a shop manual

8/6/2019 A Shop Manual

1/93

4 -SP E ED E L EC T R O N I C A U T O M AT I C T R A N S A X L E

INDEX

page page

Aluminum Thread Repair . . . . . . . . . . . . . . . . . . . 98

Bearing Adjustment Procedure . . . . . . . . . . . . . . 139Clutch Air Pressure Tests . . . . . . . . . . . . . . . . . . . 95Coolers and Tubes Reverse Flushing . . . . . . . . . . 98Diagnosis Chart B . . . . . . . . . . . . . . . . . . . . . . . . . 91Differential Repair . . . . . . . . . . . . . . . . . . . . . . . 134Distance Sensor Gear . . . . . . . . . . . . . . . . . . . . . 98Fault Code Chart A . . . . . . . . . . . . . . . . . . . . . . . . 90Fluid and Filter Changes . . . . . . . . . . . . . . . . . . . 92Fluid Drain and Refill . . . . . . . . . . . . . . . . . . . . . . 92Fluid Leakage-Torque Converter Housing Area . . . 96Fluid Level and Condition . . . . . . . . . . . . . . . . . . . 92Gearshift Linkage Adjustment . . . . . . . . . . . . . . . . 97General Information . . . . . . . . . . . . . . . . . . . . . . . 85Hydraulic Pressure Tests . . . . . . . . . . . . . . . . . . . 94Input Clutches-Recondition . . . . . . . . . . . . . . . . . 119

Neutral Safety Switch . . . . . . . . . . . . . . . . . . . . . 102

Oil Cooler Flow Check . . . . . . . . . . . . . . . . . . . . . 98Oil Pump Seal Replace . . . . . . . . . . . . . . . . . . . 134PRNDL Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 102Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Selection of Lubricant . . . . . . . . . . . . . . . . . . . . . . 92Solenoid Assembly-Replace . . . . . . . . . . . . . . . . 101Special Additives . . . . . . . . . . . . . . . . . . . . . . . . . 92Speed Sensor-Input . . . . . . . . . . . . . . . . . . . . . . 102Speed Sensor-Output . . . . . . . . . . . . . . . . . . . . . 102Torque Converter Clutch Break-In Procedure . . . . 102Transaxle General Diagnosis . . . . . . . . . . . . . . . . 88Transaxle Recondition . . . . . . . . . . . . . . . . . . . . 103Transaxle Removal and Installation . . . . . . . . . . . . 98Valve Body-Recondition . . . . . . . . . . . . . . . . . . . 130

GENERAL INFORMATIONThe electronic four-speed F WD tr ansa xle uses fully-

adaptive controls. Adaptive controls are those which

perform their functions based on real-time feedback

sensor information. The transaxle uses hydraulically

applied clutches to shift a planetary gear train.

4-SPEED ELECTRONIC T RANSAXLE IDENTIFI-

CATION

T h e t r a n s a x le i de n t ifi ca t i on cod e i s p r in t e d on a

label. The label is located on the transaxle case next

to t he solenoid assembly (Fig. 1).

R e f e r t o F i g u r e 2 f o r a n i n t e r n a l v i e w o f t h e t r a n -saxle assembly.

OPERATION

The transaxle provides forward ratios of 2.84, 1.57,

1.00, and 0.69 with torque converter lockup available

in 2nd, direct, or overdrive gear; the Reverse ratio is

2.21. The shift lever is conventional with six posi-

tions: P, R, N, OD, 3, and L. When OD is selected t he

transaxle shifts normally through all four speeds with

lockup in overdrive; this position is recommended for

most dr iving. The 3 position is ta ilored for use in h illy

or m ou n t a in ou s d r ivi n g. Wh e n 3 is s ele ct e d, t h e

transmission uses only 1st, 2nd, and direct gears with2nd-direct shift delayed to 40 mph or greater. When

operating in 3 or L positions torque converter lockup

occur s in direct gear for impr oved t ran smission cool-

i n g u n d e r h e a v y l oa d s . I f h i g h e n gi n e cool a n t t e m -

perature occurs, the torque converter will also lock up

in 2nd gear. The L position provides maximum engine

braking for descending steep grades. Unlike most cur-

rent tran saxles, upshifts are provided t o 2nd or direct

g ea r a t p e a k e n gi n e s p e ed s i f t h e a cce le r a t or i s d e -

pressed. This provides engine over-speed protection

and maximum performan ce.

CLUTCH AND GEAR

The transaxle consists of:

Three multiple disc input clutches

Two mu ltiple disc groun ded clutches

Four hydraulic accumulators

Two planetary gear sets

T h is p r ov id e s fou r for w a r d r a t i os a n d a r e ve r s e

rat io. The clutch-apply pistons were designed withcentrifugally balanced oil cavities so t hat quick re-

sponse and good control can be achieved at any speed.

A push/pull piston is incorporated for two of the three

input clutches.

CAUTION: Some clutch packs appear similar, but

they are not the same. Do not interchange clutch

components as they might fail.

Fig. 1 Identification Tag Location

TRANSAXLE 21 - 85


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Fig.

2InternalView

ofTransaxle

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HYDRAULICS

T h e h y d r a u li cs of t h e n e w t r a n s a x le p r ov id e t h e

manual shift lever select function, main line pressure

regulation, and torque converter and cooler flow con-

trol. Oil flow to the friction elements is controlled

directly by four solenoid valves. The hydra ulics also

include a un ique logic-controlled solenoid lock-up

cont rol valve. This valve locks out t he 1st gear rea c-tion element with the application of 2nd, direct, or

overdrive gear elements. It also redirects the 1st gear

solenoid output so that it can control torque converter

lockup operation. To regain access to 1st gear, a spe-

cial sequence of solenoid commands must be used to

un lock a nd move th e solenoid lock-up cont rol valve.

This precludes a ny a pplication of the 1st gear reac-

tion element with other elements applied, unless spe-

cifically commanded the controller. It also allows one

solenoid to control two friction elements.

Small, high-rate accumulators are provided in each

controlled friction element circuit. These serve to ab-sorb the pressure r esponses, and allow t he contr ols to

read a nd respond to chan ges th at are occurring.

SOLENOIDS

Since the solenoid valves perform virtually all con-

t r ol fu n ct i on s , t h e s e v a lv es m u s t b e e xt r e m e ly d u -

r a b l e a n d t o l e r a n t o f n o r m a l d i r t p a r t i c l e s . F o r t h a t

r e a son h a r d en e d-s t ee l p op pe t a n d b a ll v a lve s a r e

used. These are free from any close operating clear-

ances, and the solenoids operate the valves directly

without any intermediate element. Direct operation

means that these units must have very high output so

t h a t t h e y ca n cl os e a g a in s t t h e s iz ea b le fl ow a r e a s

a n d h ig h lin e p r es su r e s. F a s t r e sp on s e is a ls o r e -

quired to meet the control requirements.

Two of the solenoids are normally-venting and two

a r e n or m a l ly -a p p ly in g ; t h i s w a s d on e t o p r ov id e a

default mode of operat ion. With no electrical power,

t h e t r a n s m i s si on p r ov id e s 2 n d g ea r i n O D , 3 , or L

shift lever positions. All other transmission lever posi-

tions will operate normally. The choice of 2nd gear

w a s m a d e t o p r ov id e a d eq u a t e b r ea k a w a y p er for -

mance while still accommodating highway speeds.

SENSORSThere are three pressure switches to identify sole-

noid application and two speed sensors to read input

(torque converter turbine) and output (parking spra g)

speeds. There is also a position switch to indicate the

m a n u a l s h ift l ev er p os it i on . T h e p r e ss u r e s w it ch e s

are incorporated in an assembly with the solenoids.

Engine speed, th rottle position, temperatur e, etc., a re

also observed. Some of these signals are read directly

from the engine control sensors; others are read from

a multiplex circuit with the engine controller.

ELECTRONICS

The electr onic cont rol unit is located u nderh ood in a

potted, die-cast aluminum housing with a sealed, 60-

way connector.

ADAPTIVE CONTROLS

T h es e con t r o ls fu n c t ion b y r e a d in g t h e i n pu t a n d

output speeds over 140 t imes a second and respond-i n g t o e a ch n e w r e a d in g . T h i s p r ov id e s t h e p r e ci se

and sophisticated friction element control needed t o

m a k e s m oot h cl u t ch -t o-cl u t ch s h ift s for a l l g ea r

ch a n g e s. T h e u s e of ov er r u n n i n g cl u t ch e s or ot h e r

s h ift q u a lit y a id s a r e n ot r e qu ir e d. As w it h m os t

aut omatic t ransa xles, a ll shifts involve releasing one

element and applying a different element. In simpli-

fied terms, the upshift logic allows the releasing ele-

ment to slip back wards slightly to ensure th at i t does

not have excess capacity; the apply element is fi lled

unt il it begins to mak e th e speed chan ge to the h igher

gear; its apply pressure is then controlled to maintain

t h e d es ir e d r a t e of s pe ed ch a n ge u n t il t h e s h ift iscomplete. The key to providing excellent shift quality

is precision; for example, as mentioned, the release

e le m en t for u p s h ift s i s a l low ed t o s li p b a ck w a r d s

slightly; the amount of tha t sl ip is typically less t han

a total of 20 degrees. To achieve th at precision, the

controller learns the characteristics of the particular

transaxle that i t is controlling. I t learns the release

r a t e o f t h e r e l e a s i n g e l e m e n t a n d t h e a p p l y t i m e o f

the applying element. I t also learns the rate at which

the apply element builds pressure sufficient to begin

making the speed change. This method achieves more

precision than would be possible with exacting toler-

a n c es . I t ca n a l so a d a p t t o a n y ch a n g e s t h a t occu rwith age or environment, for example, alt i tude, tem-

peratur e, engine output , etc.

For kickdown shifts, the control logic a llows the

releasing element t o slip and then controls the r ate a t

w h ich t h e i n pu t (a n d e n gi n e) a cce le r a t e ; w h e n t h e

lower gear speed is a chieved, th e releasing element

r e a p p li es t o m a i n t a i n t h a t s p ee d u n t i l t h e a p p ly e l e-

ment is filled. This provides quick response since the

engine begins to accelerate immediately and a smooth

torque exchange since the release element can control

the rat e of torque increase. This control can make any

powertrain feel more responsive without in creasing

h a r s h n e s s .

Adaptive controls r espond to input speed chan ges.

They compensate for chan ges in engine or friction

e le m en t t or q u e a n d p r ov id e g ood , con s is t e n t s h i ft

quality for the life of the transaxle.

ON-BOARD DIAGNOSTICS

These cont rols p rovide compreh ensive, onboard

tra nsaxle diagnostics. The informat ion available can

a i d i n t r a n s a x le d ia g n os is . F or e xa m p l e, a p p ly e le -

m e n t b u il du p r a t e i n d ica t e s s ol en oi d p e r for m a n c e.

Also included are self diagnostic functions. Self diag-

TRANSAXLE 21 - 87


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nostics allow the technician to t est the condition of

the electronic controls. The controller continuously

monitors i ts crit ical functions, records any malfunc-

t i on s , a n d t h e n u m b e r o f e n gi n e s t a r t s s in ce t h e l a st

m a l fu n c t ion . T h is a l low s t h e t e ch n i ci a n t o u s e t h e

information in the event of a customer complaint.

TRANSAXLE GENERAL DIAGNOSISCAUTION: Before attempting any repair on a Elec-

tronic Automatic Transaxle (EATX), check for faultcodes with the DRB II. Always use the PowertrainDiagnostic Test Procedure Manual.

Tr a n s a x le m a l fu n c t ion s m a y b e ca u s e d b y t h e s e

general conditions:

Poor engine performa nce

Improper a djustments

Hydra ulic malfunctions

Mecha nical malfunctions

Electronic malfunctions

Diagnosis of these problems should always begin bychecking the easily accessible variables: fluid level

and condition, gearshift cable adjustment. Then per-

form a road test to determine if the problem h as been

corrected or that more diagnosis is necessary. If the

problem exists after the preliminary tests and correc-

tions are completed, hydraulic pressure checks should

be per formed.

DIAGNOSIS GUIDE-ABNORMAL NOISE

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DIAGNOSIS GUIDE-VEHICLE WILL NOT MOVE

DIAGNOSIS GUIDEFLUID LEAKS

TRANSAXLE 21 - 89


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FAULT CODE CHART A

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DIAGNOSIS CHART B

TRANSAXLE 21 - 91


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FLUID LEVEL AND CONDITIONT h e t r a n s m i s s i o n a n d d i f f e r e n t i a l s u m p h a v e

a c o m m o n o i l s u m p w i t h a c o m m u n i c a t i n g o p e n -

i n g b e t w e e n t h e t w o .

The torque converter fills in both the P P a r k a n d N

Neutral positions. Place the selector lever in P P a r k

to check the fluid level. T h e e n g i n e s h o u l d b e r u n -

n i n g a t i d le s p e e d f o r a t l e a s t o n e m i n u t e , w i t ht h e v e h ic le o n l ev e l g ro u n d . Th i s w i ll a s su re

c o m p l e t e o i l l e v e l s t a b i l iz a t i o n b e t w e e n d i ff e r-

e n t i al a n d t ra n s m i ss i o n . T h e fl u id s h ou l d b e a t

normal operating temperature (approximately 82 C.

or 180 F.). The fluid level is correct if it is in the HOT

region (cross-hatched area) on the oil level indicator.

Low fluid level can cause a variety of conditions

because i t allows the pump to take in air along with

t h e fl u id . A s i n a n y h y d r a u li c s ys t e m , a i r b u b bl es

make the fluid spongy, therefore, pressures will be

low and build up slowly.

Improper fi ll ing can also raise the fluid level too

h ig h . W h en t h e t r a n s a xl e h a s t oo m u ch flu id , t h eg e a r s c h u r n u p f o a m a n d c a u s e t h e s a m e c o n d i t i o n s

which occur with a low fluid level.

In either case, the air bubbles can cause over heat-

ing, fluid oxidation, and varnishing, which can inter-

fere with normal valve, clutch, and accumulator op-

e r a t ion . F oa m i n g ca n a l so r e s u lt i n fl u id e sca p in g

from the tran saxle vent where i t may be mistaken for

a leak.

Along with fluid level, i t is important to check the

condition of th e fluid. When the fluid smells burned,

and is conta minated with metal or friction material

particles, a complete transaxle overhaul is needed. Be

sure to examine the fluid on the dipstick closely. If t h e r e i s a n y d ou b t a b ou t i t s c on d i t ion , d r a in ou t a

sample for a double check.

After the fluid has been checked, seat the dipstick

fully to seal out water a nd dirt .

SELECTION OF LUBRICANTIt is important that the proper lubricant be used in

these transmissions. MOPAR ATF PLUS (AutomaticTransmission Fluidtype 7176) should be used to aid

in assuring optimum transmission performance. Flu-

ids of the type labeled DE XRON II Automatic Trans-

mission Fluid ar e n o t r e c o m m e n d e d . D E X R O N I I

ca n b e u s e d on l y i f t h e r e com m e n d ed fl u id i s n otavailable. If more than a small amount of DEXRON

I I is u s ed s h u dd er or s h ift q u a lit y p r ob le m s m a y

result . I t is important that the transmission fluid be

maintained at the prescribed level using the recom-

mended fluids.

SPECIAL ADDITIVESChrysler Corporation does not recommend the addi-

tion of any fluids to the transmission, other than the

au tomat ic tran smission fluid listed above. An excep-

tion to this policy is the use of special dyes to aid in

detecting fluid leaks. The use of transmission sealers

should be avoided, since they may adversely a ffect

seals.

FLUID AND FILTER CHANGESW h en t h e fa ct or y fi ll fl u id i s ch a n g e d a s r e com -

m e n d ed a b ov e, on l y fl u id s l a be le d M OP AR ATFP L U S (Au t om a t i c Tr a n s m i ss ion fl u id ) Ty pe 7 17 6

should be used. A filter change should be m ade a t the

time of the oil change. Also the magnet (on the inside

of t h e oi l p a n ) s h o u ld b e c le a n e d w i t h a cl ea n , d r y

cloth.

If the transaxle is disassembled for any reason, the

fluid and filter should be changed.

FLUID DRAIN AND REFILL(1) Raise vehicle on a hoist (See Lubrication, Group0 ). P la ce a d r a in con t a in e r w it h a la r ge op en in g,

under transaxle oil pan.

(2) Loosen pan bolts and tap the pan at one corner

to break it loose allowing fluid to drain, then remove

the oil pan.

(3) Install a new fil ter an d O-ring on bottom of the

valve body.

(4 ) C le a n t h e oil p a n a n d m a gn e t . R e in s t a ll p a n

u s i n g n e w M OP AR Adhesive Sealant. Tighten oilpan bolts to 19 Nm (165 in. lbs.).

(5) Pour four quarts of MOPAR ATF PLUS (Auto-

matic Transmission Fluid) Type 7176 through the filltube.

( 6 ) S t a r t e n g i n e a n d a l l o w t o i d l e f o r a t l e a s t o n e

m i n u t e. T h en , w it h p a r k i n g a n d s e r vi ce b r a k es a p -

plied, move selector lever momenta rily to ea ch posi-

tion, ending in the park or neutra l position.

(7) Add sufficient fluid to bring level to 1/8 inch

below the ADD mark.

R ech e ck fl u id l ev el a ft e r t r a n s a x le i s a t n or m a l

op e r a t in g t e m p er a t u r e . T h e l ev el s h ou l d b e i n t h e

HOT region (Fig. 3).

Fig. 3 Oil Level Indicator

21 - 92 TRANSAXLE


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To prevent dirt from entering transaxle, make cer-

tain that dipstick is seated into the dipstick fi l l tube

(Fig. 4).

ROAD TESTPrior to performing a road test , be certain that the

fluid level and condition, and control cable adjust-

ment have been checked an d a pproved.

During the road test , the transaxle should be oper-

a t e d i n e a ch p os it i on t o c h e ck for s li pp in g a n d a n y

variation in shifting.

If vehicle operates properly at highway speeds, buth a s p oor a cce le r a t ion , t h e t or q u e con v er t e r s t a t or

overrunning clutch may be slipping. If through-gear

acceleration is n ormal, but high t hrottle opening is

required to ma intain highway speeds, the torque con-

v er t e r s t a t or cl u t ch m a y h a v e s ei ze d . B ot h of t h e s e

stator defects require replacement of the torque con-

verter.

T h e c lu t ch t h a t i s s l ip p in g ca n b e d e t e r m in e d b y

n ot i n g t h e t r a n s a x le op e r a t ion i n a l l s e le ct or p os i-

t i on s . T h en com p a r i n g w h i ch i n t er n a l u n i t s a r e a p -

plied in those positions. Th e E le m e n t s i n U s e C h a rt

provides a basis for road test analysis.

Fig. 4 Oil Level Indicator Location

ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER

TRANSAXLE 21 - 93


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11/93

(5 ) T h is t e s t ch e ck s t h e r e ve r s e cl u t ch h y d r a u li c

circuit.

TEST RESULT INDICATIONS

(1) If proper l ine pressure is found in any one test ,t h e p u m p a n d p r e s s u r e r e g u l a t o r a r e w o r k i n g p r o p -

erly.

(2) Low pressure in all positions indicates a defec-

tive pump, a clogged filter, or a stuck pressure regula-

tor valve.

(3) Clutch circuit leaks are indicated if pressures

do not fall within the specified pressure range.

(4) If the overdrive clutch pressure is greater than

5 psi in step (6) of Test Three, a worn reaction shaft

seal ring is indicated.

CLUTCH AIR PRESSURE TESTSInoperative clutches can be located using a series oft e s t s b y s u b s t it u t i n g a i r p r e ss u r e for fl u id p r e ss u r e

(Figs. 2 and 3). The clutches may be tested by apply-

ing air pr essure to t heir respective passages after t he

valve body has been removed and Tool 6056 has been

installed. To make air pressure tests, proceed as fol-

lows:

T h e c o m p r e s s e d a i r s u p p l y m u s t b e f r e e o f a l l

d i r t a n d m o i s t u r e . U s e a p r e s s u r e o f 3 0 p s i .

R em ov e oi l p a n a n d v a lv e b od y. S e e Va l ve b od y

removal.

OVERDRIVE CLUTCH

Ap p ly a i r p r e ss u r e t o t h e ov er d r iv e cl u t ch a p p ly

passage and watch for the push/pull piston to move

forward. The piston should return to i ts st arting posi-

tion when t he a ir pressure is r emoved.

REVERSE CLUTCH

Apply air pressure to the reverse clutch apply pas-

sage an d wat ch for the push/pull piston to move r ear-

ward. The piston should return to i ts sta rting position

when the air pressure is removed.

PRESSURE CHECK SPECIFICATIONS

Fig. 2 Air Pressure Test Plate

TRANSAXLE 21 - 95


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2/4 CLUTCH

Apply air pressure to the feed hole located on the

2 /4 cl u t ch r e t a in e r. L ook i n t h e a r e a w h e r e t h e 2 /4

p is t on con t a c t s t h e fi r st s e pa r a t o r p la t e a n d w a t ch

ca r e fu l ly for t h e 2 /4 p is t on t o m ov e r e a r w a r d . T h e

piston should return to i ts original position after the

air pressure is removed.

LOW/REVERSE CLUTCH

Apply air pressure to t he low/reverse clutch feed

hole (rear of case, between 2 bolt holes). Then, look in

t h e a r e a w h e r e t h e l ow /r e ve r s e p i s t on con t a c t s t h e

first separator plate and watch carefully for the pis-

ton to move forward. The piston should return to i ts

original position after the air pressure is removed.

UNDERDRIVE CLUTCH

Because this clutch piston cannot be seen, its opera-

tion is checked by function. Air pressure is applied to

the low/reverse and the 2/4 clutches. This locks the

ou t p u t s h a ft . U s e a p ie ce of r u b be r h os e w r a pp ed

around the input shaft and a pair of clamp-on pliers

to turn the input shaft . Next apply air pressure to the

underdrive clutch. The input shaft should not rotate

w i t h h a n d t o r q u e . R e l e a s e t h e a i r p r e s s u r e a n d c o n -

firm that the input shaft will rotate.

FLUID LEAKAGE-TORQUE CONVERTER HOUSINGAREA

(1) Check for sour ce of leak age.

S in ce fl u id l ea k a g e a t or a r ou n d t h e t or q u e con -

verter area may originate from an engine oil leak, th e

ar ea should be exam ined closely. F actory fill fluid is

d ye d r e d a n d , t h e r e for e , ca n b e d is t in g u is h e d fr om

engine oil.

(2 ) P r i or t o r e m ov in g t h e t r a n s a x le , p e r for m t h e

following checks:

When leakage is determined to originate from the

tran saxle, check fluid level prior to removal of th e

transaxle and torque converter.

High oil level can result in oil leakage out the vent

in the manual shaft . If the fluid level is high, adjust

to proper level.

After performing this operat ion, in spect for leakage.

If a leak persists, perform the following operation on

the vehicle to determine if i t is the torque converter

or transaxle that is leaking.

LEAKAGE TEST PROBE

(1) Remove torque converter housing dust shield.

(2 ) C le a n t h e i n si de of t or q u e con v er t e r h ou s in g

(lower area) as dry as possible. A solvent spray fol-

lowed by compr essed a ir dr ying is pr eferable.

(3) Fabricate and fasten test probe (Fig. 4) securely

t o con v en i en t d u s t s h ie ld b ol t h ol e. M a k e ce r t a i n

torque converter is cleared by test probe. Tool mu st be

clean and dry.

(4 ) R u n e n gi n e a t a p p r ox im a t e ly 2 ,5 00 r p m w it h

transaxle in neutral, for about 2 minutes. Transaxle

must be at operating temperature.(5) Stop engine a nd car efully remove tool.

(6) If upper surface of test pr obe is dry, th ere is no

torque converter leak. A path of fluid across probe

indicates a torque converter leak. Oil leaking under

t h e p r ob e i s com i n g f r om t h e t r a n s a x le t or q u e con -

verter area.

(7) Remove transaxle and torque converter assem-

bly from vehicle for fur ther investigation. Th e fluid

s h o u l d b e d r a i n e d f r o m t h e t r a n s a x l e . R e i n s t a l l o i l

pan (with MOPAR Adhesive Sealant) at specifiedtorque.

Possible sources of transaxle torque converter area

fluid leakage are:

(1) Torque converter hub seal.

Seal lip cut, check torque converter hub finish.

Bushing moved and/or worn.

Oil return hole in pump housing plugged or omit-

ted.

Seal worn out (high-mileage vehicles).

(2 ) F l u id le a k a ge a t t h e ou t s id e d ia m e t er fr om

pump housing O-ring.

( 3 ) F l u i d l e a k a g e a t t h e f r o n t p u m p t o c a s e b o l t s .

C h e ck con d it i on of w a s h e r s on b ol t s a n d u s e n e w

bolts, if necessary.

Fig. 3 Testing Reverse Clutch

Fig. 4 Leak Locating Test Probe Tool

21 - 96 TRANSAXLE


13/93

(4) Fluid leakage due to case or front pump housing

porosity.

TORQUE CONVERTER LEAKAGE

Possible sources of torque converter leakage are:

Tor q u e con v er t e r w el d l ea k s a t t h e ou t s id e (p e -

ripheral) weld.

Torque converter hu b weld.H ub w e ld i s i ns id e a n d n o t v is ib le . D o n o t

a t t e m pt t o r e pa i r . R e pl a c e t o r que c o nv e r t e r .

I f t h e t o r q u e c o n v e r t e r o n a I m p e r i a l o r 5 t h

Av e n u e (AY b o d y ) m u s t b e r e p la c e d , r e f e r t o

T o r que C o nv e r t e r C l ut c h B r e a k- i n P r o c e dur e i n

t hi s s e c t i o n. T hi s pr o c e dur e w i l l r e s e t t he E A T X

c o n t r o ll e r b r e a k -i n s t a t u s . F a i l u re t o p e r fo r m

t h i s p r o c e d u r e m a y c a u s e t r a n s a x le s h u t t e r.

AIR PRESSURE T EST OF T RANSAXLE

F a b r i ca t e e qu i pm e n t n e e de d for t e s t a s s h ow n i n

Figures 5 and 6.

The transaxle should be prepared for pressure test

as follows a fter removal of the torque convert er:

(1) Plug dipstick tube and plug oil cooler l ine fi t-

t i n g . R e m o v e v e n t f r o m m a n u a l s h a f t a n d i n s t a l l a

1/8 inch pipe plug.

CAUTION: Prevent manual shaft rotation during in-

stallation and removal.

(2) With rotary m otion, install converter hub seal

cup over input shaft , and through the converter hub

s ea l u n t il t h e cu p b ot t om s a g a in s t t h e p u m p g ea r

lu gs . S ecu r e w it h cu p r e t ai n er s t r a p u s in g s t a r t er

upper hole and opposite bracket hole.(3 ) At t a ch a n d cl a m p h os e fr om n oz zl e of Tool

C-4080 to the upper cooler l ine fi t t ing position in

case.

CAUTION: Do not, under any circumstances, pres-

surize a transaxle to more than 10 psi.

(4) Pressurize the transaxle using Tool C-4080 until

the pressure gauge reads 8 psi. Position transaxle so

t h a t p u m p h ou s in g a n d ca s e fr on t m a y b e c ov er e d

with soapy solution of water. Leaks are sometimes

caused by porosity in the case or pump housing.

If a leak source is located, that part and all associ-ated seals, O-rings, and gaskets should be replaced

with new parts.

GEARSHIFT LINKAGE ADJUSTMENTNormal operation of the PRNDL and neutral safety

s w it ch p r ov id e s a q u ick ch e ck t o con fi r m p r op e r

manual l inkage adjustment.

Move th e selector level slowly upwa rd unt il it clicks

into t he P Par k notch in the selector gate. If th e

sta rt er will opera te t he P position is corr ect.

After checking P position, move selector towar d

N Neu tr al position un til lever d rops in th e N stop.

If the starter will also operate at this point the gear-

shift linkage is properly adjusted.

CAUTION:When it is necessary to disassemble link-age cable from levers, which use plastic grommetsas retainers, the grommets should be replaced withnew grommets. Use a prying tool to force rod from

grommet in lever, then cut away old grommet. Usepliers to snap new grommet into lever and rod intogrommet.

(1) Set parking brake.

(2) Place gearshift lever in P (PARK) position.

(3) Loosen clamp bolt on gear shift cable bra cket.

(4 ) C ol u m n s h i ft : I n s u r e t h a t p r e loa d a d ju s t m e n t

spring engages fork on transaxle bracket.

(5) Pull the shift lever by hand to the front detent

position (PARK) and t ighten lock screw to 11 Nm

(100 in. lbs.) . Gearshift l inkage should now be prop-

erly adjusted.

(6) Check adjustm ent as follows:

(a) Detent position for neutra l an d drive sh ould

be within limits of hand lever gate stops.

(b) Key start must occur only when shift lever is

in par k or neutra l positions.

Fig. 5 Torque Converter Hub Seal Cup

Fig. 6 Hub Seal Cup Retaining Strap

TRANSAXLE 21 - 97


14/93

DISTANCE SENSOR GEARWhen the distance sensor is removed for any rea-

s o n , a N E W O - r i n g m u s t b e i n s t a l l e d o n i t s o u t s i d e

diameter.

REMOVAL AND INSTALLATION

(1) Remove har ness connector from sensor. Make

sure weatherseal stays on harn ess connector.(2) Remove bolt securing the distance sensor in the

extension housing.

(3) Carefully pull sensor and pinion gear assembly

out of extension housing.

(4) Remove pinion gear from sen sor.

(5) To install, reverse the above pr ocedure. Make

sure extension housing a nd sensor flange are clean

p r ior t o in s t a lla t ion . Al wa ys u s e a N E W s en s or

O-ring.

(6 ) T ig h t en s e cu r i n g b ol t t o 7 Nm (60 in. lbs.).

Tighten speedometer cable to 4 Nm (35 in. lbs.).

ALUMINUM THREAD REPAIRD a m a ge d o r w or n t h r e a ds in t h e a lu m in u m t r a n -

saxle case and valve body can be repaired by the use

of Heli-Coils, or equivalent. This repair consists of

drill ing out t he worn-out damaged th reads. Then t ap-

ping the hole with a special Heli-Coil tap, or equiva-

lent, and installing a Heli- Coil insert , or equivalent,

into the hole. This brings the hole back to its original

thread size.

H e li-C oil, or e qu iva le n t , t ools a n d i n se r t s a r e

readily available from most aut omotive pa rts suppli-

ers.

COOLERS AND TUBES REVERSE FLUSHINGWh e n a t r a n s a xle fa ilu r e h a s con t a m in a t e d t h e

fluid, the oil cooler(s) must be flushed and the cooler

bypass valve in the transaxle must be replaced. The

t or q u e con v er t e r m u s t a l so b e r e p la ce d w it h a n e x-

change unit . This will insure that metal particles or

s lu d g ed oi l a r e n ot l a t er t r a n s fe r r ed b a ck i n t o t h e

reconditioned (or replaced) tra nsa xle.

CAUTION: If the vehicle is equipped with two oilcoolers (one in the radiator tank, one in front of the

radiator) they must be flushed separately. Do notattempt to flush both coolers at one time.

(1) Disconnect the cooler lines at the transmission.

(2 ) U s i n g a h a n d s u ct i on g u n fi ll ed w it h m i n er a l

spirits, reverse flush the cooler. Force mineral spirits

i n t o t h e F r o m C o o l e r line of the cooler (Fig. 1) and

ca t ch t h e e xi t in g s p ir i t s fr om t h e To C o o l e r line.

Observe for the presence of debris in th e exiting fluid.

C on t i n u e u n t i l fl u id e xi t in g i s cl ea r a n d fr e e fr om

debris.

(3 ) U s in g com p r e ss ed a i r i n i n t er m i t t en t s p u r t s ,

blow any remaining m ineral spirits from the cooler,

again in the reverse direction.

(4) To remove any remaining mineral spirits from

the cooler, one (1) quart of a utomatic tr ansmission

fl u id s h ou l d b e p u m p ed t h r o u gh t h e cool er b efor ereconnecting.

(5 ) If a t a n y s t a ge of t h e cle a n in g p r oce ss , t h e

cooler does not freely pass fluid, the cooler must be

replaced.

OIL COOLER FLOW CHECKAft e r t h e n e w o r r e p a ir e d t r a n s m i ss ion h a s b ee n

installed and filled to the proper level with automatic

transmission fluid. The flow should be checked using

the following procedure:

(1) Disconnect the F r o m c o o l e r li n e a t t h e t r a n s -

m i ss ion a n d p la ce a col le ct i n g con t a i n e r u n d e r t h e

disconnected line.

( 2 ) R u n t h e e n g i n e a t c u r b i d l e s p e e d , w i t h t h e

shift selector in neutral.

(3) If the fluid flow is intermittent or i t ta kes more

t h a n 2 0 s e con d s t o col le ct on e q u a r t of a u t om a t i c

transmission fluid, the cooler should be replaced.

CAUTION: With the fluid set at the proper level, fluidcollection should not exceed (1) quart or internaldamage to the transmission may occur.

(4) If f low is found to be within acceptable l imits,

reconn ect the cooler line. Then fill tr an smission to th e

p r op e r l ev el , u s in g t h e a p p r ov ed t y pe of a u t o m a t ic

transmission fluid.

TRANSAXLE REMOVAL AND INSTALLATIONTr a n s a x le r e m ov a l d oe s N O T r e qu i r e e n gi n e r e -

moval.

See Group 7-Cooling, to drain engine cooling system

and remove coolant return extension (3.0 liter engine

only).

(1 ) Th e t r a n s a xle a n d t or q u e con ve r t er m u s t b e

removed a s an assembly; otherwise, t he torque con-

v e r t e r d r i v e p l a t e , p u m p b u s h i n g o r o i l s e a l m a y b e

Fig. 1 Cooler Line Location

21 - 98 TRANSAXLE


15/93

d a m a g ed . T h e d r iv e p l a t e w il l n o t s u p p or t a l oa d ;

therefore, none of the weight of the transaxle should

be allowed to rest on the drive plate during removal.

(2) Disconnect negative bat tery cable.

(3) Disconnect transaxle shift linkage.

(4 ) I n s t a l l e n g in e s u p p or t fi xt u r e a n d s u p p or t e n -

gine (Fig.1).

(5) Remove upper bell housing upper bolts.

(6) Raise vehicle. Remove front wheels. Refer to

S u s p en s i on , G r ou p 2 t o r e m ov e w h e el h u b n u t a n d

both drive shafts.

(7) Remove left plastic splash to gain access to the

transaxle (Fig. 2).

(8 ) R em ov e t or q u e con v er t e r d u s t s h ie ld t o g a in

access to torque converter bolts (Fig. 3).

(9 ) Ma r k t or q u e con ve r t er a n d d r ive p la t e w it h

ch a l k , for r e a s se m bl y. R em ov e t or q u e con v er t e r

mounting bolts.

(10) Disconnect electrical connectors at PRNDL

switch and neutral safety switch (Fig. 4).

(11 ) R em ov e fr on t e n gin e m ou n t in s u la t or a n d

bracket (Fig. 5).

Fig. 1 Engine Support Fixture

Fig. 2 Remove Left Splash Shield

Fig. 3 Remove Torque Converter Dust Shield

Fig. 4 Disconnect PRNDL Switch and Neutral SafetySwitch

Fig. 5 Remove Front Engine Mount

TRANSAXLE 21 - 99


16/93

(12) On vehicles equipped with D.I.S. ignition sys-

t e m , r e m ov e cr a n k s h a ft p os it i on s e n sor fr om b el l

housing (Fig. 6). For installation procedure refer to

section 8D of this service manual.

CAUTION: Failure to remove the crankshaft position

sensor from the bell housing could damage the

sensor or torque converter drive plate during trans-mission removal or installation.

(13) Disconnect an d r emove vehicle dista nce sensor

(Fig. 7).

(14) Remove starter bolts and set starter aside. Do

not allow the starter to hang from battery cable (Fig.

8).

(1 5) P os it i on t r a n s m i ss ion ja ck s e cu r e ly u n d e r

transaxle.

(16) With transmission jack in position, remove the

left transmission mount (Fig. 10).

Fig. 6 Remove Crank Position Sensor (D.I.S. IgnitionOnly)

Fig. 7 Remove Distance Sensor

Fig. 8 Remove Starter Assembly

Fig. 9 Position Transmission Jack

Fig. 10 Remove Left Transmission Mount

21 - 100 TRANSAXLE


17/93

(17) Carefully lower the tran saxle assembly from

vehicle.

When installing transaxle, reverse the above proce-dure.

I f t h e t o r q u e c o n v e r t e r o n a I m p e r i a l o r 5 t h

Av e n u e (AY b o d y ) h a s b e e n r e p la c e d , r e fe r t o

T o r que C o nv e r t e r C l ut c h B r e a k- i n P r o c e dur e i n

t hi s s e c t i o n. T hi s pr o c e dur e w i l l r e s e t t he E A T X

c o n t r o ll e r b r e a k -i n s t a t u s . F a i l u re t o p e r fo r m

t h i s p r o c e d u r e m a y c a u s e t r a n s a x le s h u t t e r.

Check and/or adjust gear shift cable.

Refill tran saxle with MOPAR ATF PLUS (Auto-mat ic Tran smission Fluid) Type 7176.

SOLENOID ASSEMBLY-REPLACE

Fig. 11 Lower Transaxle Assembly

Fig. 1 Input Speed Sensor

Fig. 2 Input Speed Sensor Removed

Fig. 3 Sound Cover

Fig. 4 Attaching Screws

TRANSAXLE 21 - 101


18/93

PRNDL SWITCHThe PRNDL switch is the white switch located on

the front of the t ran saxle, just above th e t ransa xle oilp a n .

CAUTION: Switch seal washer must be seated prop-

erly before tightening switch. Failure to do so may

result in leakage of transmission fluid (Fig. 6).

NEUTRAL SAFETY SWITCHThe N eutral Safety Switch is the black switch lo-

cated to the right of the PRNDL switch.

CAUTION: Switch seal washer must be seated prop-

erly before tightening switch. Failure to do so may

result in leakage of transmission fluid (Fig. 7).

SPEED SENSOR-INPUT

CAUTION: When disconnecting speed sensor con-

nector, be sure that the weather seal does not fall

off or remain in old sensor.

The input speed sensor is located to the right of the

manual shift lever.

SPEED SENSOR-OUTPUT

CAUTION: When disconnecting speed sensor con-nector, be sure that the weather seal does not fall

off or remain in old sensor.

The output speed sensor is located to the left of the

manual shift lever.

TORQUE CONVERTER CLUTCH BREAK-IN PROCE-DURE

A lock-up clutch break-in program is being used in

the Imperial and 5th Avenue (AY body) models. This

program will properly condition the torque converter

cl u t ch . T h is w il l e l im i n a t e s h u d d er d u r i n g p a r t i a l

lock-up operation on a new torque converter.

If the torque converter is replaced, the new clutch

w it h i n t h e t or q u e con v er t e r w il l r e qu i r e b r ea k -i n .

Fig. 5 Solenoid Assembly

Fig. 6 PRNDL Switch

Fig. 7 Neutral Safety Switch

Fig. 8 Output Speed Sensor

21 - 102 TRANSAXLE


19/93

The current break-in status stored in the EATX con-

t r ol le r w il l h a v e t o b e r e s et t o t h e s t a r t of b r e a k -i n

with the DRB II.

If a new EATX controller is put on the vehicle, the

s t a t u s w i l l b e a t t h e s t a r t o f b r e a k - i n . T h i s s t a t u s i s

a cce p t a bl e r e ga r d l es s of t h e m i le a ge on t h e t or q u e

converter. No modification of t he break-in statu s is

required.To properly service these vehicles, it is necessary to

u s e a D RB I I t o r e a d or r e se t t h e b r ea k -in s t a t u s.

Perform the following steps with the DRB II to reset

the break-in status:

(1) Plug th e DRB II into the blue CCD Bus connec-

t or . T h e con n e ct or i s l oca t e d u n d e r t h e i n s t r u m en t

panel on the drivers side of the vehicle.

(2) Insert the 1992 DRB II cartridge into the DRB

II .

(3 ) T h e r e d a n d g r ee n lig h ts on t h e D RB I I w ill

l ight u p a nd then begin flashing. Wait u ntil the l ights

stop flashing before continuing with this procedure.(4) Press the number 4 key (Select System) on the

D R B I I k e y p a d . I t e m n u m b e r 4 w i l l n o t a p p e a r o n

the DRB II screen unless you scroll down. It is not

necessary to scroll down to be able to choose item 4.

(5 ) P re ss t h e n u m be r 2 on t h e D RB I I k e y p a d

(Transmission).


(EATX). Wait for the DRB II to perform the following

t h r e e t e s t s b efor e con t i n u in g (T h es e t e s t s a r e d on e

automatically by the DRB II).

Bus Test

Initialize

Contr oller P art Number


(Adjustments).


(Reset LU Clutch). The DRB II will display one of

three screens.

(a) LU Clutch Break-in Status: St a r t

(b ) L U C lu t ch B r ea k -in S t a t u s: In-progress

Press ENTER to Reset Break-in status

(c) LU Clutch Break-in Status: C o m pl e t e Press

ENTER to Reset Break-in status

If screen (a) appears, the controller is at the begin-

n i n g o f i t s b r ea k -i n p r og r a m . N o fu r t h e r a ct i on i s

required.

If screen (b) appears, the controller is in the middle

of a i ts break-in program. Press the enter key on the

D R B I I k e y p a d t o r e t u r n t h e s t a t u s t o t h e s t a r t o f

break-in.

If screen (c) a ppears, the controller has completed

i t s b r e a k - i n s t a t u s p r o g r a m . P r e s s t h e e n t e r k e y o n

the DRB II key pad to return the status to the start of

break-in.

(9 ) A ft e r p r e ss in g t h e e n t e r k e y a s e con d t i m e i n

s t e p 8 a s cr e en w il l a p p e a r t h a t s a y s R E S E T L U

CLUTCH ARE YOU SURE ?. P ress th e ent er key on

t h e D RB I I k e y p a d . T h e D R B I I w il l t h e n ca r r y ou t

the r eset comman d.

(10) After the DRB II has completed the reset com-

m a n d a s cr e en w ill a p p ea r t h a t s a ys L U C lu t ch

B r ea k -in S t a t u s h a s b ee n R E SE T t o S t a r t . T h is

screen will indicate tha t the reset procedure h as been

successfully complet ed.(11) Disconnect the DRB II from the blue CCD Bus

connector.

TRANSAXLE RECONDITIONTa g a ll c lu t ch p a ck a s se m b li e s, a s t h ey a re

r e m o v e d, f o r r e a s s e m bl y i de nt i f i c a t i o n.

CAUTION: Do not intermix clutch discs or plates asthe unit might then fail.

Fig. 1 Oil Pan Bolts

Fig. 2 Oil Pan

TRANSAXLE 21 - 103


20/93

Fig. 3 Oil Filter

Fig. 4 Valve Body Attaching Bolts

Fig. 5 Push Park Rod Rollers from Guide Bracket

Fig. 6 Remove or Install Valve Body

Fig. 7 Valve Body Removed

Fig. 8 Accumulators

21 - 104 TRANSAXLE


21/93

Measuring input shaft end play before disassembly

will usua lly indicate when a #4 thr ust plate change is

required, (except when major parts are replaced). The

#4 th rust plate is located behind the overdrive clutch

h u b .

At t a c h a d ia l i n di ca t or t o t r a n s a x le b el l h o u s in g

w it h i t s p l u n ge r s ea t e d a g a in s t e n d o f in p u t s h a ft

(Fig. 14).

M ove in p u t s h a ft in a n d ou t t o o bt a in e n d p l a y

r e a d in g . E n d p la y s p eci fi ca t i on s a r e .13 t o .64 m m

(.005 to .025 inch).

Fig. 14 Measure Input Shaft End Play

Fig. 9 Accumulator

Fig. 10 Low/Reverse Accumulator Snap Ring

Fig. 11 Low/Reverse Accumulator Plug (Cover)

Fig. 12 Low/Reverse Accumulator Piston

Fig. 13 Low/Reverse Accumulator

TRANSAXLE 21 - 105


22/93

Record indicator reading for reference when reas-

sembling the tran saxle.

CAUTION: Be sure input speed sensor is removedbefore removing oil pump.

Fig. 15 Pump Attaching Bolts

Fig. 16 Install Tool C-3752

Fig. 17 Remove Oil Pump

Fig. 18 Oil Pump Removed

Fig. 19 Oil Pump Gasket

Fig. 20 Remove Bypass Valve

21 - 106 TRANSAXLE


23/93

CAUTION:The cooler bypass valve must be replacedif a transaxle failure has occurred. Do not reuse oldvalve or attempt to clean old valve. When installingbypass valve, insert with O-ring end towards rear of

case.

Fig. 21 No.1 Caged Needle Bearing

Fig. 22 Input Clutches Assembly

Fig. 23 Front Sun Gear Assembly

Fig. 24 Front Carrier and Rear Annulus Assembly

Fig. 25 Rear Sun Gear

Fig. 26 2/4 Clutch Retainer Snap Ring

TRANSAXLE 21 - 107


24/93

Ta g 2 /4 c l u t c h p a c k f o r r e a s s e m b l y i d e n t i fi c a -

t i o n .

Fig. 32 Tapered Snap Ring

Fig. 27 Remove 2/4 Clutch Retainer

Fig. 28 2/4 Clutch Retainer

Fig. 29 2/4 Clutch Return Spring

Fig. 30 2/4 Retainer and Spring Indexed

Fig. 31 2/4 Clutch Pack

21 - 108 TRANSAXLE


25/93

Fig. 33 Tapered Snap Ring Instructions

Fig. 34 Snap Ring Installed

Fig. 35 Low/Reverse Reaction Plate

Fig. 36 Remove One Disc

Fig. 37 Low/Reverse Reaction Plate Snap Ring

TRANSAXLE 21 - 109


26/93

Ta g l o w /r e v e rs e c lu t c h p a c k fo r r e a ss e m b ly

i de nt i f i c a t i o n.

Fig. 38 Low/Reverse Clutch Pack

Fig. 39 Rear Cover Bolts

Fig. 40 Rear Cover

Fig. 41 Remove Transfer Shaft Gear Nut

Fig. 42 Transfer Shaft Gear Nut and Washer

Fig. 43 Remove Transfer Shaft Gear

21 - 110 TRANSAXLE


27/93

Fig. 44 Install Transfer Shaft Gear

Fig. 45 Tighten Nut to 271 Nm (200 Ft. Lbs.)

Fig. 46 Transfer Shaft Gear and (Select) Shim

Fig. 47 Bearing Cup Retainer

Fig. 48 Remove Transfer Shaft Bearing Cone

Fig. 49 Install Transfer Shaft Bearing Cone

TRANSAXLE 21 - 111


28/93

Fig. 50 Remove Transfer Shaft Bearing Cup

Fig. 51 Install New Bearing Cup

Fig. 52 Transfer Shaft Bearing Snap Ring

Fig. 53 Transfer Shaft

Fig. 54 Remove Transfer Shaft Bearing Cone

Fig. 55 Install Bearing Cone

21 - 112 TRANSAXLE


29/93

Fig. 56 Bearing Cup Removed

Fig. 57 Remove Output Gear Bolt

Fig. 58 Output Gear Bolt and Washer

Fig. 59 Remove Output Gear

Fig. 60 Install Output Gear

Fig. 61 Tighten Output Gear to 271 Nm (200 ft. lbs.)

TRANSAXLE 21 - 113


30/93

Fig. 62 Output Gear and (Select) Shim

Fig. 63 Remove Bearing Cone

Fig. 64 Install New Bearing Cone

Fig. 65 Rear Carrier Assembly

Fig. 66 Remove Rear Carrier Bearing Cone

Fig. 67 Install Rear Carrier Bearing Cone

21 - 114 TRANSAXLE


31/93

CAUTION: When installing, be sure guide bracketand split sleeve touch the rear of the transaxle case.

Fig. 68 Low/Reverse Spring Compressor Tool

Fig. 69 Compressor Tool in Use

Fig. 70 Remove or Install Snap Ring

Fig. 71 Low/Reverse Piston Return Spring

Fig. 72 Drive Out Anchor Shaft

Fig. 73 Anchor Shaft and Plug

TRANSAXLE 21 - 115


32/93

Fig. 74 Guide Bracket Pivot Shaft

Fig. 75 Pivot Shaft and Guide Bracket

Fig. 76 Guide Bracket Assembled

Fig. 77 Guide Bracket Disassembled

Fig. 78 Low/Reverse Clutch Piston

Fig. 79 Piston Retainer Attaching Screws

21 - 116 TRANSAXLE


33/93

CAUTION: Drift bearing cup all the way around.

To assemble, reverse the above procedure. Be sure

to check both grounded clutch clearan ces. Before in-

s t a ll in g t h e i n pu t cl u t ch e s r e t a in e r, fol low t h e i n -

structions in D e te rm i ni n g N o . 4 Th ru s t P l at e

T h i c k n e s s.

Fig. 80 Piston Retainer

Fig. 81 Piston Retainer Gasket

Fig. 82 Remove Output Bearing Inner Cup

Fig. 83 Remove Output Bearing Outer Cup

Fig. 84 Install Both Output Bearing Cups

Fig. 85 Checking Output Gear Bearings End Play

TRANSAXLE 21 - 117


34/93

P r e s s d ow n cl u t ch p a ck w it h fi n ge r a n d z er o d i a l

indicator. L o w /R e v e r s e c l u t c h p a c k c l e a r a n c e i s

1.04 to 1.65mm (.042 to .065 inch).

S e le ct t h e p r op e r l ow /r e ve r s e r e a ct i on p la t e t o

achieve specificat ions:

P r e s s d ow n cl u t ch p a ck w it h fi n ge r a n d z er o d i a l

indicator. T he 2 / 4 c l ut c h pa c k c l e a r a nc e i s 0 . 7 6 t o

2 . 6 4 m m ( . 0 3 0 t o . 1 0 4 i nc h) . If not within specifica-

tions, the clutch is not assembled properly. T h e r e i s

no a dj us t m e nt f o r t he 2 / 4 c l ut c h c l e a r a nc e .

DETERMINING NO. 4 THRUST PLATE

THICK NESSINPUT SHAFT END PLAY

To d et e r min e t h e p r op er t h ick n es s of t h e N o. 4

t h r u s t p l a t e , s e l e c t t h e t h i n n e s t N o . 4 t h r u s t p l a t e .

U s in g p e t r ol a t u m (F i g. 8 7) t o h ol d t h r u s t p la t e i n

position, install input clutches assembly. Be sure the

input clutches assembly is completely seated (Fig.

88).

CAUTION: If view through input speed sensor hole

is not as shown above, the input clutches assembly

is not seated properly.

By removing the oil pump O-ring, you will be able

t o i n s t a l l a n d r e m o v e t h e o i l p u m p a n d g a s k e t v e r y

easily to select the proper No. 4 t hrust plate.

CAUTION: Be sure to reinstall O-ring on oil pump

after selecting the proper No. 4 thrust plate.

Fig. 86 Checking Output Gear Bearings TurningTorque

Fig. 87 Check Low/Reverse Clutch Clearance

LOW/REVERSE REACTI ON PLATE CHART

Fig. 88 Check 2/4 Clutch Clearance

Fig. 89 Select Thinnest No. 4 Thrust Plate

21 - 118 TRANSAXLE


35/93

I nput s ha f t e nd pl a y m us t be . 0 0 5 t o . 0 2 5 i nc h.

For example, if end play reading is .055 inch, select

No. 4 Thrust Plate which is .071 to .074 thick. This

s h ou l d p r o vi de a n i n pu t s h a ft e n d p la y r e a d in g of

.020 inch which is within specifications.

S e e c h a r t b el ow t o s e le ct t h e p r op e r N o. 4 t h r u s t

plate.

INPUT CLUTCHES-RECONDITIONDISASSEMBLY

Fig. 90 View Through Input Speed Sensor Hole

Fig. 91 Remove Oil Pump O-Ring

Fig. 92 Measure Input Shaft End Play

NO. 4 THRUST PLATE CHART

Fig. 1 Tapping Reaction Plate

Fig. 2 Reverse Clutch Snap Ring

TRANSAXLE 21 - 119


36/93

T a g r e v e r s e c l ut c h pa c k f o r r e a s s e m bl y i de nt i -

f i c a t i o n.

Fig. 3 Pry Reverse Clutch Reaction Plate

Fig. 4 Reverse Clutch Reaction Plate

Fig. 5 Reverse Clutch Pack

Fig. 6 OD/Reverse Pressure Plate Snap Ring 192195

Fig. 7 OD/Reverse Pressure Plate

Fig. 8 Waved Snap Ring

21 - 120 TRANSAXLE


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Ta g o v e rd ri v e c lu t ch p a ck fo r r ea s se m bl y


Fig. 9 Remove OD Clutch Pack

Fig. 10 Overdrive Clutch Pack

Fig. 11 Overdrive Shaft Assembly

Fig. 12 Underdrive Shaft Assembly

Fig. 13 No. 2 Needle Bearing

Fig. 14 OD/UD Reaction Plate Tapered Snap Ring

TRANSAXLE 21 - 121


38/93

Ta g u n d e r d ri v e c l u tc h p a c k f or r e a ss e m b ly


CAUTION: Compress return spring just enough toremove or install snap ring.

Fig. 18 Underdrive Clutch Pack

Fig. 19 UD Spring Retainer Snap Ring

Fig. 20 UD Return Spring and Retainer

Fig. 15 OD/UD Reaction Plate

Fig. 16 Remove One UD Clutch Disc

Fig. 17 UD Clutch Flat Snap Ring

21 - 122 TRANSAXLE


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Fig. 21 Underdrive Clutch Piston

Fig. 22 Input Hub Tapered Snap Ring

Fig. 23 Tap on Input Hub

Fig. 24 Input Hub Removed

Fig. 25 Pull Retainer from Piston

Fig. 26 Install Snap Ring

TRANSAXLE 21 - 123


40/93

ASSEMBLY

U s e p et r ola t u m on a ll s ea l s t o e a se a s se m bly of

components.

Fig. 1 Install Input Shaft

Fig. 2 Install Input Shaft Snap Ring

Fig. 3 Return Spring and Snap Ring

Fig. 27 Snap Ring and Return Spring

Fig. 28 Remove Input Shaft Snap Ring

Fig. 29 Remove Input Shaft

21 - 124 TRANSAXLE


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Fig. 4 Install Snap Ring

Fig. 5 Install OD/Reverse Piston

Fig. 6 Install Input Shaft Hub Assembly

Fig. 7 Input Hub Tapered Snap Ring

Fig. 8 Underdrive Clutch Piston

Fig. 9 Seal Compressor Tool 5067

TRANSAXLE 21 - 125


42/93

CAUTION: Compress return spring just enough to

remove or install snap ring.

Fig. 10 UD Return Spring and Retainer

Fig. 11 Install UD Spring Retainer and Snap Ring

Fig. 12 Underdrive Clutch Pack

Fig. 13 UD Clutch Flat Snap Ring

Fig. 14 Install Last UD Clutch Disc

Fig. 15 OD/UD Reaction Plate

21 - 126 TRANSAXLE


43/93

S n a p r i ng e n d s m u s t b e l oc a te d w i th i n o n e

f in g e r o f t h e i n p u t c l u t c h h u b . B e s u r e t h a t s n a p

ri ng i s fu lly s e at ed , b y p u sh in g w i th s cre w -d ri ve r, in to s na p rin g g ro ov e a ll t he w a y

a r o u n d .

U n de r dr iv e c lu t ch p a ck c le a ra n c e m u s t b e

0 .9 1 t o 1 .4 7m m ( .0 36 t o .0 58 i n c h ). S e le ct t h e

proper reaction plate to a chieve specificat ions:

Fig. 17 Seating Tapered Snap Ring

Fig. 18 Set Up Dial Indicator for Clutch Clearance

Fig. 19 Use Hook Tool to Raise One Clutch DiscFig. 16 Tapered Snap Ring

UNDERDRIVE REACTION PLATE CHART

Fig. 20 Install OD Clutch Pack

TRANSAXLE 21 - 127


44/93

Th e o v e rd r iv e ( OD ) c l u t c h p a c k c l e ar a n ce i s

. 9 6 5 t o 2 . 2 6 m m ( . 0 3 8 t o . 0 8 9 i nc h) . If not within

specifications, t he clutch is n ot assembled properly.

There is no adjustment for the OD clutch clearance.

Fig. 26 Install Reverse Clutch Pack

Fig. 21 Install Waved Snap Ring

Fig. 22 OD/Reverse Pressure Plate

Fig. 23 Pressure Plate Installed

Fig. 24 Install Flat Snap Ring

Fig. 25 Check OD Clutch Pack Clearance

21 - 128 TRANSAXLE


45/93

Th e r e v e rs e c lu t c h p a c k c l e a r an c e i s 0 .7 6 t o

1 .2 4 m m ( .0 3 0 t o .0 4 9 i nc h ) . S e le ct t h e p r op e r r e -

verse clutch sn ap ring t o achieve specificat ions:

All clutch clearances in the input clutches retainer

have now been checked and approved.

To complete the assembly of the input clutches re-t a i n e r, t h e r e ve r s e cl u t ch a n d t h e ov er d r i ve cl u t ch

must be removed from the retainer.

CAUTION: Do not intermix clutch parts. Keep inexact same order.

Now proceed with the next phase of the assembly:

Fig. 31 Install No. 2 Needle Bearing

Fig. 27 Install Reaction Plate

Fig. 28 Install Reverse Clutch Snap Ring

Fig. 29 Seating Snap Ring to Determine ReverseClutch Clearance

Fig. 30 Check Reverse Clutch Pack Clearance

REVERSE CLUTCH SNAP RING CHART

TRANSAXLE 21 - 129


46/93

Now that both shaft assemblies and thrust washers

are properly installed, reinstall overdrive clutch and

r e ve r s e c lu t c h a s s h ow n i n F i gu r e s 2 0 t h r o u g h 2 8.

R e c h e c k i n g t h e s e c l u t c h c l e a r a n c e s i s n o t n e c -

e s s ar y, a s t h e y w e r e s e t a n d a p pr ov e d p re v i-

ously.

VALVE BODY-RECONDITIONP r i or t o r e m ov in g a n y t r a n s a x le s u b a s se m bl ie s,

plug all openings and thoroughly clean exterior of the

unit , preferably by steam. Cleanliness t hrough ent ire

disassembly and assembly cannot be overemphasized.When disassembling, each part should be washed in a

suitable solvent, then dried by compressed a ir. D o

n o t w i p e p a r t s w i t h s h o p t o w e l s . All mating sur-

fa ce s i n t h e t r a n s a xle s a r e a ccu r a t e ly m a ch in e d;

therefore, careful handling of all parts must be exer-

cised to avoid nicks or burrs.

Ta g a l l s p r in g s , a s t h e y a r e r e m o v e d , f o r r e a s -

s e m bl y i de nt i f i c a t i o n.

Fig. 32 Install Underdrive Shaft Assembly

Fig. 33 Install No. 3 Thrust Washer

Fig. 34 Install No. 3 Thrust Plate

Fig. 35 Install Overdrive Shaft Assembly

Fig. 36 Input Clutches Assembly

21 - 130 TRANSAXLE


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Fig. 1 Oil Pan Bolts

Fig. 2 Oil Pan

Fig. 3 Oil Filter

Fig. 4 Valve Body Attaching Bolts

Fig. 5 Push Park Rod Rollers from Guide Bracket

Fig. 6 Remove or Install Valve Body

TRANSAXLE 21 - 131


48/93

Fig. 12 Ball Check and Retainer Locations

Fig. 7 Valve Body Removed

Fig. 8 Manual Shaft Screw

Fig. 9 Retaining Plate Screw

Fig. 10 Transfer Plate and Separator Plate

Fig. 11 Transfer Plate

21 - 132 TRANSAXLE


49/93

Fig.

13SpringsandValvesIdentification

TRANSAXLE 21 - 133


50/93

W h en i n s t a ll in g v a lv e b od y a s s em b ly on t o t r a n -

saxle, observe Figure 5. Guide park rod rollers into

guide bracket, while shifting manual lever assembly

out of the installation position.

OIL PUMP SEAL REPLACE

DIFFERENTIAL REPAIRThe transfer shaft should be removed for differen-

tial repair and bearing turn ing torque checking.

Fig. 14 Remove or Install Dual Retainer Plate

Fig. 15 Remove or Install Retainer Plate

Fig. 16 Remove Oil Pump Seal

Fig. 17 Install Oil Pump Seal

Fig. 1 Remove Extension Seal

21 - 134 TRANSAXLE


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Fig. 2 Install New Seal Into Extension

Fig. 3 Differential Cover Bolts

Fig. 4 Remove or Install Differential Cover

Fig. 5 Differential Retainer Bolts

Fig. 6 Remove or Install Bearing Retainer

Fig. 7 Differential Bearing Retainer

TRANSAXLE 21 - 135


52/93

Fig. 8 Extension Bolts

Fig. 9 Remove or Install Extension

Fig. 10 Differential and Extension

Fig. 11 Remove Differential Bearing Cone

Fig. 12 Install Differential Bearing Cone

Fig. 13 Remove Differential Bearing Cone

21 - 136 TRANSAXLE


53/93

CAUTION: Always install NEW ring gear bolts. Bolts

must be properly torqued.

Fig. 14 Install Differential Bearing Cone

Fig. 15 Torque New Ring Gear Bolts to 95 Nm (70ft. lbs.)

Fig. 16 Remove Pinion Shaft Roll Pin

Fig. 17 Remove or Install Pinion Shaft

Fig. 18 Remove or Install Pinion Gears, Side Gears,and Tabbed Thrust Washers, by Rotating Pinion

Gears to Opening in Differential Case

Fig. 19 Differential Gears

TRANSAXLE 21 - 137


54/93

CAUTION: Side gear end play must be within .001 to

.013 inch.

Four select thrust washers are available: .032, .037,

.042, and .047 inch.

CAUTION: Side gear end play must be within .001 to

.013 inch.

Four select thrust washers are available: .032, .037,

.042, and .047 inch.

DETERM I NI NG SHI M THI CKNESS

S h i m t h i c k n e s s n e e d o n l y b e d e t e r m i n e d i f a n y o f

the following parts are replaced:

Transaxle case

Different ial carrier

Differential bearing retainer

Extension housing

Differential bearing cups and cones

Fig. 20 Checking Side Gear End Play

Fig. 21 Checking Side Gear End Play

Fig. 22 Remove Oil Seal

Fig. 23 Install New Oil Seal

Fig. 24 Remove Bearing Cup

21 - 138 TRANSAXLE


55/93

Refer to B e a r i n g A d ju s t m e n t P r o c e d u r e i n r e a r

of this section to determine proper shim thickness for

cor r e ct b ea r i n g p r e loa d a n d p r op e r b ea r i n g t u r n i n g

torque.

When rebuilding, reverse the above procedure.

R e m o v e o l d s e a l a n t b e f o r e a p p l y i n g n e w s e a l -

a nt . U s e MOP AR A d h e s i v e S e a l a n t o n r e t a i n e r

t o s e a l r e t a i n e r t o c a s e .

BEARING ADJUSTMENT PROCEDURE

GENERAL RULES ON SERVICIN G BEARINGS

(1) Take extreme care when removing and in stall-

in g b ea r in g cu p s a n d con e s. U se o n ly a n a rb or

p r e s s f o r i n s t a l la t i o n , a s a h a m m e r m a y n o t p r o p -

erly align the bearing cup or cone. Burrs or nicks on

t h e b ea r i n g s e a t w il l g iv e a fa l se e n d p la y r e a d in g ,

while gauging for proper shims. Improperly seated

b ea r i n g cu p a n d con e s a r e s u b je ct t o l ow -m i le a ge

failure.

(2 ) B e a r i n g c u p s a n d con e s s h ou l d b e r e p la ce d i f

they show signs of pitting or heat distress.

I f d is t r es s is s ee n on e it h e r t h e cu p or b ea r in g

rollers, both cup and cone must be replaced.

B e a r i n g e n d p l a y a n d d r a g t o r q u e s p e c i f i c a -

t io n s m u s t b e m a i n ta i n e d t o a v o id p r e m a tu r e

be a r i ng f a i l ur e s .

Used (original) bearing may lose up to 50

of the original drag torque after break-in.

Al l b e a ri n g a d j u s tm e n t s m u s t b e m a d e w i t h n o

o th e r c o mp o n e nt i n te rfe re n c e o r g e a r i n te r-

m e s h , e x c e p t t h e t r a n s fe r g e a r b e a r i n g .

Oil all bearings before checking turning torque.

OUTPUT GEAR BEARING

With output gear removed:

Fig. 25 Differential Bearing Retainer

Fig. 26 Install Bearing Cup

Fig. 27 Checking Differential End Play

Fig. 28 Tool L-4436 and Torque Wrench

TRANSAXLE 21 - 139


56/93

(1) Install a 4.50 mm (0.177 inch) gauging shim on

t h e r e a r ca r r i er a s s em b ly h u b , u s in g g r ea s e t o h o ldthe shim in place.

(2 ) I n st a ll ou t pu t ge ar a n d b ea r in g a s sem bly.

Torque to 271 Nm (200 ft. lbs.).

(3) To measure bearing end play:

(a) Attach Tool L-4432 to t he gear.

(b ) P u s h a n d p u l l t h e g ea r w h il e r o t a t in g b a ck

and forth to insure seating of the bearing rollers.

( c ) U s i n g a d i a l i n d i c a t o r , m o u n t e d t o t h e t r a n -

saxle case, measure output gear end play.

(4 ) O n ce b ea r i n g e n d p la y h a s b ee n d e t er m i n ed ,

r e f e r t o t h e o u t p u t g e a r b e a r i n g s h i m c h a r t f o r t h e

required shim to obtain proper bearing setting.

(5) Use Tool 6259 to remove the retaining nut andwasher. To remove the output gear, use Tool L-4407.

(6) Remove the gauging shim a nd install the proper

shim. Use grease to hold t he shim in place. Install the

output gear and bearing assembly.

(7 ) I n s t a ll t h e r e t a i n in g n u t a n d w a s h e r a n d t o r q u e

to 271 Nm (200 ft. lbs.).

(8) Using an inch-pound torque wrench, check the

turning torque. T h e t o r q u e s h o u l d b e b e t w e e n 3

a n d 8 i n c h -p o u n d s .

I f t h e t u r n i n g t o r q u e i s t o o h i g h , i n s t a l l a .0 4 m m

(.0016 inch) th icker shim. If th e t urning torque is t oo

low, install a .04 mm (.0016 inch) thinner shim. Re-

p ea t u n t il t h e p r op er t u r n in g t or q u e i s 3 t o 8 in ch

pounds.

DIFFERENTIAL BEARING

(1) Remove t he bearing cup from the differential

bearing retainer using Tool L-4518, and remove th e

existing shim from under the cup.

(2) Install a .50 mm (.020 inch) gauging shim and

r e in s t a ll t h e b ea r in g cu p in t o t h e r e t a in e r. U s e a n

arbor press to install the cup.

O i l B a f f l e i s n o t r e q u i r e d w h e n m a k i n g s h i m

s e l e c t i o n .

(3 ) I n s t a l l t h e b ea r i n g r e t a i n e r i n t o t h e ca s e a n d

torque bolts to 28 Nm (250 in. lbs.).

(4) Position the tran saxle assembly vertically on

t h e s u p p or t s t a n d a n d i n st a l l T ool C -4 99 5 i n t o s i de

gear.

(5) Rotate the differential at least one full revolu-

t i on t o e n s u r e t h e t a p e r ed r ol le r b ea r i n gs a r e fu l ly

seated.

(6) Attach a dial indicator to the case and zero the

dial indicator. Place th e indicator t ip on the end of

Tool L-4436.

(7 ) P l a ce a l a r ge s cr e wd r iv er t o e a c h s id e of t h e

r i n g g e a r a n d l ift . C h e ck t h e d ia l i n di ca t or for t h e

amount of end play.

CAUTION: Do not damage the transaxle case and/or

differential cover sealing surface.

(8) When the end play has been determined, refer

to the Differential Bearing Shim Chart for the correct

s h im com b in a t i on t o ob t a in t h e p r op e r b ea r i n g s e t -

ting.(9) Remove the differential bearing retainer. Re-

m ove t h e b ea r in g cu p a n d t h e .5 0 m m (.0 20 in ch )

gauging shim.

(10) Install the proper shim combination under the

b ea r i n g cu p . M a k e s u r e t h e oi l b a ffl e i s i n st a l le d

p r op e r ly i n t h e b ea r i n g r e t a in e r, b el ow t h e b ea r i n g

shim and cup.

(11) Insta ll th e differential bearing r etainer. Seal

t h e r e t a i n e r t o t h e h o u s i n g w i t h M O P A R Adhesive

Sealant a nd torque bolts to 28 Nm (250 in. lbs.).

Fig. 29 Checking Differential Bearings TurningTorque

OUTPUT GEAR BEARING SHI M CHART

21 - 140 TRANSAXLE


57/93

(12) Using Tool C-4995 and an inch-pound torquewrench, check the turning torque of the differential .

T h e t u r n i n g t o r q u e s h o u l d b e b e t w e e n 5 a n d 1 8

i n c h - p o u n d s .

I f t h e t u r n i n g t o r q u e i s t o o h i g h , i n s t a l l a . 0 5

m m (.0 02 i n ch ) t h in n e r s h im . If t h e t u rn i n g

t o r q u e i s t o o l o w , i n s t a l l a . 0 5 m m ( . 0 0 2 i n c h )

t h i ck e r s h i m . R e p e a t u n t i l 5 t o 1 8 i n c h -p o u n d s

t u r n i n g t o r q u e i s o b t a i n e d .

TRANSFER SHAFT BEARING

(1) Use Tool 6259 to remove the retaining nut and

w a s h er . R e m ov e t h e t r a n s fe r s h a ft g ea r u s in g ToolL-4407.

(2) Install a 4.66 mm (.184 inch) gauging shim on

the transfer shaft .

(3) Install tran sfer shaft gear a nd bearing assembly

a n d t o r q u e t h e n u t t o 2 71 Nm (200 ft. lbs.).

(4) To measure bearing end play:

(a) Attach Tool L-4432 to the transfer gear.

(b) Mount a steel ball with grease into the end of

the transfer shaft .

(c) P u s h a n d p u ll t h e g ea r w h il e r o t a t in g b a ck

and forth to insure seating of the bearing rollers.

(d) Using a dial indicator, measur e tr ansfer shaft

end play.

(5 ) R e fe r t o t h e Tr a n s fe r B ea r i n g S h i m C h a r t for

the required shim combination to obtain the proper

bearing setting.

(6) Use Tool 6259 to remove the retaining nut and

w a s h er . R e m ov e t h e t r a n s fe r s h a ft g ea r u s in g Tool

L-4407.

(7 ) R e m ov e t h e g a u gi n g s h i m a n d i n st a l l t h e cor -

r e c t s h i m . I n s t a l l t h e t r a n s f e r g e a r a n d b e a r i n g a s -

sembly.

(8) Install the retaining nut and washer and torquet o 2 7 1 Nm (200 ft. lbs.). M e a s u r e t r a n s f e r s h a f t

e nd pl a y , e nd pl a y s ho ul d be . 0 5 t o . 1 0 m m ( . 0 0 2

to .004 inch).

(9 ) M e a s u r e b e a r i n g e n d p la y a s ou t l in e d i n S t e p

(4). End play should be between .05 mm and .10 mm

(.002 to .004 inch).

TRANSFER BEARING SHIM CHARTDIFFERENTIAL BEARING SHI M CHART

TRANSAXLE 21 - 141


58/93

I f e n d p l a y i s t o o h i g h , i n s t a l l a .0 4 m m ( .0 0 16

i nc h) t hi nne r s hi m . I f e nd pl a y i s t o o l o w , i ns t a l l

a . 0 4 m m ( . 0 0 1 6 i nc h) t hi c ke r s hi m c o m bi na t i o n.

R e pe a t unt i l . 0 5 t o . 1 0 m m ( .0 0 2 t o . 0 04 i nc h ) e nd

p l a y i s o b t a i n e d .

BEARING SHI M CH ART

21 - 142 TRANSAXLE


59/93

4-SPEED ELECTRONIC TRANSAXLE ON-BOARD DIAGNOSTICS

INDEX

page page

CCD Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143DRB II (Diagnostic Read-Out Box) . . . . . . . . . . . 144Fault Code Charts . . . . . . . . . . . . . . . . . . . . . . . 144General Information . . . . . . . . . . . . . . . . . . . . . . 143

Limp-In Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 143On-Board Diagnostics Information . . . . . . . . . . . . 143System Fault Messages/Codes . . . . . . . . . . . . . . 143

GENERAL INFORMATIONThe information in this manual is designed to help

t h e t e ch n i ci a n u n d e r st a n d a n d r e p a ir t h e t r a n s a x le

with the aid of the built in on-board diagnostics.

C h ry s le r Co r po r at i on h a s d e v e lo p e d a c o m -

p l e t e s e t o f d i a g n o s t i c m a n u a l s w h i c h c o v e r t h e

d i a gn o s i s o f t h i s t ra n s a x le . T h e y h a v e b e e n d e -

s ig n e d t o m a ke t ra n s ax le d ia g n os is a c cu r at e

a n d s i m p l e . U s e t h e s e m a n u a l s w i t h t h e D R B I Ia n d t h e l a t e s t c a r t r i d g e , w h e n d i a g n o s i n g t r a n -

s a x l e p r o b l e m s .

ON-BOARD DIAGNOSTICS INFORMATIONT h e t r a n s a x le i s c on t r o ll ed a n d m on i t or e d b y t h e

Electronic Automatic Tran saxle (EATX) controller.

The controller monitors critical input and output cir-

cuits within th e tr ansaxle.

CAUTION: A 1992 EATX Controller will not inter-

change with any previous model year controllers.

Use of a previous year controller on a 1992 vehicle

will cause transaxle performance problems.

S om e ci r cu i t s a r e t e s t ed con t i n u ou s ly ; o t h e r s a r e

checked only under certain conditions. Each circuit

monitored by the EATX contr oller has a correspond-

ing fault m essage assigned to i t th at can be read with

the DRB II.

If the on-board diagnostic system senses that one of

th e circuits is ma lfun ctioning, the corresponding fault

message is stored in memory. If the malfunction goes

away after the fault code is stored, the controller will

erase the fault after 75 key cycles.

CCD BUSIn order to diagnose t he EATX, fault codes in the

EATX contr ollers memory should be read using the

Diagnostic Readout Box (DRB II). If m ore than one

fault code exists, diagnostic priority should be given to

the most recent code. With CCD bus bias and commu-

nication problems, however, t he DRBII displays an

a p p rop ria te m e ss a ge a n d fa u lt cod es m igh t n ot b e

accessible until the bus problem is fixed. The following

is a list of probable causes for a bus problem:

Open or short to ground/battery in either or both

CCD bus wires (pins 4 and 43).

Open or short to ground/battery in either or both

EATX bias wires (pin 5 and 44) on vehicles requiring

EATX to bias th e bus.

Open or short to ground/battery in the diagnostic

connector bus wire.

Internal failure of any controller connected to the

bus.

The CCD bus should have 2.5 volts (+2.5 volts on

CCD+ and -2.5 volts on CCD-).T h e b u s e r r or m e ss a ge d is pl ay ed b y t h e D RB I I

should be helpful in diagnosing the CCD bus.

For more information on diagnosing CCD bus prob-

lems, refer to the 1992 Diagnostic Procedures Manual

for non-commun ication with the CCD bus problems.

All other problems refer to the 1992 Body Vehicle

Communications Diagnostic Procedures Manual.

SYSTEM FAULT MESSAGES/CODESF a u l t cod e s a r e t w o-d ig it n u m b e r s t h a t i de n t ify

which circuit is m alfun ctioning. A fau lt code can be

set for hydraulic and mechanical reasons as well as

for electrical problems. In most cases, fault codes do

not pinpoint which specific component is defective.

F a u l t c o d e c a n o n l y b e r e a d w i t h t h e u s e o f

t he D R B I I R e a d- o ut B o x o r e qui v a l e nt .

HARD FAULTS

An y fa u l t cod e t h a t com e s b a ck w it h i n 3 e n gi n e

sta rts (reset coun t 3 or less) is a Ha rd Fa ult. Th is

means that the defect is there every t ime the control-

ler checks that circuit.

SOFT FAULTS

A Soft Fa ult is one t ha t occurs int erm itt ent ly. It isnot there every time the controller checks the circuit.

Most soft faults are caused by wiring or connector

p r ob le m s . I n t e r m it t e n t d e fe ct s m u s t b e l ook e d for

under the specific conditions that caused them.

LIMP-IN MODEThe EATX contr oller continuously checks for elec-

trical and internal transaxle problems. When a prob-

lem is sensed, the controller stores a fault code. All

b u t t w el ve of t h e se cod e s c a u s e t h e t r a n s a x le t o g o

int o th e Limp-in mode. Wh ile in th is m ode, electri-

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ca l p ow er i s t a k e n a w a y f r om t h e t r a n s a x le . W h e n

t h is h a p pe n s, t h e on ly t r a n s a xle r a n ge s t h a t w ill

function are:

P a r k

N e u t r a l

Reverse

Second Gear

No upshifts or downshifts are allowed while in theLimp-in m ode. The position of the m an ua l valve alone

allows the three ranges that are available.

Although engine performance will be reduced while

in this mode, the vehicle can be driven in for service.

DRB II (DIAGNOSTIC READ-OUT BOX)The DRB II is a diagnostic read-out box designed by

Chrysler to gain access to the on-board diagnostics

tha t are found on all Chrysler-built cars and tru cks.

T h e D R B I I h a s a fe w d ia g n os t ic c a p a b il it i es b y

itself. To perform most diagnostic t ests, a program

cartridge must be inserted. I t contains the diagnostic

test pr ograms.There are diagnostic read-out boxes available from

ot h e r m a n u fa ct u r e s t h a t ca n b e u s ed on C h r ys le r

vehicles. However, th e diagnostic test procedures in

t h is m a n u a l h a ve b ee n d es ig n ed for u s e w i t h t h e

Chryslers DRB II diagnostic readout box.

T h e D RB I I op e r a t es b y c om m u n i ca t i n g w i t h t h e

controller of the vehicle system being tested. To com-

municate with the EATX controller, t he DRB II must

be connected to the blue CCD bus connector located

under the instrument panel. Refer t o the Using the

DRB IIm an ua l or t he Diagnostic Pr ocedures Ma nu al

for information on how to use the DRB II.

FAULT CODE CHARTSBelow is a brief description of what each section of

the fault code charts are addressing.

FAULT CODE-Te ll s t h e cod e n u m b er a n d n a m e

(as shown on the DRBII).

BACKGROUND-A brief description of the circuit

that the controller is monitoring.

WHEN CHECKED-The point of time or condition

when the controller m akes its system check.

ARMING CONDITIONS-Th e p ar a met er s t h at

must be met before a code can be set.

FAULT CONDITION-Wh a t t h e con t r olle r s a w

t h a t i s d e t e r m in e d t o b e a p r ob le m . ( ie . v ol t a ge t ohigh or low, switch/solenoid problems)

FAULT SET TIME-R e f e r s t o t h e a m o u n t o f t i m e

(in seconds) a failure must occur before a fault code is

set in memory.

EFFECT-Refers to how the fault effects transaxle

operations.

POSSIBLE CAUSE-Refers to the systems or cir-

cuits which could cause the fault to be recorded.

FAULT CODE 11

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FAULT CODE 1 2

FAULT CODE 1 3

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FAULT CODE 14

FAULT CODE 1 5

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FAULT CODE 1 6

FAULT CODE 1 7

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FAULT CODE 1 8

FAULT CODE 1 9

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FAULT CODE 2 0

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FAULT CODE 2 1-27

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FAULT CODE 2 8

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FAULT CODE 2 9

FAULT CODE 3 1-32

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FAULT CODE 36

FAULT CODE 3 7

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FAULT CODE 3 8

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FAULT CODE 4 1-44

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FAULT CODE 4 5

FAULT CODE 4 6

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FAULT CODE 4 7

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FAULT CODE 6 0-63

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4-SPEEDELECTRONICWIRINGDIAGRA

M

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ON BOARD DIAGNOSTICS GLOSSARY

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F O U R S P E E D E L EC T R O N I C T R A N S A X L E H Y D R AU L I C S C H E M AT I C S

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FOURSPEEDELECTRO

NICTRANSAXLEHYDRAULICSCHEMATIC

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FOURSPEEDELECTRO


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FOURSPEEDELECTRO


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FOURSPEEDELECTRO


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FOURSPEEDELECTRO


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FOURSPEEDELECTRO


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FOURSPEEDELECTRO


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FOURSPEEDELECTRO


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FOURSPEEDELECTRO


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FOURSPEE

DELECTRONICTRANSAXLE

HYDRAULICSCHEMATIC

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FOURSPEEDELECTRO


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4-SPEED ELECTRONIC TRANSAXLE

MANUAL TRANSAXLE FLUID FILL

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4-SPEED ELECTRONIC TRANSAXLE T IGHTENIN G REFERENCE

MANUAL TRANSAXLE TIGHTENING REFERENCE

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CONVERSION CHART

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a shop manual

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