gear shift
transaxle mating surfaces are precisely machined. Therefore, all adjustment must be correctly adjusted.
parts should be handled with care in order to avoid remove (9) Check the adjustment as follows:
nicks or burrs. • The position of the detent corresponding to NEUTRAL
(neutral) and DRIVE (direct) must be between the limits of the
NOTE: Label all springs as you remove them for
stops of the manual shift lever.
identification during reassembly. blah
• Starting with the key must occur only when the shift lever
is in the positions PARK or NEUTRAL settings.
SETTINGS
AUTOSTICK
The Autostick switch is serviced in conjunction with the gear
ADJUSTMENT OF THE GEAR SHIFT LINKAGE shift mechanism. The switch is not adjustable. In case of
Normal operation of the position switch parking and neutral
position provides
Quick check to confirm if the joint fit is correct.
Move the selector lever forward slowly until it engages in the
PARK (P) position. The starter motor should work.
Once the position (P) has been checked, move the selector
slowly towards the NEUTRAL (N) position (neutral) until the
lever is in said position (N). If the starter motor also worked tion
at this point, this means that the gear shift linkage is correctly
adjusted.
If the starter does not work in any of the positions, the linkage
needs to be adjusted.
ADJUSTMENT
(1) Apply the parking brake.
(2) Remove the shift knob adjusting screw
(3) 3 m ) a R rc e h ti a r s e and el el m pa or m co o. sea change

selector chas and light wiring.
(4) Install the cam knob adjusting screw gear bio and knob.
(5) Place the gear shift lever in position (P) (Park).
SETTINGS (Continued)
If a problem occurs with the switch, refer to the Diagnosis and
Testing section.
ADJUSTING THE INTERLOCK SYSTEM

If the ignition key cannot be turned to the position LOCK
operation with the shifter in PARK, adjustment of the interlock
system may be required. To adjust the shift and ignition
interlock system, follow the procedure below. continuation.
(1) Disconnect and insulate the negative battery cable
estuary of the vehicle.
(2) Remove the adjusting screw from the shift knob and
knob.
(3) Remove the console assembly. See group 23,
Bodywork.
(4) Install the gear shift knob adjusting screw and knob.
(5) Place the shift lever in PARK. Des
Place the ignition key in the LOCK position (Fig. 319) and
remove the key.
NOTE: Do not adjust the interlock cable in the position

shown in (Fig. 318).
Fig. 320 Cable Interlock and Latch Fastener

8009a5581
• With the lock cylinder in the LOCK position (Fig. 319) and
Fig. 318 Do not adjust interlock cable here
the ignition key removed, the shifter MUST NOT be able to be
(6) If you are replacing the interlock cable, remove the removed from the PARK position.
retaining pin (Fig. 320). This allows It will cause the cable to • With the ignition key in the ON/RUN position (Fig. 3 19), the
“auto-adjust” to the correct position. Tighten the latch retainer by shifter MUST be able to move from PARK to ANY shift range
pushing it down (Fig. 320). bios.
(7) If the interlock cable is not replaced, the retaining pin is • Place the shifter in DRIVE. The ignition key MUST NOT
missing. Pull the latch retainer outward (Fig. 320) to allow be removable.
automatic cable adjustment. • Return the shifter to PARK. The ignition key MUST be
(8) Check interlock system operation: returnable to the LOCK position (Fig. 319) and withdraw.
• If these correct system responses are not met, repair is
required.
(9) Install the shifter console frame.
(10) Install the shifter handle.
SCHEMES AND DIAGRAMS
SCHEMATIC DIAGRAMS OF THE SYSTEM

41TE TRANSAXLE HYDRAULIC
PARK/NEUTRAL LR(RN-1) 24(2-4) UD(1-2-3) 00(34) R(REV) S
´) BELOW B KM/H (8 MPH) v4
LR =LOW/REVERSE 24 =IN RAGUE OF 2-4
C
UD =SUBMULTIPLICATION
R = REVERSE
AC = ACCUMULATOR
OD =se SW REMARK
=CO CC =ED MUTATOR "
H
E
PT = PRESSURE SPUCK
S =SOLENOID =COE V =REB IRADERO OIL CONVERT CTOR DRAG
COOLER
TIC M
E
LR SWITCH
S
DERIVATION
A
N
OFF D
ON DI
DC SWITCH
sw
A
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DEPOSIT OF
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F LTER 888888 =xxE-a EXCITED SOLENOIDS
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120-145 60110 45-100 0-5 15—40 PRESSURE U N C 31 )A
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FUNCTIONING DC OFF DC ON RESIDUAL LUBRICATION SUCTION
SCHEMATIC DIAGRAM OF THE TRANSAXLE HYDRAULIC SYSTEM M E BC8a583

NEUTRAL LR(RN-1) 24(2- 00(1-2-3) OD(3- R(REV S
OF 13
4) 4) )
C
VEL ´ DAD ABOVE
1)
(8MPH)
LR =LOW/REVERSE
R = REVERSE
24 =EN OD 2-4 RAGE RAGE
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AC = ACCUMULATOR SW =C NMUTER
PT = PRESSURE SPUCK
S =SOLENOID CC =EB D IRADERO OIL CONVERT CTOR DRAG
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FUNCTIONING DC OFF DC ON Yes 24/LRR U .
SCHEMATIC DIAGRAM OF THE TRANSAXLE HYDRAULIC SYSTEM TO ME

REVERSE GEAR
LR =LOW/REVERSE ontSinuacLion)N
S 24 =EMER WATER OF 2-4 OD =SOR EMARCHA SW
LR(RN-1) 24(2-4) UD{ 1-2-3) OD(3-4) R(REV| S
R = REVERSE
AC = ACCUMULATOR
PT = PRESSURE SPUCK
=COM UTADOR
CC = CONVERT WATER EMB D = OIL COLLE TOR
C
S =SOLENOID
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V = COOLER
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LR =LOW/REVERSE GEAR UD 24 =ENB ODRAGUE OF 2-4 MUTADOR REMARCH

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TEMP.
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DEPOSIT OF
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BOMB SOLENOD IS EXCITED

F TRO
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35-85 0-5 LR CC 24/LRA
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120-145 50-100 RFUE
FUNCTIONING DC OFF DC ON RESIDUAL LUBRICATION SUCCD N
SCHEMATIC DIAGRAM) THE TRANSAXLE HYDRAULIC SYSTEM E M

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LR(RNI) 24(2-4)
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REG. T.C.
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TEMP.
DEPOSIT OF
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REGULATOR MANUAL VALVE
BOMB
EXCITED SOLENOIDS
FILTER
120-145 60—110 15-40

PRESSURE (P I N C AS)
RP FU N AND LR/CC
T y_r -to FUNCTIONING
LUBRI DIRTY
DC OFF DC ON RESIDUAL
24/LR
CATIO
SCHEMATIC DIAGRAM OF THE HYDRAULIC SYSTEM TRANSAXLE M E
600a5er
N
LR(RN-1) 24(2-4) YOU(1-2-3) OD(3-4) R(REV)
SECOND SPEED AD S
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R = REVERSE SW DE CONVERT
H
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AC = ACCUMULATOR =CO CC =EN
PT = PRESSURE SPUCK
COOLER
S =SOLENOID
D = OIL COIE CTOR
V =RESP RADERO
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REGULATOR MANUAL VALVE
BOMB F LTER EXCITED SOLENOID S
120-145 60-110 45-100 PRESSURE ( I N C I) S 00

R FU N S LR,CC 24/LRR
FUNCTIONING DC OFF DC ON RESIDUAL LUBRICATION SUCTION
A
SCHEMATIC DIAGRAM OF THE DB HYDRAULIC SYSTEM. TRANSAXLE ME 80C8a588
SECOND SPEED D on) EMCC LR(RN-1) 2442- OD(3- R(REV S
V4 4} 4) ) C
LR =LOW/REVERSE 24 =EMB OD WATER 2-4 RAGE MUTADOR RAGUE
znaxe
R = REVERSE
AC = ACCUMULATOR
=S SW =CO CC DE CONVERT
=ENB
H
MW
COOLER,
PT = PRESSURE SPUCK
S =SOLENOID
D = OIL COIE CTOR V = BREATH
E
33*33333
T/c M
E
S
A
N
OFF D
DI
DC SWITCH S.W A
.
G
R
8
8
8
H
A
333333333
333353
M
S.W S
. (C
o
CONT CC
LR'CC
24 LR R
REG. T.C.
DEPOSIT OF
VENT
VAL F F LA
REGULATOR XX NUAL
-TV i 1 i 1
V ©NR
3P
l
BOMB xRm-RM EXCITED SOLENOID S
FILTER
120-145 45-100 0-5 15-40 PRESSURE (PF U AS) RPM E LRLCC 24 /LR R
FUNCTIONING DC OFF DC ON RESIDUAL
LUBRI SUCCN MOD.
ESSENTIAL DIAGRAM OF THE HYDRAULIC SYSTEM DR. TRANSAXLE 4M EBa5B9

CATIO
SCHEMES AND DIAGRAMS (Continued)
0o
an
d
•
you
SOLENOIE S EXCITED
it -J
N
•
an
d
í£
UM UE T U M A G T R
AGE
OA D
BRBR N BREC IPR
EITHEREITHERM
L.S.
M
=Yes cANDEITHER
T A = E = = = CR toilet = =
d
CER 2 4 4 OSCDV
ID
NOI
Yes
A
SR E
R ROD PR
A
TA E
A
L D
H U MT A
M OR TO OR TO
/ J.A.B.M. CH U MIT P
P
B A HIS A R A.C.E S
=
= M ==E
-
or 0
=
LR(RN- 24(2-4) UD(1-2-3) OD(3- R(REV) 21-
DIRECT DC ON
1) 4)
144
LR =LOW/REVERSE GEAR UD 24 =EMBR OD GEAR 2-4 GEAR
TRAN
=SUBMULTIPLY R =REVERSE GEAR AC =SOBR sw =cow CONNECTION GAUGE
=ACMULATOR CC =EMBR VERT. USER
D =COLEC
PT = PRESSURE SPUCK
S =SOLENOID OR OF OIL
P.T
SAXL
V = BREATH
.
D2 E
DERIVATION
--------
SCH
EMES
AND
DIAG
RAMS
(Conti
W.
S.
O.D
nued)
.
S2
02
VALVE
EXCITED SOLENOIDS
Yo
75-95 60-95 PRESSURE ( U N C I) A

1500 RF U
LR,CC 24/LRr YO O.D
FUNCTIONING DC ON
x
U x .
80097d36
LR(RN-1) 24(2-4) UD(1-2-3) OD(3-4) R(REV) S
n) C
LR =LOW/REVERSE GEAR UD 24 =EMB OD =S WATER OF 2-4 EMARCH MUTADOR
=SUBMULTIPLY R =REVERSE GEAR AC
^ACMULATOR
sw =CO CC CONVERT WATER ADERO OIL TOR H
=EMR D =COLE
V =RESR E
M
PT = PRESSURE SPUCK S = SOLENOID
P.T A.C P.T

. . . E
D1 D2 S
A
N
D
DI
A
G
R
A
M
S
S.W (C
O.D
. on
.
CHAIN LUBRICATION
S2
02
VAIVUI A
m
EXCITED SOLENOID
PRESSURE F U N SS N
45-80 F
FRI
LR_ CC 24 LRp YO O.D.
U
DC ON SUCTION x x
80C97d37
cn
n)3RESTART n)
LR(RN-1) 24(2-4) UD(1 -2-3) OD(3-4) R(REV) S
C
LR =LOW/REVERSE
24 =M 2-4 OD BRACELET 6 GAP SW €
ONCC SWITCH =EI CONNECTOR H
R = REVERSE
AC = ACCUMULATOR
BRACELET RT.
D =C OIL READER E
PT = PRESSURE SPUCK
S =SOLE N M
SDI V =RE PIRADERO
A.
C.
P.T
.
E
D2 S
A
N
D
DI
A
G
R
A
OFF
M
S
S.W
(C
. on
O.D
.
S2
02
VALVE
Y
o
SOLENOIB S EXCITED
PRESSURE F
3S LR¿CC 24 LR R UD O.D
FUNC CNAMENC LUBRICATION 1500 RP E MOD. .
DC ON
x x
SYSTEM 80C97d39
LR(RN-1) 24(24) UD(1-2-3) 0D(3-4) R(REV)
n) RESTART
DC ON
LR =LOW REVERSE GEAR 24 =EB OD RAGUE 2-4 GAP NUTLER

R =M ARC TO BACK CONNECTOR BRAG
AC = ACCUMULATOR
PT = PRESSURE SPUCK =D sw =o
S =SOLENOID
CC =M VERT
D =C(D
OIL ECTOR
V =RE PIRADERO
VALVE
3P m
SOLENOD IS EXCITED
N
LR_CC 24 LR R
PRESSURE F U p S
60-95 1500 RPN E YO O.D
FUNC CNAM ENC DC ON SUCCO N
xU .
E09rd3b
SPECIFICATIONS (9.48 in.)

Oil capacity ................................. 8,6 liters (1 8.25 pints)
Type of oil .............................. Mopar ® ATF+3 Type 7176
AUTOMATIC TRANSAXLE41TE
Cooling method. . . Inter water heat exchanger and/or air-oil
heat exchanger
Guy ................................ Completely adaptable, controlled
Lubrication ............................. b omba (type of gear is
electronically, with four-speed automatic
internal-external)
transmission, with torque converter and integrated
differential
Gear ratio Transmission
Torque converter diameter ..................................... 24 1mm
DESCRIPTION AND OPERATION (Continued).....52
DIAGNOSIS AND VERIFICATION (Continued)....62
SERVICE PROCEDURES (Continued)....................68

DISASSEMBLY AND ASSEMBLY (Continued)....86
DISASSEMBLY AND ASSEMBLY (Continued). .100

TRANSAXLE—ASSEMBLY.................................116

CLEANING THE VALVE BODY..........................132
AUTOSTICK............................................................132
SETTINGS (Continued)...........................................133
ADJUSTING THE INTERLOCK SYSTEM...........133
v4................................................................................92
OFF ON......................................................................92
sw................................................................................92
sw................................................................................92
0-5...............................................................................92
=xxE-a.........................................................................92
N.................................................................................94
_k................................................................................94
NMS............................................................................95
DC...............................................................................96
LR_CC........................................................................96
LUBRICATION.........................................................96
33*33333....................................................................98
2442-4}.......................................................................98
SCHEMES AND DIAGRAMS (Continued)............142

SCHEMES AND DIAGRAMS (Continued)............143
45-80.........................................................................102
AUTOMATIC TRANSAXLE41TE.........................148
SPECIFICATIONS (Continued)..............................152
AUTOMATIC TRANSAXLE41TE.........................152
SPECIAL TOOLS (Continued)................................153
2.4 selective) ............. 0.91-1.47 mm (0.036-0.058 in.)
Clutch assembly clearances Drive shaft longitudinal play. . 0.1 2-0.63 mm (0.005-0.025 in.)
Low and reverse clutch (selective reaction plate) 0.89-1.04
mm (0.035-0.042 in.) drive shaft
2/4 clutch (no selection) ................................ 0.76-2.64mm Longitudinal game ...................................... 0,127–0,635 mm
(0.030-0.104 in.) (0.005–0.025 in.)
reverse clutch
Pump clearances
(selective spring ring) . . . (.0.,0. 3 0 0- .7 0, 6 0 -1 49 .24p u m l
External gear to cavity ................................. 0,045-0,141 mm
gm .) (0.0018-0.0056 in.)
Gear side clearance
Overdrive clutch (no selection) .................. 1 .355-3.188mm external . . . 0.020-0.046 mm (0.0008-0.0018 in.)
Gear side clearance
(0.053-0.125 in.) internal . . . 0.020-0.046 mm (0.0008-0.0018 in.)
Sub-speed clutch (pressure plate
Bearing pre-adjustment
Differential assembly. . Drag torque 0.56 to 2.03 N·m (5 to 18 lbs. in.)
Transmission hub. . . Drive torque 0.33 to 0.90 N·m (3 to 8 lbs.
in.)
Transfer shaft. . . End play 0.050 to 0.10 mm (0.002 to 0.004 in.)
Total drag on the transmission hub. . Drag torque 0.33 to 1.80 N·m (3 to 16 lbs. in.)
SPECIFICATIONS (Continued)
41TE TRANSAXLE DETORSION SPECIAL TOOLS
SPECIFICATIONS
C-3339 Dial Indicator

AUTOMATIC TRANSAXLE41TE
DESCRIPTION TORSION
Cooler tube connections .......................................... 12 N·m
(105 lbs. in.)
differential cover ............................ 19 N·m (165 lbs. in.)
Differential crown .............................. 95 N·m (70 lbs. foot)
Differential bearing retainer ........................................ 28 N·m
(21 lbs. foot)
Drive plate bolts on crankshaft. . 95 N·m (70 lbs. foot)
Control plate on the torque converter. . . 75 N·m (55 lbs. foot)
Solenoid eight-way connector ...................................... 4 N·m
(35 lbs. in.)
Rear bearing retainer. . 28 N·m (21 lbs. foot) Extractor C-637
Drive speed sensor .................................................... 27 N·m
L/R clutch retainer. . 5 N·m (45 lbs. p . uplg.) Oil pan in

transaxle case . . . 19 N·m (165 lbs. in.)
Transmitter gear bolt ............................................... 271 N·m
(200 lbs. foot)
Drive gear bracket retainer. . 23 N·m (17 lbs. foot)
Transmission speed sensor ....................................... 27 N·m
Pressure indicator (low) C-3292

(20 lbs. foot)
pressure spigots ................................ 5 N·m (45 lbs. in.)
Pump bolts in the case. . 27 N·m (20 lbs. ft) Reaction shaft
bolts on pump ............................................................ 27 N·m
(20 lbs. foot)
Rear end cap. . . 20 N·m (175 lbs. in.) Sixty-way connector 4
....................................N·m (35 lbs. in.)
Solenoid assembly in the box .................................... 1 2 N·m
(105 lbs. in.)
Transmission position sensor ...................................... 5 N·m
(45 lbs. in.)
Transfer gear nut ..................................................... 27 1 N·m Pressure Gauge (High) C-3293SP
(200 lbs. foot)
Transfer plate to box ................................................. 1 2 N·m
(105 lbs. in.)
Valve body bolts to housing. . . 1 2 N·m
(105 lbs. in.)
Valve body bolts. . 5 N·m (45 lbs. in.) Breather Assembly . . .
12 N·m (105 lbs. in.)
C-3339 Dial Indicator

SPECIAL TOOLS (Continued)
C-3752 Oil Pump Puller C-4996 Adapter
Joint extractor C-3981B Extractor set L-4406
Gear Puller L-4407A
Universal handle C-4171
L-4410 Bearing Installer
Gasket Installer C-4193A

L-4432 Gear Check Disc Installer L-4520
L-4435 Bearing Puller Push Button L-4539-2
Differential Tool L-4436A P-334 bearing splitter
L-4518 Special Jaw Set 5048 Extractor Set

JA TRANSAXLE 21 157
5049-A Extractor and Installer

5059-A Compressor
5050A Installer
(0)
Installer 5067
o'ssh
Installer 5052
Pliers 6051
5
-either
5058A Compressor Installer 6052

Installer 6053 Installer 6061
Button 6055 Extractor 6062-A
Disk 6057 Bolt 6260

JA TRANSAXLE 21 159
Extractor/installer Installer 6261 6302
Installer 6536-A Tip 6268
6906A Chiller Extractor/installer 6301 Pressure Washer
Extractor 7794-A
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A604 -41 TE

DESCRIPTION AND OPERATION (Continued)......52

DISASSEMBLY AND INSTALLATION (Continued)84

DISASSEMBLY AND ASSEMBLY (Continued)...120

• Transmission speed sensor

NOTE: The transmission manifold and differential have a

TRANSMISSION AND DIFFERENTIAL

DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION (Continued) 52

DESCRIPTION AND OPERATION (Continued) 55

DISASSEMBLY AND ASSEMBLY (Continued) 95

DISASSEMBLY E AND ASSEMBLY E (Continued)130

DESCRIPTION AND OPERATION (Continued) 52

DESCRIPTION AND OPERATION (Continued) 54

DISASSEMBLY AND ASSEMBLY (Continued) 94

DISASSEMBLY AND ASSEMBLY (Continued) 129

• Crankshaft position sensor (CKP)

• Transmission position sensor (TRS)

• Pressure Switches (L/R, 2/4, OD)

• Transmission temperature sensor grade to TRS)

• Transmission shaft speed sensor

TCM MEASURES TIME

Programming Condition Planned operation

(prevents shifts that can cause a clutch to fail

Programming Condition Planned operation

information regarding pressure switches, see “Pressure

BATTERY POWER (TCM) fault diagnosis (DTC).

TCM activates momenta the pressure element of the 2/4 and/or

DRIVE AND TRANSMISSION SPEED

Speed ratio error detection

CHANGE L/R 2/4 O.D.

R OPEN OPEN OPEN

The TRS has an integrated thermistor that the TCM uses to

sequence to ensure movement of the SSV to the shifting

wire. When a solenoid is energized, the solenoid valve moves

GEAR POSITION INDICATOR • Engine coolant temperature

gd dashboard instrument cluster. Indicates

SWITCHING SOLENOID VALVE

SHIFT AND IGNITION INTERLOCK

NOTE: If the vehicle has column shifts, install a new interlock

NOTE: If the vehicle has ground shifts, adjust the interlock

Freewheeling downshift 2-1 8 km/h (5 mph)

MANUAL CHANGES ARE NOT ALLOWED UNDER THE FOLLOWING CONDITIONS

EXCHANGE RATE APPROXIMATE CHANGE POINT

(38 mph) in other conditions

The diagnosis of these problems should always begin by

To detect slipping units and confirm mar the correct operation

HYDRAULIC PRESSURE TESTS

TRY TWO-GEAR SELECTOR IN 2ND. TEST FIVE-TRANSMISSION SHIFT SELECTOR

TEST SIX-REVERSE SHIFT SELECTOR

(1) Connect the pressure gauge to the underdrive clutch

TEST THREE-OVERDRIVE CLUTCH CHECK

TEST FOUR-SHIFT SELECTOR IN

ALL SPECIFICATIONS ARE IN KPA (PSI IN PARENTHESES)

Gear selector position Royal march PRESSURE SPITCHES

* PARK 0-14 (0-2) 0-35 (0-5) 0-14 (0-2)

PRESSURE CHECK SPECIFICATIONS

Fig. 8 Reverse Clutch Test OVERDRIVE CLUTCH

TORQUE CONVERTER LEAKS Transmission position sensor

CONDITION POSSIBLE CAUSE

• DTC P1797, Manual Transmission Overheat (Transmission

>124° C (>255° F)).