manual de transmisiones chrysler aÑos 90 principalmente
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TRANSAXLE
CONTENTS
page page
41TE FOUR SPEED AUTOM ATIC TRANSAXLE . 8541TE FOUR SPEED TRANSAXLE HYDRAULIC
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 17 041TE ON-BOARD DIAGNOSTICS . . . . . . . . . . 14 5A-523, A-543, and A-568 MANUAL
TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 18 3THREE SPEED TORQUEFLITE AUTOMATIC
TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . .. 35THREE SPEED TRANSAXLE HYDRAULIC
SCHEM ATICS . . . . . . . . . . . . . . . . . . . . . . . . 162
A-523, A-543, and A-568 MANUAL TRANSAXLE
INDEX
page page
Bearing Adjustment Procedure . . . . . . . . . . . . .. 31Differential Bearing Preload Adjustment . . . . . . .. 33Gearshift Linkage Adjustment (Cable Operated) . . 2General Information . . . . . . . . . . . . . . . . . . . . . . . . 1
In-Car Transaxle Disassemble/Assemble . . . . . . . . 4Out of Car TransaxleDisassemble and Assemble . 6Subassembly-Recondition . . . . . . . . . . . . . . . . . . 15Transaxle Removal and Installation . . . . . . . . . . .. 5
GENERAL INFORMATIONSafety goggles should be worn at all times
when working on these transaxles. A l l m a n u a l
t r a n sa x le s u se SAE 5W-30 e n g in e o i l, m e et in g SG
an d/or SG -CC qua lifications, as the lubricant in orderto reduce wear.
This 5-speed manual transaxles combine gear reduc-
tion, rat io selection, and differential functions in one
unit . I t is housed in a die-cast aluminum case (Fig. 1).
All shift forks are cast iron.Do not interchange 1-2
or 5th shift fork padswith the 3-4 shift fork pads.
All sy n ch r on iz er s u se a winged strut d es ig n t h a t
prevents the struts from popping out of position.
If any synchronizer is to bedisassembled,markall parts so that they will be reassembled in the
same position.
CAUTION: 1-2 synchronizer assembly components
must NOT be interchanged with any other synchro-
nizer assembly. Do not interchange with previous
model years transaxles; they will NOT function cor-
rectly.
A-523 AND A-543 MANUAL TRANSAXLE
The A-523 ma nua l tr a nsa xle is used in a ll 4-cylinder
applications, except high output turbocharged engines.Th e A-543 m a n u a l t r a n sa x le is u sed on ly w it h V-6
engines.
To r ed u ce w e a r, t h e m a n u a l t r a n s a x le u s es S AE
5W-30 engine oil as the lubricant.
G ear rat ios for the A-523 a nd A-543 a re a s follows:
1st3.31, 2cd2.06, 3rd1.36, 4th0.97, 5t h0.71,
Reverse3.14. The final drive ratio is 3.77.
CAUTION: All gears and shafts must not be inter-
changed with previous model years; they will not
function correctly.
Fig. 1 External Transaxle Components
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s h i f t l e v e r t h r o u g h a l l g e a r r a n g e s . I f t h e g e a r s h i f t
lever moves smoothly, the cable(s) should NOT be re-
p la ced . I f t h e g e a r lever bin ds r e pla ce t h e ca ble t h a t
is causing the binding condition.
(1) Working over the left front fender, remove the
lock pin from the transaxle gearshift (selector shaft)
housing (Fig. 4).
(2) Reverse the lock pin (so long end is down) and
insert lock pin int o sam e threa ded hole. A hole in these le ct o r sh a f t w il l a l ig n w it h t h e lo ck p in , a l lo w in g
the lock pin to be screwed into the housing. This op-
eration locks the selector shaft in the 3-4 neutral po-
sition.
(3) Remove or install gearshift knob (Fig. 5 or 6).
(4) Remove or install boot (Fig. 7) or console.
(5) Remove or install selector and crossover cables
(Fig. 8 or 9).
Cable attachment clips must be installed fromthe side. Install cable fittings to shifter pins bypushing with thumb.
Fig. 4 Manual Transaxle Pinned in the Neutral
Position to Adjust Gearshift
Fig. 5 Remove Gearshift Knob
Fig. 6 Install Gearshift Knob
Fig. 7 Remove or Install Boot
Fig. 8 Remove Cables
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CAUTION: Be sure crossover bellcrank does NOT
move when tightening adjusting screw (Fig. 10).
CAUTION: Proper torque to the crossover cable ad-justing screw is very important (Fig. 10).
(6) Remove lock pin from gearshift housing a nd re-
install lock pin (so long end is up) in gear shift hous-
ing. Tighten lock pin to 8 Nm (70 in. lbs.).
(7) Check for shift into first and reverse.
(8) Ge a r sh if t m e ch a n ism a n d ca ble s a r e n o w f u n c-
tioning properly.
IN- CAR TRANSAXLE DISASSEM BLE/ASSEM BLEThe following items can be serviced without remov-
in g t h e t r a n sa x le f r o m t h e ve h icle:
Ge a r sh if t h o u sin g
Synchronizers
I n t e r m e d ia t e sh a f t sp e e d g e a r s
I n p u t sh a f t
Re ve r se id le r g e a r a n d sh a f t
Sh if t f o r k s a n d p a d s
Sh if t r a i ls
Roller detents
Speedometer pinion
All external covers
Observe follow ing procedure:
(1) Disconnect negative cable from battery.
(2) Remove both shift cables from shift cover levers.
(3) Re m ove le ft f r on t w h e e l a n d t ir e a ssem bly a n d
left splash shield.(4) P l a c e d r a i n p a n u n d er t r a n s a x le a n d r em ov e
tra nsaxle rear end cover.
(5) P ush out th e fifth fork roll pin a nd slide the fifth
fork an d s ynchronizer sleeve off the ra il/hub.
(6) Re m o ve t h e f i f t h h u b sn a p r in g , h u b a sse m bly
and speed gear.
(7) Remove fifth gear nut and fifth input gear.
(8) Re m ove t h e bea r in g r e t a in er p la t e , in t er lock
p la t e a n d sh u t t les.
CAUTION: Before removing the gearshift housing
assembly, reverse the lock pin (so the long end is
down) and insert lock pin into the same threaded
hole. This procedure will save time when the gear
shift housing assembly is reinstalled.
(9) Remove selector sha ft housing bolts (note the tw o
pilot bolts) and remove housing.
(10) Remove roller detents a nd springs, noting t hat
the rollers align with the shift rails.
(11) Push out the 1-2 and 3-4 lug roll pins, remove
the reverse pivot lever and fifth rail C-Clip. If a roll
pin or C-Clip falls, be sure to remove it from the
bottom of the case.
(12) P ull out t he fifth shift ra il and r emove the fifthshift lug and interlock pin.If the pin falls, be sureto
remove it from the bottom of the case.
(13) R e m ov e t h e i n t er m ed ia t e s h a f t b a l l b ea r i n g
snap ring and the bearing support plate.
(14) Remove reverse shift ra il a nd lug assembly.
(15) Remove the reverse idler sha ft a nd gear assem-
bly.
(16) Rotate the 1-2 shift lug and rail , and 3-4 shift
lug towa rds t he front of the vehicle.
(17) F ir m ly g r a sp bot h t h e in p u t a n d in t er m e d ia t e
shaft assemblies and pull them out of the tra nsmission
with the 1-2 and 3-4 shift ra ils, lugs and forks.The differential assembly can only be serviced
by removing the complete transaxle from the
vehicle because bearing preload must be reset.
The component s listed in the first pa ra gra ph can now
be se r vice d . Re f e r t o t h e a p p r o p r ia t e subassembly
recondition section.
To reassemble t he t ran saxle in the vehicle, reverse
the a bove procedure using t he proper sea lant s. Fill th e
tra nsaxle w ith SAE 5W-30 engine oil to t he bottom of
the fill hole in the end cover.
Fig. 9 Install Cables
Fig. 10 Adjusting Crossover Cable
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TRANSAXLE REMOVAL AND INSTALLATIONTransaxle removal does not require engine re-
moval.After insta lling tra nsa xle, f ill tran saxle to bott om of
fill plug hole wit h SAE 5W-30 engine oil before lower-
ing vehicle to floor.
(1) Disconnect or connect negative battery cable.
(2) Install a lifting eye on batt ery ground strap bolton left side of engine. Then install the engine supportfixture as shown in Figure 1.
(3) Disconnect or connect gearshift cables at tran-
saxle. Disconnect speedometer. Disconnect or connect
gearshift cables bracket at transaxle.
(4) R em ov e or i n st a l l b ot h f r on t w h e el a n d t i r e
assemblies.
(5) Remove or install left front splash shield.(6) Remove or install engine left mount from tran-
saxle.
CAUTION:Left engine mounting bolts used in posi-tion number 1 and number 3 are the same length. Thebolt in the number 2 position is longer. If bolt number2 is used in position number 3 it can damage the
selector shaft housing when the bolt is seated (Fig.2).
(7) Re m ove or in st a l l a n t i-r ot a t ion a l l in k (or a n t i-
hop damper) from crossmember bracket. Do not re-
move bracket from transaxle.(8) R e fe r t o G r o up 2 Suspension, t o r em ov e or
in st a l l bot h d r ive sh a f t s .
When removing or installing the transaxle, itmay be helpful to use locating pins in placeof the
top transaxle to engine bolts (Fig. 3).
Ma k e t h e lo ca t in g p in s f r o m t w o st o ck ( t r a n sa x le
case to engine block) bolts as follows: Using a hacksaw,
remove bolt heads, cut slot in end of bolts for a screw
driver, and remove burrs with a grinding wheel.
I n st a l l t h e lo ca t in g p in s in t o t h e e n g in e blo ck a n d
proceed with transaxle installat ion. After transaxle is
in place, insta ll bolts an d r emove locating pins before
removing t ra nsmission jack.
Fig. 1 Engine Support Fixture
Fig. 2 Left Engine Mount Bolt Location
Fig. 3 Remove or Install Bolts
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OUT OF CAR TRANSAXLE DISASSEMBLE ANDASSEMBLE
DIFFERENTIAL
Fig. 1 Remove or Install 2 Extension Outer Bolts
Fig. 2 Remove or Install 3 Differential Bearing
Retainer Outer Bolts
Fig. 3 Remove or Install Differential Cover Bolts
Fig. 4 Remove Differential Cover
Fig. 5 Differential Cover Removed
Fig. 6 Remove or Install 2 Extension Bolts
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GEAR SET
CAUTION: Tool 6252 must be used to remove or in-
stall this nut. Always install a NEW nut and tighten
to 258 Nm (190 ft. lbs.).
Fig. 7 Remove or Install Extension
Fig. 8 Remove or Install 3 Differential BearingRetainer Bolts
Fig. 9 Remove or Install Differential BearingRetainer
Fig. 10 Differential Assembly Removed
Fig. 1 Rear End Cover Bolts
Fig. 2 Rear End Cover Removed
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Fig. 3 Remove 5th Fork Roll Pin
Fig. 4 Install 5th Fork Roll Pin
Fig. 5 5th Fork and Sleeve
Fig. 6 Snap Ring
Fig. 7 Remove 5th Synchronizer Hub
Fig. 8 Install 5th Synchronizer Hub
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Fig. 9 Remove or Install 5th Gear Nut
Fig. 10 Bearing Retainer Plate Bolts
Fig. 11 Bearing Retainer Plate
Fig. 12 Interlock Shuttles
Fig. 13 Interlock Plate
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CAUTION: Before removing the gearshift housing,
reverse the lock pin (so the long end is down) andinsert lock pin into the same threaded hole. Thisprocedure will save time when the gearshift hous-ing assembly is reinstalled.
Fig. 14 A-523/A-543/A-568 Shift Forks and Shift Rail Components
Fig. 15 Gearshift Housing Bolts
Fig. 16 Gearshift Housing Removed
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To install gearshift housing, be sure to reversethe lock pin in the housing to lock the selectorshaft in the 3-4 neutral position.
CAUTION: Install roller detents so roller and slots are
parallel with shift rails.
Remove or install 3-4 lug roll pin, 3-4 fork roll pin,
an d reverse lug roll pin using the above procedure.
CAUTION: If any roll pin falls out, retrieve roll pin from
bottom of case.
Fig. 19 Install 1-2 Shift Lug Roll Pin
Fig. 20 Remove 1-2 Shift Fork Roll Pin
Fig. 21 Reverse Pivot Lever
Fig. 17 Remove Roller Detents
Fig. 18 Remove 1-2 shift Lug Roll Pin
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Fig. 22 5th Shift Rail C-Clip
Fig. 23 5th Shift Rail and Shift Lug
Fig. 24 5th Shift Lug with Interlock Pin
Fig. 25 5th Shift Lug Properly Installed
Fig. 26 Reverse Shift Rail and Shift Lug
Fig. 27 3-4 Shift Rail and Shift Lug
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CAUTION: Pry only at slot as shown (Fig. 30).
Fig. 28 1-2 Shift Rail and Shift Lug
Fig. 29 Remove or Install Large Snap Ring
Fig. 30 Pry Bearing Retainer Plate to Remove
Fig. 31 Bearing Support Plate
Fig. 32 Remove or Install Reverse Idler Gear
Fig. 33 Reverse Idler Gear Assembly
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CLUTCH RELEASE BEARING INPUT SHAFT OIL SEAL
Fig. 34 Remove or Install Gear Set
Fig. 35 Gear Set
Fig. 1 Remove Retaining E-Clip
Fig. 2 Remove or Install Clutch Release Shaft
Fig. 3 Clutch Release Shaft Components
Fig. 4 Remove or Install Input Shaft Seal Retainer
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REVERSE SHIFT LEVER
SUBASSEMBLY-RECONDITION
TRANSAXLE CASE
Fig. 6 Install New Input Shaft Seal
Fig. 7 Remove or Install Reverse Shift Lever E-Clip
Fig. 8 Reverse Shift Lever Components
Fig. 1 Remove Input Shaft Front Bearing Cup
Fig. 2 Install Input Shaft Front Bearing Cup
Fig. 5 Input Shaft Seal Retainer
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Use Tool C-4660-2A Screw. The screw has a larger
hole in the lower end to fit over the larger oil feeder
nipple (Fig. 5).
INTERMEDIATE SHAFT ASSEMBLY
Intermediate shaft ball bearing seal color:A-525/A-523/A-543 B la ck, A-568 B lu e.
Fig. 3 Remove or Install Bearing Retaining Strap
Fig. 4 Remove Intermediate Shaft Front Bearing
Fig. 5 Oil Feeder
Fig. 6 Install Intermediate Shaft Front Bearing
Fig. 1 Intermediate Shaft Bearing Snap Ring
Fig. 2 Remove Intermediate Shaft Rear Bearing
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When assembling intermediate shaft, makesure all speed gears turn freely.
1-2 SYNCHRONIZER (DUAL-CONE)
Fig. 6 Install 3-4 Synchronizer Hub and 3rd SpeedGear
Fig. 1 2nd Speed Gear
Fig. 2 1-2 Synchronizer Hub Snap Ring
Fig. 3 Install Intermediate Shaft Rear Bearing
Fig. 4 3-4 Synchronizer Hub Snap Ring
Fig. 5 Remove 3-4 Synchronizer Hub and 3rd SpeedGear
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Fig. 3 1st Speed Gear and 1-2 Synchronizer
Assembly
Fig. 4 Split Thrust Washer
Fig. 5 Intermediate Shaft Assembly
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SYNCHRONIZERS
Fig. 1 1-2 and 3-4 Synchronizer Sleeves and Hubs
Fig. 2 5th Speed Synchronizer
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CAUTION: 1-2 synchronizer assembly componentsmust NOT be interchanged with any other synchro-
nizer assembly, or with previous model years tran-saxles; they will NOT function correctly.
Fig. 3 Synchronizer Identification
Fig. 4 Synchronizers
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GEARSHIFT HOUSING
Roll pin must be flush with top of lever.
Fig. 1 Gearshift Housing Disassembled
Fig. 2 Remove or Install Roll Pin and Lever Fig. 3 Dust Boot
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For Disassembly: Drive roll pin out far enoughto clear the selector shaft, but not through. Thepin must remain in the selector so not to breakthe housing.
Fig. 10 Crossover Shaft
Fig. 11 Selector Shaft C-Clip
Fig. 12 Selector Shaft C-Clip
Fig. 13 Selector Assembly Roll Pin
Fig. 14 Remove or Install Selector Shaft
Fig. 15 Disassembled View
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DIFFERENTIAL BEARING RETAINER
Fig. 1 Remove Differential Bearing Retainer Seal
Fig. 2 Install Differential Bearing Retainer Seal
Fig. 3 Remove Differential Bearing Retainer Cup
Fig. 4 Differential Bearing Retainer
Fig. 5 Install Oil Baffle
Fig. 6 Insert (Select) Shim and Differential BearingRetainer Cup
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INPUT SHAFT
Sh im t h ick n e ss n e e d o n ly be d e t e r m in e d i f a n y o f
the following parts are replaced:
Transaxle case
I n p u t sh a f t se a l r e t a in e r
B e a r in g r e t a in e r p la t e
Rear end cover
I n p u t sh a f t
I n p u t sh a f t be a r in g s
Re f e r t o Bearing Adjustment Procedure in r e a r
of this section t o determine proper shim thickness for
correct bearing end play and proper turning torque.
Fig. 1 Remove Input Shaft Rear Bearing Cone
Fig. 2 Install Input Shaft Rear Bearing Cone
Fig. 3 Remove Input Shaft Front Bearing Cone
Fig. 4 Install Input Shaft Front Bearing Cone
Fig. 5 Remove Input Shaft Rear Bearing Cup
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CAUTION: Bolt on bearing support plate before in-
stalling input shaft rear bearing cup.
A-523, A-543 DIFFERENTIALSh im t h ick n e ss n e e d o n ly be d e t e r m in e d i f a n y o f
the following parts are replaced:
Transaxle case
Differential bearing retainer
Extension housing
Differential case
Differential bearings
CAUTION: Differential covers are not interchange-
able from case to case.
Re f e r t o Bearing Adjustment Procedure in r e a r
of this section t o determine proper shim thickness for
cor r e ct bea r in g p r eloa d a n d p r op er bea r in g t u r n in g
torque.
Fig. 6 Install Input Shaft Rear Bearing Cup
Fig. 1 Remove Differential Bearing Cone
Fig. 2 Install Differential Bearing Cone
Fig. 3 Remove Differential Bearing Cone
Fig. 4 Install Differential Bearing Cone
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CAUTION: Always install new ring gear bolts. Bolts
must be properly torqued (See Tightening Refer-ence).
After assembling the differential side gears, pinion
gears and pinion gears with the pinion gear washers,bu t without t h e sid e g ea r t h r u st w a sh e r s. Rot a t e t h ea s s em b ly t w o f u ll r ev ol ut i on s b ot h cl ock w i se a n d
counterclockwise.
Se t u p d ia l in d ica t or a s sh o w n a n d r e cor d e n d p la y .
Ro t a t e sid e g e a r 90 d e g r e e s a n d r e co r d a n o t h e r e n d
play. Again, rotate side gear 90 degrees and record a
f in a l e n d p la y .U s i n g t h e s m a l les t e nd p la y r ecor d ed , s h im t h a t
side gear to within .001 to .013 inch. The other side
gear should be checked using the same procedure.
Fig. 5 Remove or Install Ring Gear Bolts and Ring
Gear
Fig. 6 Remove Pinion Shaft Roll Pin
Fig. 7 Remove or Install Pinion Shaft
Fig. 8 Remove or Install Pinion Gears, Side Gears,and Thrust Washers by Rotating Side Gears to
Opening in Case
Fig. 9 Differential Gears
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CAUTION: Always install new ring gear bolts. Boltsmust be properly torqued (See Tightening Refer-ence).
Fig. 4 Install Differential Bearing Cone
Fig. 5 Remove or Install Ring Gear Bolts
Fig. 6 Remove Ring Gear
Fig. 7 Remove 3 Roll Pins
Fig. 8 Install 3 Roll Pins
Fig. 9 Ring Gear and Side Gear Removed
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CAUTION: See Figure 14 to determine side gear
thrust washer thickness. Side gear end play must be
within.001 to .013 inch.
Four select thrust washes are available: .032, .037,
.042, and .047 inch.
Side gear thrust washers are available in 4
select thicknesses: .032, .037, .042, and .047 inch.
Me a su r e t h e d e p t h f r om t h e d if f er e n t ia l ca se t o t h e
machined surface in 3 places, as shown in Figure 13.
Then measure the height of raised step o n t h e r in g
gear. The difference, minus the proper side gear end
p la y ( .001 t o .013 in ch ) is t h e p r o p e r t h r u st w a sh e r
thickness.
For the other side gear: After a ssembling t he differ-
ential side gears, pinion gears, and pinion gears with
t h e p in io n g e a r w a sh e r s bu t without t h e sid e g e a r
t h r u st w a sh e r s. Ro t a t e t h e a sse m bly t w o f u l l r e vo lu -
tions both clockwise and counterclockwise.
S e t u p d i a l i n d ica t o r a s s h ow n i n F i g u re 1 4 a n d
r ecor d e nd p la y. R ot a t e s id e g ea r 90 d eg r ee s a n d
r e co r d a n o t h e r e n d p la y . Ag a in , r o t a t e sid e g e a r 90
degrees a nd record a f inal end play.
Using t he smallest end play recorded, shim tha t sidegear to w ithin .001 to .013 inch.
CAUTION: After reassembly of the differential assem-
bly, insert the inner joint housing spline from a drive
shaft into the side gear. By hand, turn the side gear
with the joint housing spline. If the side gear will NOT
turn, or it feels very tight, remove the ring gear and
install a thinner side gear thrust washer.
Side gear thrust washers are available in four
select thicknesses: .032, .037, .042, and .047 inch.
BEARING ADJUSTMENT PROCEDURE
GENERAL RULES ON SERVICING BEARINGS
(1) Ta ke extreme car e when removing and inst a lling
be a r in g cu p s a n d co n e s. U se o n ly a n a r bo r p r e ss f o r
in st a l la t io n , a s a h a m m e r m a y n o t p r o p e r ly a l ig n t h e
b ea r i n g cu p or con e. B u r r s or n i ck s on t h e b ea r -
Fig. 12 Differential Gears
Fig. 13 Determine Proper Side Gear Thrust WasherThickness
Fig. 10 Remove or Install Pinion Shafts
Fig. 11 Remove or Install 4 Pinion Gears and 2 SideGears
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i ng s ea t w i ll g iv e a f a ls e e n d pl a y r ea d in g w h i le
gauging for proper shims. Improperly seated bearing
cups a nd cones a re subject to low mileage failure.(2) B earin g cups an d cones should be replaced if they
show signs of pitting or heat distress. If distress is seen
on either the cup or bearing rollers, both cup and cone
must be replaced.
(3) Bearing preload and drag torque specifications
must be maintained t o a v oi d p re ma t u r e b ea r i n gfailures. Used (original) bearing may lose up to 50%of
t h e o r ig in a l d r a g t o r q u e a f t e r br e a k in . All bearingadjustments must be made with no other compo-nent interference or gear intermesh.
(4) Replace bearings as a pair . For example, if one
differential bearing is defective, replace both differen-
t ia l be a r in g s. I f o n e in p u t sh a f t be a r in g is d e f e ct ive ,replace both input shaft bearings.
(5) B earing cones must not be reused if removed.(6) Tu r n in g t o r q u e r e a d in gs sh ou ld be obt a in e d
w h ile sm oot h ly r ot a t in g in e it h e r d ir ect ion (br ea k -
a w a y r ea d i n g i s n ot i n di ca t i v e o f t h e t r u e t u r n i ng
torque).
(7) Replace oil baffle, if da ma ged.
INPUT SHAFT BEARING END PLAY ADJUST-
MENT
(1) U sing Tool C-4656 w ith Ha ndle C-4171, press
input shaft front bearing cup slightly forward in case.
Then, using Tool C-4655 w ith Ha ndle C-4171, pressbe a r in g cu p ba ck in t o ca se f r o m t h e f r o n t . Pr o p e r ly
posit ion bearing cup, before checking input sha ft end
p la y (s ee i n pu t s h a f t f r on t b ea r i n g cu p r ep la c e i n
Subassembly Recondition section). This step isnot necessary if Tool C-4655 was previously usedto install input shaft front bearing cup in thecase. Also no input shaft shim has been installedsince pressing cup into case.
(2) Select a gauging shim which will give 0.025 to
0.254mm (.001 to .010 inch) end pla y. SUGGESTION:Measure original shim from input shaft
seal retainer and select a shim 0.254mm (.010
inch) thinner than original for the gauging shim.
(3) I n st a l l g a u g in g sh im o n be a r in g cup a n d in st a l l
input shaft seal retainer.
CAUTION: The input shaft seal retainer is used to
draw the input shaft front bearing cup the proper
distance into the case bore during this step. Alter-nately tighten input shaft seal retainer bolts until
input shaft seal retainer is bottomed against case.
Tighten bolts to 28 Nm (21 ft. lbs.).
(4) Oil input shaft bearings with SAE 5W-30 engine
oi l a n d i n st a l l i n pu t s h a f t i n c a s e. I n s t a l l b e a r in g
r et a i ner pl a t e w i t h i np ut s h a ft r ea r b ea r in g cu p
pressed in and bearing support plate installed. Tighten
a ll bo lt s a n d n u t s t o 28 Nm (21 ft. lbs.).
(5) Posit ion dial indicator to check input shaft end
p la y . Ap ply m od e ra t e lo a d , by h a n d , t o in p u t sh a f t
splines (Fig. 1). P ush towa rd rear while rotating input
sh a f t ba ck a n d f o r t h a n u m be r o f t im e s t o se t t le o u t
bea r in g s. Z e ro d ia l in d ica t or. P u ll in p ut sh a f t t o w a r d
t h e f r o n t w h ile r o t a t in g in p u t sh a f t ba ck a n d f o r t h a
num ber of times to settle out bear ings. Record end play.
(6) The shim required for proper bea ring end pla y is
the t otal of the ga uging shim t hickness, plus end play,
minus (consta nt) end play of 0.051mm (.002 inch).Combine shims, if necessary, to obtain a shim within
.04mm (.0016 inch) of the required shim (see Sh im
Cha rt for proper sh im).
(7) Rem ove in p ut sh a f t se a l r e t a in e r a n d g a u g in g
shim. I nst a ll shim(s) selected in step (6). Then reinst a ll
i n pu t s h a f t s ea l r et a i n er w i t h a 1/16 i n ch b ea d of
MOPAR Ga sk e t Ma k e r , L o ct i t e , o r e q u iva le n t f o r a
g a sk e t . Re co r d e n d p la y . O bse r ve t h e CAUTION in
step (3). Tighten input shaft seal retainer bolts to 28
Nm (21 ft. lbs.).
Fig. 14 Checking Side Gear End Play
Fig. 1 Checking Input Shaft Bearing End Play to De-termine Shim Thickness
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(8) Verify tha t a preload condition does not exist .
Use Special Tool L-4508 a nd an inch-pound torque
w r e n ch t o ch e ck in p u t sh a f t t u r n in g t o r q u e (F ig . 2) .
The turning torque should be less than 5 in. lbs.
CAUTION: Step (1) MUST be repeated every time a
thinner shim is installed. This will assure that the
input shaft bearing cup is pressed the proper dis-tance into the case. If the turning torque is too high,
install a .04mm (.0016 inch) thinner shim.
(9) Recheck input sha ft t urning torque. Repeat step
(8) until the proper bearing turning torque is obtained.
Observe CAUTION in step (8).
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT(1) R e mov e b ea r i n g cu p a n d e xi st i n g s h im f r om
differential bearing reta iner. (See Differential B earing
Retainer in Subassembly Reconditionsecti on).
(2) S e le ct a g a u g in g sh im w h ich w ill g ive 0.025 t o
0.254mm (.001 to .010 inch) end pla y. SUGGESTION:
Measure original shim from differential bearing
retainer and select a shim 0.381mm (.015 inch-
)thinner than original for the gauging shim.I n -
stall gauging shim in differential bearing retainer and
press in bearing cup. Installation of oil baffle is not
necessary when checking differential assembly
end play.
(3) Oil differential bearings with SAE 5W-30 engineoil and install differential assembly in transaxle case.
Check extension housing O-ring for damage (replace if
necessa ry). Add a 1/16 inch bead of MOPAR Ga sk e t
Maker, Loctite 518, or equiva lent to extension flange.
Install extension housing and differential bearing re-
ta iner. Torque b olts (see Tight ening Reference).
(4) P osit ion tra nsa xle with bell housing facing down
on w orkbench with C-clam ps. P osit ion dia l indicator.
(5) Apply a medium load to differentia l w ith Tool
C-4995 and a T-Ha ndle, in the downwa rd direction.
Roll differential assembly back and forth a number of
times. This will settle the bearings. Zero dial indicator.
To obta in end play readings, a pply a medium load in
the upward direction while rolling differential assem-
bly back and forth (Fig. 3). Record end play.
(6) The shim required for proper bearing preload is
total of gauging shim thickness, plus end play,
Fig. 2 Checking Input Shaft Bearing Turning Torque
INPUT SHAFT SHIM CHART
Fig. 3 Checking Differential Bearing End Play to De-termine Shim Thickness
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plus (constant) preload of 0.254mm (.010 in.).
Combine shims, if necessary, to obtain a shim within
.05m m (.002 in ch ) o f t h e r e q u ir e d sh im (se e S h im
Cha rt for proper sh ims).
(7) Re m ove d iff er e n t ia l bea r in g r e t a in er . Re m ove
b ea r i n g cu p a n d g a u g in g s h im . P r o pe rl y i n st a l l oi l
baffle. Be sure oil baffle is not damaged. I n st a l l
shim(s) selected in step (6). Then press in the bearingcup into differential bearing r etainer.
(8) U sin g a 1/16 in ch bea d of MO PAR Ga sk e t
Ma k e r, L oct it e 518, o r e q u iva le n t f or g a sk e t , in st a l l
d i ff er e n t ia l bea r in g r e t a in er . Tor q u e a l l bolt s (Se e
Tightening Reference).
(9) U sing Special Tool C-4995 a nd an inch-pound
torque w rench, check t urning t orque of th e differential
assembly in clockwise and counterclockwise directions
(Fig. 4). The turning torque should be 9 to 14 in.
lbs. for new bearings or a minimum of 6 in. lbs.
for used bearings. If the turning torque is too
high, install a .05mm (.002 inch) thinner shim. Ifthe turning torque is too low, install a .05mm
(.002 inch) thicker shim.
(10) Recheck turning torque. Repeat Step (9) until
the proper turning torque is obtained.
Fig. 4 Checking Differential Bearing Turning Torque
DIFFERENTIAL BEARING SHIM CHART
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THREE SPEED TORQUEFLITE AUTOMATIC TRANSAXLE
INDEX
page page
Accumulator-Recondition . . . . . . . . . . . . . . . . . . . 67
Aluminum Thread Repair . . . . . . . . . . . . . . . . . . . 48Assembly Subassembly Installation . . . . . . . . . . . 57Band Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 47Bearing Adjustment Procedures . . . . . . . . . . . . . . 81Clutch and Servo Air Pressure Tests . . . . . . . . . . 43Differential Repair . . . . . . . . . . . . . . . . . . . . . . . . 76Disassembly Subassembly Removal . . . . . . . . . . 50Fluid and Filter Change . . . . . . . . . . . . . . . . . . . . 40Fluid Drain and Refill . . . . . . . . . . . . . . . . . . . . . 40Fluid Leakage-Transaxle Torque Converter
Housing Area . . . . . . . . . . . . . . . . . . . . . . . . . . 44Fluid Level and Condition . . . . . . . . . . . . . . . . . . 40Front Clutch-Recondition . . . . . . . . . . . . . . . . . . . 62Front Planetary & Annulus Gear-Recondition . . .. 65Gearshift Linkage Adjustment . . . . . . . . . . . . .. . 46
General Information . . . . . . . . . . . . . . . . . . . . . . . 35Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Hydraulic Control Pressure Adjustments . . . . .. . 47Hydraulic Pressure Tests . . . . . . . . . . . . . . . . . . . 42Kickdown Servo (Controlled Load)-Recondition . . 67
Low/Reverse Servo-Recondition . . . . . . . . . . . . . . 66
Oil Cooler Flow Check . . . . . . . . . . . . . . . . . . . . 48Oil Coolers and Tubes Reverse Flushing . . . . . . 48Oil Pump-Recondition . . . . . . . . . . . . . . . . . . . . . 62Output Shaft Repair . . . . . . . . . . . . . . . . . . . . . . 71Park/Neutral Position and Back-Up Lamp Switch . 47Parking Pawl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Pump Oil Seal-Replacement . . . . . . . . . . . . . . . . 61Rear Clutch-Recondition . . . . . . . . . . . . . . . . . . . 64Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Selection of Lubricant . . . . . . . . . . . . . . . . . . . . . 40Special Additives . . . . . . . . . . . . . . . . . . . . . . . . . 40Three Speed Torqueflite General Diagnosis . . . . . 36Throttle Pressure Linkage Adjustment . . . . . . . .. 46Torque Converter Clutch Solenoid Wiring
Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Transaxle and Torque Converter Removal . . . .. . 48Transfer Shaft Repair . . . . . . . . . . . . . . . . . . . . . 68Valve Body-Recondition . . . . . . . . . . . . . . . . . . . . 57Vehicle Speed Sensor Pinion Gear . . . . . . . . . .. 47
GENERAL INFORMATIONSafety goggles should be worn at all times
when working on these transaxles.Th is t r a n sa x le com bin es a f u lly a u t o m a t ic 3 sp e ed
transmission, f inal drive gearing, and differential into
a f r on t w h e el d r iv e s y s t em . Th e u n i t i s a Metricdesign. The identification markings and usage of the
tra nsa xle ar e cha rted in D iagnosis and Tests.
Transaxle operation requirements are differ-ent for each vehicle and engine combination andsome internal parts will be different to providefor this. Therefore,when replacingparts, refer tothe seven digit part number stamped on rear ofthe transaxle oil pan flange.
Wit h in t h is t r a n sa x le , t h e r e a r e 3 p r im a r y a r e a s:
(1) Main center line plus valve body.
(2) Tra nsfer sha ft center line (includes governor an d
parking sprag).
(3) D if fe r en t ia l ce n t er l in e . Ce n t e r d ist a n ces be-
tw een the main rota ting parts in these 3 area s are held
p r ecise. Th is m a in t a in s a low n oise le vel t h r o ug hsmooth accurate mesh of the gears.
The torque converter, transaxle area, and differential
a r e h ou sed in a n in t eg r a l a lu m in u m d ie ca st in g . Th e
differential oil sump is common with the transaxlesump. Separa te filling of the differential is NOT nec-essary.
Th e t or q u e con ve rt e r is a t t a ch ed t o t h e cr a n k sh a f t
t h r o ug h a f lex ible d r ivin g p la t e . C oolin g o f t h e con -
ver t e r is a ccom p lish ed by cir cu la t in g t h e t r a n sa x le
fluid through an oil-to-water type cooler located in the
r a d ia t or s id e t a n k a n d /or a n oi l-t o a i r h ea t ex -
ch a n g e r . Th e t o r q u e con ve rt e r a sse m bly is a se a led
u n it t h a t ca n n o t be d isa sse m ble d .
Th e t r a n sa x le f luid is f il t e re d by a n in t er n a l f i lt e r
a t t a ch e d t o t h e lo w e r sid e o f t h e va lve bo d y a sse m -
bly.
E n g in e t or q u e i s t r a n s m i t t ed t o t h e t or q u e c on -
verter then, through the input shaft to multiple-disc
clutches in the tra nsa xle. The power flow depends ont h e a p pl ica t i on of t h e cl ut ch es a n d b a n d s . R ef er t o
Elements in Use Chart in Diagnosis and Tests sec-
t i on . Th e t r a n s a x le con s is t s of t w o m u lt i pl e-d i sc
clu t ch e s, a n over r u n n in g clut ch , t w o se r vos, a h y -
d r a u li c a ccu m u la t o r , t w o b a n d s , a n d t w o p la n e t a r y
gear sets. They provide three forward ratios and a re-
ve r se r a t io . T h e co m m o n su n g e a r o f t h e p la n e t a r y
gear sets is connected to the front clutch by a driving
sh e ll . T h e d r ive sh e ll is sp lin e d t o t h e su n g e a r a n d
t o t h e f r on t cl ut ch r et a i n er . Th e h y d r a u li c s y s t em
con s is t s of a n oi l pu m p, a n d a s in gl e v a lv e b od y
which contains all of the valves except the governor
valves. The transaxle sump and differential sump are
b ot h v en t ed t h r ou g h t h e dipstick. Ou t p u t t o r q u e
from the main center line is delivered through heli-
c a l g e a r s t o t h e transfer shaft. Th i s g e a r s et i s a
f a ct or of t h e f in a l d r ive (a x le ) r a t io. Th e sh a f t a lso
ca r r ie s t h e g o ve r n o r a n d p a r k in g sp r a g . An in t e g r a l
h e lica l g ea r on t h e t r a n sf e r sh a f t d r ive s t h e d iff er e n -
t ia l r in g g e a r . T h e f in a l d r ive g e a r in g is co m p le t e d
with one of th ree gear sets producing overall t op gear
ratios of 2.78, 3.02, or 3.22 depending on model and
application.
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DIAGNOSIS GUIDEABNORMAL NOISE
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DIAGNOSIS GUIDEVEHICLE WILL NOT MOVE
DIAGNOSIS GUIDEFLUID LEAKS
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DIAGNOSTICCHART
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FLUID LEVEL AND CONDITIONThe transmission and differential sump have a
common oil sump with a communicating opening
between the two.
B efore removing t he dipstick, w ipe all dirt off of the
protective disc and t he dipstick ha ndle.
The torqu e converter will fill in both the P Pa r k or N
Neutral positions. Place the selector lever in PP a r k t ocheck fluid level.
I n sp ect f luid level on d ipst ick e ver y six m on t h s.
Allow the engine to idle for at least one minutewith vehicle on level ground. This will assurecomplete oil level stabilization between differen-tial and transmission. A properly filled tra nsa xlewill read near t headd ma rk when fluid temperature is21 degrees Celsius (70 degrees Fahrenheit). When the
t r a n s a x le r ea c h es op er a t i n g t e mp er a t u r e t h e f lu id
should be in the HOT region.L ow f luid leve l ca n ca u se a va r ie t y o f con d it ion s
because it a llows t he pump to ta ke in a ir along with t he
fluid. As in a ny hydr aulic system, air bubbles make th efluid spongy, th erefore, pressures w ill be low a nd build
up slowly.
I m p r op er f i ll in g ca n a lso r a ise t h e f luid leve l t o o
high. When the t ran saxle ha s too much fluid, the gears
ch u r n u p f o a m a n d ca u se t h e sa m e co n d it io n s w h ich
occur with a low fluid level.
In either case, the a ir bubbles can ca use overheating,
f lu id o x id a t io n , a n d va r n ish in g , w h ich ca n in t e r f e r e
with normal va lve, clutch, a nd servo operat ion. Foam-
ing can a lso result in fluid escaping from the tr ansa xle
vent (dipstick ha ndle) where it ma y be mista ken for a
leak.
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
a n d i s con t a m i n a t e d w i t h m et a l or f r ict i on m a t e r ia l
part icles, a complete t ra nsa xle overhaul is needed. B e
su r e t o e x a m in e t h e f lu id o n t h e d ip st ick clo se ly . I f
t h er e i s a n y d ou b t a b ou t i t s con d it i on , d r a i n o u t a
sample for a double check.
After the fluid has been checked, seat the dipstick
f u lly t o sea l o u t w a t e r a n d d ir t .
SELECTION OF LUBRICANTI t is im p or t a n t t h a t t h e p r op er lu br ica n t be u sed in
these transmissions. MOPAR ATF PLUS (AutomaticTra nsm ission F luid-Type 7176) should be used t o a id in
assuring optimum transmission performance. Fluids of
the type labeled DE XRON II Automat ic Tran smission
Fluid should be used only if the recommended fluid is
n o t a v a i l a b l e . I t i s i m p o r t a n t t h a t t h e t r a n s m i s s i o n
f luid be m a in t a in e d a t t h e p r e scr ibed level u sin g t h e
recommended fluids.
SPECIAL ADDITIVESChry sler C orporation does not recommend the a ddi-
t io n o f a n y f lu id s t o t h e t r a n sm issio n , o t h e r t h a n t h e
a u t om a t i c t r a n s m i ss ion f lu id l is t ed a b ov e. An e x-
ception to th is policy is th e use of special dyes t o aid in
detecting fluid leaks. The use of transmission sealers
sh ou ld be a void ed , s in ce t h e y m a y a d ve r sely a f f ect
seals.
FLUID AND FILTER CHANGEWhen the factory fill fluid is changed, only
fluids of the type labeled MOPAR ATF PLUS(Automatic Transmission fluid) Type7176 should
be used. A band adjustment and filter change
should be madeat the time of the oil change. The
magnet (on the inside of the oil pan) should also
be cleaned with a clean, dry cloth.
If the transaxle is disassembled for any reason,
the fluid and filter should be changed, and theband(s) adjusted.
FLUID DRAIN AND REFILL(1) Ra ise vehicle on a hoist (See Lubrication, G roup
0). P lace a dra in conta iner with a large opening, under
t r a n sa x le oi l p a n .(2) Loosen pan bolts and tap the pan at one corner to
break it loose allowing fluid to dra in, then remove the
oil pa n.
(3) I n st a l l a n e w f i l t er a n d g a sk et on bo t t om of t h e
valve body and t ighten retaining screws to 5 Nm (40
in. lbs.).
(4) C l ea n t h e o il p a n a n d m a g n et . R ei n st a l l p a n
using new MOPAR Adhesive sealant. Tighten oil panbolts to 19 Nm (165 in. lbs.).
(5) Pour four quarts of MOPAR ATF PLUS (Auto-m a t ic Tr a n sm ission F lu id) Ty p e 7176 t h r o ug h t h e
dipstick opening.
( 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 in u t e . T h e n , w it h p a r k in g a n d se r vice br a k e s a p -
plied, move selector lever momentarily to each posi-
tion, ending in the pa rk or neutra l posit ion.
(7) Add sufficient f luid to bring level to 1/8 inch
below the ADD mark.
R ech eck f lu id l ev el a f t er t r a n s a x le i s a t n or m a l
operat ing tempera tur e. The level should be in the H OT
region (Fig. 1).
To prevent dirt from entering tr ansa xle, m ake cer-
ta in tha t d ipstick is full seated into th e dipstick open-
ing.
TORQUE CONVERTER CLUTCH SOLENOID WIRINGCONNECTOR
I f w ir in g con n e ct o r is u n p lu g g ed , t h e t o r q u e con -
verter clutch will not operate (Fig. 2).
ROAD TESTPr io r t o p e r f o r m in g a r o a d t e st , be ce r t a in t h a t t h e
fluid level and condition, an d cont rol cable a djustment s
ha ve been checked a nd approved.
D u r in g t h e r oa d t e st , t h e t r a n sa x le sh o u ld be o pe r-
a t e d in e a ch p osit ion t o ch eck f or sl ip pin g a n d a n y
variat ion in shift ing.
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If vehicle operates properly at highway speeds, but
h a s p oor a c ce le ra t i on , t h e t or q u e con v er t er s t a t o r
overrunning clutch may be slipping. If through-gear
a cce le r a t io n is n o r m a l , bu t h ig h t h r o t t le o p e n in g isrequired to maintain highway speeds, the torque con-
ve r t e r st a t o r clu t ch m a y h a ve se iz e d . B o t h o f t h e se
stator defects require replacement of the torque con-
verter.
Observe closely for slipping or engine speed flare-
up. Slipping or flare-up in any gear usually indicates
clutch, band, or overrunning clutch problems. If the
con d it ion is f a r a d va n ce d , a n ove rh a u l w il l p r oba bly
be necessary to restore normal operation.
Th e clut ch o r ba n d t h a t is s l ipp in g ca n be d e t er -
mined by noting the transaxle operation in all selec-
t o r p osit ion s. Th e n com p a r in g w h ich in t er n a l u n it sare applied in those posit ions. The Elements in Use
Chart p r o vid e s a ba sis f o r r o a d t e st a n a ly sis .
The rear clutch is applied in both the D f i rst g ea r
a n d 1 fi r st g ea r p os it i on s . Al so t h e ov er r u n ni n g
clutch is applied in D f irst gear and the low/reverse
ba n d is a p p lie d in 1 f i r st g e a r p o sit io n . I f t h e t r a n -
saxle slips in D r a n g e f ir st g e a r , bu t d oe s n o t s l ip in
1 f irst gear, the overrunning clutch is slipping. Sim-
i la r ly , if t h e t r a ns a xle s lips in a n y t w o for w a rd
gears, the rear clutch is slipping.
U s in g t h e s a m e pr oced ur e, t h e r ea r cl ut ch a n d
front clutch are applied in D t h i r d g e a r . I f t h e t r a n -sa x le sl ip s in t h ir d g ea r , e it h e r t h e f r o n t clu t ch or
the rear clutch is slipping. By selecting another gear
which does not use one of those units, the unit which
is sl ip p in g ca n be d e t e r m in e d . I f t h e t r a n sa x le a lso
sl ip s in r e ve r se , t h e f r on t clu t ch is s l ip pin g . I f t h e
t r a n sa x le d o e s n o t s l ip in r e ve r se , t h e r e a r clu t ch is
slipping.
Th e p r oce ss of e lim in a t ion ca n be u sed t o d e t ect
any unit which slips and to confirm proper operation
of g ood u n it s . R oa d t e st a n a l y s is ca n u s ua l l y d i a g -
n o se sl ip p in g u n it s , bu t t h e a ct u a l ca u se o f t h e m a l-
f u n ct ion u su a lly ca n n o t be d e cid ed . P r a ct ica l ly a n y
condition can be caused by leaking hydraulic circuits
or st icking valves.
ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER
Fig. 1 Dipstick and Transaxle Vent
Fig. 2 Torque Converter Clutch Solenoid WiringConnector
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Unless the condition is obvious, like no drive in Dr a n g e f ir st g ea r on ly . Th e t r a n sa x le sh o u ld n e ve r be
d i sa s s em b le d u n t il h y d ra u l ic p re ss u r e t e st s h a v e
been performed.
HYDRAULIC PRESSURE TESTSP r e ssu r e t e st in g is a ver y im p or t a n t st e p in t h e d i-
a g n o st ic p r oced u r e. Th e se t e st s u su a lly r e ve a l t h e
cause of most transaxle problems.
B e f or e p er f or m in g p r essu r e t e st s , be cer t a in t h a t
f luid leve l a n d con d it ion , a n d con t r o l ca ble a d ju st -
ments have been checked and approved.
Fluid must be at operating temperature (150 to 200
degrees F.).
Install an engine tachometer, raise vehicle on hoist
w h i ch a l l ow s f r on t w h e el s t o t u r n , a n d p os it i on t a -
ch om e t er so i t ca n be r e a d .
Disconnect thrott le cable and shift cable from tran-
sa x le le ver s so t h e y ca n be con t r o lled f r om ou t sid e
the vehicle.
Attach 150 psi gauges to ports required for test be-ing conducted. A 300 psi gauge (C-3293) is required
for reverse pr e ssu r e t e st a t r e a r se rvo.Test port locations are shown in (Fig. 3).
TEST ONE (SELECTOR IN 1)
(1) At t a ch g a u g e s t o line a n d low-reverse ports(Fig. 3).
(2) Operate engine at 1000 rpm for test .
(3) Move se lect or lever on t r a n sa x le a l l t h e w a y
r e a r w a r d (1posit ion).(4) Read pressures on both gauges as thrott le lever
on transaxle is moved from full clockwise posit ion tofull counterclockwise position.
(5) L i n e p re ss u r e s h ou ld r ea d 52 t o 58 p si w i t h
thrott le lever clockwise and gradually increase, as le-
ver is moved counterclockwise, to 80 to 88 psi.
(6) L o w - r e ve r se p r e ssu r e sh o u ld r e a d t h e sa m e a s
line pressure within 3 psi.
(7) Th is t e st s p u m p ou t p u t , p r essu r e r e gu la t ion ,
and condition of rear clutch and rear servo hydraulic
circuits.
TEST TWO (SELECTOR IN 2)
(1) At t a ch on e g a u g e t o line pressure por t a n d
tee another gauge into lower cooler line fit t ing. Thisw il l a l lo w y o u t o r e a d lubrication pressure (Fig 3).(2) Operate engine at 1000 rpm for test .
Fig. 3 Transaxle (Left Side)
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(3) Move se le ct o r lever on t r a n sa x le on e detent
forward from full rearward posit ion. This is selector
2 position.
(4) Read pressures on both gauges as thrott le lever
on transaxle is moved from full clockwise posit ion to
full counterclockwise position.
(5) L i n e p re ss u re s h ou ld r ea d 52 t o 58 p si w i t h
thrott le lever clockwise and gradually increase, as le-ver is moved counterclockwise, to 80 to 88 psi.
(6) L u b r ica t i on p re ss u re s h ou ld b e 10 t o 25 p si
with lever clockwise and 10 to 35 psi with lever full
counterclockwise.
(7) Th is t e st s p u m p ou t p u t , p r essu r e r e gu la t ion ,
a n d co n d it io n o f r e a r clu t ch a n d lu br ica t io n h y d r a u -
lic circuits.
TEST THREE (SELECTOR IN D)
(1) At t a ch g a u g e s t o line a n d kickdown release
ports (Fig. 3).
(2) Operate engine at 1600 rpm for test .
(3) Move se le ct o r leve r on t r a n sa x le t w o detents
forward from full rearward posit ion. This is selector
D position.
(4) Read pressures on both gauges as thrott le lever
on transaxle is moved from full clockwise posit ion to
full counterclockwise position.
(5) L i n e p re ss u re s h ou ld r ea d 52 t o 58 p si w i t h
thrott le lever clockwise and gradually increase, as le-
ver is moved counterclockwise to 80 to 88 psi.
(6) Kickdown release is pressurized only in direct
d r iv e a n d s h ou ld b e s a m e a s l in e p r es s ur e w i t h in 3
psi, up to kickdown point .
(7) Th is t e st s p u m p ou t p u t , p r essu r e r e gu la t ion ,a n d con d it i on of r ea r cl ut ch , f r on t cl ut c h, a n d h y -
dra ulic circuits.
TEST FOUR (SELECTOR IN REVERSE)
(1) Attach 300 psi gauge to low-reverseport (Fig.
3).
(2) Operate engine at 1600 rpm for test .
(3) Move selector lever on t ra nsa xle four detents
forward from full rearward posit ion. This is selector
R position.
(4) L ow -r e ve r se p r essu r e sh ou ld r e a d 180 t o 220
p si w i t h t h r ot t l e l ev er cl ock w i se a n d g r a d u a l ly i n -crease, as lever is moved counterclockwise to 260 to
300 psi.
(5) Th is t e st s p u m p ou t p u t , p r essu r e r e gu la t ion ,
and condition of front clutch and rear servo hydraulic
circuits.
(6) Move selector lever on transaxle to D position
to check that low-reverse pressure drops to zero.
(7) Th is t e st s f or lea k a g e in t o r e a r ser vo, d u e t o
ca s e p or os i t y, w h i ch ca n ca u s e r ev er s e b a n d b u rn
out.
TEST RESULT INDICATIONS
(1) If proper line pressure, minimum t o ma ximum, is
found in a ny one test , the pump a nd pressure regulat or
are working properly.
(2) Low pressure in D, 1, and 2 but correct pressure
in R indicat es rear clutch circuit leaka ge.
(3) Low pressure in D and R but correct pressure in
1 indicat es front clutch circuit leakage.(4) Low pressure in R and 1 but correct pressure in
2 indicat es rear servo circuit leakage.
(5) L ow l ine p r essu r e in a l l p osi t ion s in d ica t e s a
defective pump, a clogged filter, or a stuck pressure
regulator valve.
GOVERNOR PRESSURE
Test only if t ran saxle shifts at wrong vehicle speeds
wh en thr ott le cable is correctly adjusted.
(1) Connect a 0-150 psi pressure gauge to governor
pressure take-off point , located at lower right side of
case, below differential cover (Fig. 3).
(2) O p er a t e t r a n s a x le i n t h i rd g ea r t o r ea d p res -sures. The governor pressure s hould respond sm oothly
t o ch a n g es in m p h a n d sh ou ld r e t u r n t o
0 to 3 psi w hen vehicle is st opped. H igh pressure at
sta ndstill (above 3 psi) will prevent the t ra nsaxle from
downshift ing.
THROTTLE PRESSURE
N o g a u g e p or t is p r ovid ed f or t h r o t t le p r e ssu r e.
Incorrect throttle pressure should only be suspected if
part throttle upshift speeds are either delayed or occur
t oo ea r l y, w i t h a cor r ect l y a d ju s t ed t h r ot t l e ca b l e.
En g in e r u n a w a y on e it h e r u p sh if t s o r d o w n sh ift s ca n
also be an indicator of incorrect (low) throttle pressure
sett ing, or misa djusted thrott le cable.
In no case should t hrott le pressure be adjusted unt il
the transaxle thrott le cable adjustment has been veri-
fied t o be correct.
CLUTCH AND SERVO AIR PRESSURE TESTSAno drive condition might exist even with correct
f luid p r essu r e, beca u se of in op er a t ive clu t ch es or
ba n d s. Th e in op er a t ive u n it s , c lu t ch es, ba n d s, a n d
s er v os ca n b e l oca t e d t h r ou g h a s er i es of t e st s b y
substituting air pressure for fluid pressure (Fig. 4).
Th e f r on t a n d r e a r clu t ch e s, k ick d ow n ser vo, a n d
low-reverse servo may be tested by applying air pres-
sure to th eir respective passa ges aft er
the va lve body a ssembly ha s been removed. To make
air pressure t ests, proceed as follows:
Compressed air supply must be free of all dirtor moisture. Use a pressure of 30 psi.
Re m o ve o i l p a n a n d va lve bo d y Se e Disassembly-Subassembly Removal.
FRONT CLUTCH
Apply air pressure to front clutchapply p a ssa g e a n dl is t en f or a d ul l thud w h ich i n di ca t e s t h a t f r on t
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clu t ch is op er a t in g . Ho ld a ir p r essu r e on f or a f ew
seconds and inspect system for excessive oil leaks.
REAR CLUTCH
Ap ply a ir p r essu r e t o r e a r clu t ch apply p a ssa g e
a n d l ist e n f o r a d u ll thud w h ich in d ica t e s t h a t r e a r
clu t ch is op er a t in g . Also in spe ct f or e xcessive oi l
le a k s. I f a d u ll thud cannot be heard in the clutches,
p la ce f in g e r t ip s o n clu t ch h o u sin g a n d a g a in a p p ly
a ir p r e ssu r e . Mo ve m e n t o f p ist o n ca n be f e l t a s t h e
clutch is applied.
KICKDOWN SERVO (FRONT)
D ir e ct a ir p r essu r e in t o k ickd ow n se r vo ON p a s-
sa g e . O p er a t ion of ser vo is in d ica t e d by a t ig h t e n in g
of front band. Spring tension on servo piston shouldr e le a se t h e ba n d .
LOW AND REVERSE SERVO (REAR)
D ir e ct a ir p r essu r e in t o L O W-REV ERSE SERV O
APPLY passage. Operation of servo is indicat ed by a
t ightening of rear band. Spring tension on servo pis-
t o n sh o u ld r e le a se t h e ba n d .
If clutches a nd servos opera te properly, no upshift
or erratic shift conditions indicate t ha t ma lfunctions
e xist in t h e va lve bod y .
FLUID LEAKAGE-TRANSAXLE TORQUECONVERTER HOUSING AREA
(1) Check for Source of Leakage.S i n ce f lu id l ea k a g e a t or a r ou n d t h e t or q u e c on -
v er t er a r e a m a y or i gi n a t e f r om a n e ng in e o il l ea k ,
t h e a r e a s h ou ld b e ex a m in ed cl os el y. F a c t or y f il l
f luid is dyed red and, therefore, can be dist inguished
from engine oil.
(2) Pr ior t o r e m ovin g t h e t r a n sa x le , p e r for m t h e
following checks:
When leakage is determined to originate from the
t r a n sa x le, ch eck f luid level p r ior t o r e m ova l of t h e
t r a n sa x le a n d t o r q u e con ver t e r .
H ig h oi l l e ve l c a n r es u lt i n oi l l e a k a g e o ut t h e
ve n t in t h e d ip st ick . I f t h e f lu id le ve l is h ig h , a d ju st
to proper level.
After performing this operation, inspect for leak-
a g e . I f a lea k p er sist s , p e rf or m t h e f ol low in g op er a -
t i on on t h e v eh i cl e t o d et e rm i n e i f i t i s t h e t or q u e
con ver t e r o r t r a n sa x le t h a t is le a k in g.
LEAKAGE TEST PROBE
(1) Remove torque converter housing dust shield.
(2) Clea n t h e in sid e of t o r q u e con ver t e r h ou sin g
(lo w e r a r e a ) a s d r y a s p o ssible . A so lve n t sp r a y f o l-
lowed by compressed air drying is preferable.
Fig. 4 Air Pressure Tests
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(3) Fa bricat e a nd fast en test probe (Fig. 5) securely
t o con v en i en t d u st s h ie ld b ol t h ol e. M a k e ce rt a i n
torque converter is cleared by test probe. Tool must
be cle a n a n d d r y .
(4) Ru n e n gin e a t a p p r ox im a t e ly 2,500 r p m w it h
t r a n sa x le in n e u t r a l , f or a bo u t 2 m in u t es. Tr a n sa x lem u st be a t o p e r a t in g t e m p e r a t u r e .
(5) Stop engine and carefully remove tool.
(6) If upper surface of test probe is dry, there is no
t o r q u e con ver t e r lea k . A p a t h of f lu id a cr oss p r obe
indicat es a torque converter leak. Oil leaking under
t h e p r o be is co m in g f r o m t h e t r a n sa x le p u m p a r e a .
(7) Re m o ve t r a n sa x le a n d t o r q ue con ver t e r a sse m -
bly from vehicle for further investigation.The fluid
sh ou ld be d r a in e d f r o m t h e t r a n sa x le . Re in st a l l o il
p a n (w i t h M OP AR Ad h e sive Se a la n t ) a t sp ecif ied
torque.
Possible sources of transaxle torque converter areaf luid lea k a g e a r e :
(1) Torque converter hub seal.
(a ) Se a l l ip cu t , ch e ck t o r q u e co n ve r t e r h u b f in -
ish.
(b) B ushing moved and /or w orn.
(c) O il r e t u r n h ole in p u m p h o u sin g p lu g g ed or
omitted.
(d) Seal worn out (high-mileage vehicles).
(2) F lu id l ea k a g e a t t h e ou t s id e d ia m e t er f r om
pump housing O-ring.
(3) F lu id lea k a g e a t t h e p u m p t o ca se bo lt 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 b ol t s i f
necessary.
(4) Fluid leakage due to case or pump housing po-
rosity.
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
Torque converter weld leaks at the outside diame-
ter (peripheral) weld.
Torque converter hub weld.
Torque converter impeller shell cracked adjacent
t o h u b.
At drive lug welds.
Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter.
AIR PRESSURE TEST OF TRANSAXLE
F a br ica t e e q u ip m en t n e ed e d f or t e st a s sh ow n in
figures 6 and 7.
The tra nsa xle should be prepared for pressure test a s
follows aft er removal of th e torque converter:
(1) Inst all a dipstick bore plug a nd plug oil cooler
line fitting (lower fitting).
(2) Wit h r ot a r y m ot ion , in st a l l con ver t e r h u b se a l
cup over input sha ft . I t must go through the converter
h u b se a l u n t i l t h e cu p bot t o m s a g a in st t h e p u m p g e a r
lugs. B efore use, inspect h ub sea l cup (Fig. 6) for n icks
or b u rr s t h a t cou ld d a m a g e s ea l . S e cu r e w i t h cu pr e t a in e r st r a p (F ig . 7) u sin g st a r t e r u p p e r h o le a n d
opposite bra cket hole.
(3) Atta ch a nd cla mp hose from n ozzle of Tool C-4080
to the upper cooler line fitting position in case.
CAUTION: Do not, under any circumstances, pressur-
ize a transaxle to more than 10 psi.
(4) P ressurize t he tr a nsa xle using Tool C-4080 until
t h e p re ss u re g a u g e r e a d s 8 p si . P o s it i on t r a n s a x le
Fig. 5 Leak Locating Test Probe Tool
Fig. 6 Torque Converter Hub Seal Cup
Fig. 7 Hub Seal Cup Retaining Strap
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so t h a t p u m p h ou sin g a n d ca se f r on t m a y be cover e d
w it h soa p y solu t ion or w a t e r . L e a k s a r e som e t im e s
caused by porosity in the case or pump housing.
I f a le a k so u r ce is lo ca t e d , t h a t p a r t a n d a l l a sso ci-
a t e d se a ls , O -r in g s, a n d g a sk et s sh ou ld be r e p la ce d
w i t h n e w p a r t s .
GEARSHIFT LINKAGE ADJUSTMENTN or m a l op er a t i on of t h e P a r k /N eu t r a l P o s it i onS w i t ch p rov id es a q u ick ch eck t o con f ir m p rop er
m a n u a l l in k a g e a d ju st m e n t .
M ov e t h e s el ect or l ev el s l ow l y u pw a r d u n t il i t
clicks into the P Park notch in the selector gate. I f
the starter will operate the P posit ion is correct .
After checking P posit ion, move selector slowly
toward N Neutral posit ion until lever drops in the
N stop. If the starter will also operate at this point
t h e g ea r s h i ft l in k a g e i s p rop er ly a d ju s t ed . I f t h e
starter fails to operate in either posit ion, linkage ad-
justment is required.
CAUTION: When it is necessary to disassemblelinkage cable from levers, which use plastic grom-mets as retainers, the grommets should be replacedwith new grommets. Use a prying tool to force rod
from grommet in lever, then cut away old grommet.Use pliers to snap new grommet into lever and rodinto grommet.
(1) S e t p a r k in g br a k e .
(2) Place gearshift lever in P (PARK) position.(3) Loosen clamp bolt on gearshift cable bracket.
(4) Colu m n sh ift : I n su r e t h a t p r eloa d a d ju st m en t
spring engages fork on transaxle bracket.
(5) P u ll t h e sh if t le ver by h a n d t o t h e f r o n t d e t e n t
posit ion (P ARK) a nd t ighten lock. Tighten screw to
11 Nm (100 in. lbs.). Gearshift linkage should now
be properly adjusted.
(6) Check adjustment as follows:
(a ) D e t e n t p o sit io n f o r n e u t r a l a n d d r ive sh o u ld
be w it h in l im it s o f h a n d le ve r g a t e st o p s.
(b) Key start must occur only when shift lever is
in park or neutral posit ions.
THROTTLE PRESSURE LI NKAGE ADJUSTMENTThe thrott le pressure cable adjustment is very im-
p or t a n t t o p r op er t r a n sa x le op er a t io n . Th is a d ju st -
m e n t p osit ion s a va lve w h ich con t r o ls sh ift sp ee d ,
sh if t q u a l i t y , a n d p a r t t h r o t t le d o w n sh if t se n sit ivi t y .
If the sett ing is too long, early shifts and slippage be-
t w e e n s h i f t s m a y o c c u r . I f t h e s e t t i n g i s t o o s h o r t ,
s h if t s m a y b e d e la y e d a n d p a r t t h r ot t l e d ow n s h i ft s
m a y be ve r y se n sit ive .
CABLE ADJUSTMENT PROCEDURE (4-CYL.)
(1) P e r for m t r a n sa x le t h r o t t le p r essu r e ca ble a d -
ju s t m en t w h i le en g in e i s a t n or m a l op er a t i n g t e m -
perature.
(2) Loosen cable mounting bracket lock screw.
(3) Bracket should be posit ioned with both bracket
a l ig n m en t t a bs t o uch in g t h e t r a n sa x le ca st su r f a ce .
Tighten lock screw to 12 Nm (105 in. lbs.) see Fig-
ure 8.
(4) Release cross-lock on the cable a ssembly (pullcross-lock upward) see Figure 7.
(5) To insure proper adjustment, the cable must be
f r e e t o s l i d e a l l t h e w a y t o w a r d t h e e n g i n e , a g a i n s t
its stop, after the cross-lock is released.
(6) M ov e t r a n s a x le t h r ot t l e con t r ol l ev er f u ll y
clo ck w ise , a g a in st i t s in t e r n a l s t o p , a n d p r e ss cr o ss-
lock downward into locked position (Fig. 7).
(7) Th e a d ju st m en t i s com pl et e a n d t r a n s a xl e
t h r ot t le ca ble ba ck la sh w a s a u t o m a t ica l ly r e m oved .
(8) Test cable freedom of operation by moving the
tra nsaxle thrott le lever forwa rd (counterclockwise).
Then slowly release it to confirm it will return fullyrearward (clockwise).
(9) No lubrication is required for any component of
t h e t h r o t t le ca ble sy st e m .
ROD ADJUSTMENT PROCEDURE (6-CYL.)
(1) P e r for m t r a n sa x le t h r ot t le p r essu r e ca ble a d -
ju s t m en t w h i le e ng in e i s a t n or m a l op er a t i n g t e m -
perature.
(2) Loosen adjustment swivel lock screw.
(3) To in su r e p r op er a d ju st m e n t , sw ivel m u st be
free to slide along flat end of thrott le rod so that pre-
loa d sp r in g a ct ion is n o t r e st r ict ed . D isa sse m ble a n d
cle a n o r r e p a ir p a r t s t o a ssu r e f r e e a ct io n , i f n e ce s-s a r y .
(4) H old t r a n sa x le t h r o t t le le ver f ir m ly t o w a r d e n -
gine, against its internal stop and t ighten swivel lock
scr e w t o 11 Nm (100 in. lbs.)
(5) Th e a d ju st m en t is f in ish e d a n d l in k a g e ba ck
l a s h w a s a u t om a t i ca l ly r em ov ed b y t h e pr el oa d
spring.
(6) I f l ub ri ca t i on i s r eq u ir ed s ee L u br ica t i on ,
Group 0.
Fig. 8 Throttle Pressure CableTypical
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BAND ADJUSTMENT
KICKDOWN BAND (FRONT)
Th e k ick d ow n ba n d a d ju st in g scr e w is loca t e d o n
left side (top front) of the transaxle case.
(1) Loosen locknut and back off nut approximately
f ive t u r n s. Te st a d ju st in g scr e w f or f r ee t u r n in g in
t h e t r a n sa x le ca se .(2) U sing w rench, Tool C-3880-A wit h a da pter Tool
C-3705, t ighten band adjusting screw to 5 Nm (47 to
50 in. lbs.). I f adapter C-3705 is not used, t ighten ad-
justing screw to 8 Nm (72 in. lbs.) which is the true
torque.
(3) B a ck of f a d ju st in g scr ew t h e n u m ber of t u r n s
listed in Specifications. Hold adjusting screw in this
posit ion and t ighten locknut to 47 Nm (35 ft . lbs.)
LOW/REVERSE BAND-REAR
To adjust low-reverse band, proceed as follows:
(1) L oosen a n d ba ck of f lockn u t a p p r ox im a t e ly 5
t u r n s.(2) U sin g a n in ch -p ou n d t o r q u e w r e n ch , t ig h t en
a d ju st in g scr e w t o 5 Nm (41 in. lbs.) true torque.
(3) B a ck of f a d ju st in g scr ew t h e n u m ber of t u r n s
listed under Specifications in t h e r e a r o f t h e T r a n -sa x le Se ct ion in t h is se rvice m a n u a l .
(4) Tighten locknut to 14 Nm (10 ft. lbs.).
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
LINE PRESSURE
An incorrect thrott le pressure sett ing will cause in-
correct line pressure readings even though line pres-
s ur e a d ju st m en t i s cor r ect . Al w a y s i ns pect a n dcorrect thrott le pressure adjustment before adjusting
the line pressure.
Th e a p p r ox im a t e a d ju st m e n t f or l in e p r essu r e is
1-5/16 in ch e s, m e a su r ed f r om va lve bod y t o in n er
e d g e o f a d ju st in g n u t . Ho w e ve r , d u e t o m a n u f a ct u r -
in g t o ler a n ces, t h e a d ju st m e n t ca n be va r ie d t o ob-
tain specified line pressure.
T h e a d ju st in g scr e w m a y be t u r n e d w it h a n Alle n
w r en ch . O ne com pl et e t u rn of a d ju st i ng s cr ew
changes closed thrott le line pressure a pproximately
1-2/3 psi. Turning a djusting screw count erclockwise
increases pressure, an d clockwise decreases pressure.
THROTTLE PRESSURE
Th r ot t l e p re ss u re s ca n n ot b e t e st e d a c cu r a t e ly ;
t h er ef or e, t h e a d ju s t m en t s h ou ld b e m ea s u r ed i f a
malfunction is evident.
(1) I n se rt g a u g e p in of Tool C-3763 bet w e e n t h e
thrott le lever cam and kickdown valve.
(2) B y p us h in g i n on t ool , com pr es s k ick d ow n
v a lv e a g a i ns t i ts s pr in g s o t h r ot t l e v a l v e i s com -
pletely bottomed inside the valve body.
(3) While compressing spring, turn thrott le lever
st o p scre w w it h a d a p t er C-4553. Tu r n u n t i l h e a d of
screw touches thrott le lever tang, with thrott le lever
cam t ouching tool and t hrott le valve bottomed. B e sure
adjustment is made with spring fully compressed and
valve bottomed in the valve body.
VEHICLE SPEED SENSOR PINION GEARWhen the speed sensor is removed for any reason, a
NEW O-ring must be installed on its outside diameter.
REMOVAL AND INSTALLATION
(1) Remove speedometer cable (if so equ ipped).
(2) Remove ha rness connector from sensor. Ma ke
sure weatherseal stays on harness connector.
(3) Remove bolt securing t he dista nce sensor in the
extension housing.
(4) Carefully pull sensor and pinion gear assembly
out of extension housing.
(5) Remove pinion gear from sensor.
(6) To inst all , reverse the above procedure. Make
su r e e x t en sion h ou sin g a n d se n sor f la n g e a r e clea n
prior to installation. Always use a NEW sensor O-ring.
(7) Tig h t en se cu r in g bolt t o 7 Nm (60 in . lbs.).
Tighten speedometer cable to 4 Nm (35 in. lbs.).
PARK/NEUTRAL POSITION AND BACK-UP LAMPSWITCH
REPLACEMENT AND TEST
The P a rk/Neutra l swit ch is the cent er termina l of the
3 t e r m in a l sw it ch . I t p r o vid e s g r o u n d f o r t h e st a r t e r
solenoid circuit through the selector lever in only Park
and Neutral posit ions.
(1) To test switch, remove wiring connector fromsw it ch a n d t e st f o r co n t in u it y be t w e e n ce n t e r p in o f
swit ch and t ran saxle case. Continuity should exist only
w h e n t r a n sa x le is in P a r k o r N eu t r a l .
(2) Check gearshift cable adjustment before replac-
in g a sw it ch w h ich t e st s ba d .
(3) U n s cr ew s w i t ch f r om t r a n s a x le ca s e a l l ow i n g
fluid to drain into a container. Move selector lever to
P ark a nd then to Neutral posit ions. Inspect to see that
t h e s w i t ch op er a t i n g l ev er f in g er s a r e ce nt e re d i n
swit ch opening in the case.
(4) S cr e w t h e sw it ch w it h a n e w se a l in t o t r a n sa x le
ca se a n d t ig h t en t o 33 Nm (24 ft. lbs.). Retest switch
w it h t h e t e st la m p .
(5) Add fluid to tra nsa xle to bring up t o proper level.
(6) The back-up lamp switch circuit is through the
two outside terminals of the 3 terminal switch.
(7) To test switch, remove wiring connector from
swit ch and test for continuity between the tw o outside
pins.
(8) Co n t in u it y sh o u ld e x ist o n ly w it h t r a n sa x le in
Reverse position.
(9) No continuity should exist from either pin to the
case.
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GOVERNORTo service the governor assembly in the vehicle, it
is n o t n e ce ssa r y t o r e m ove t h e t r a n sf e r g ea r cove r,
t r a n sf e r g ea r , a n d g over n or su pp or t . Th e g over n or
m a y be se r vice d by r e m o vin g t h e t r a n sa x le o i l p a n
a n d va lve bod y a ssem bly . Wit h t h e o il p a n a n d va lve
bod y r e m ove d, t h e g ove rn or m a y be u n bolt e d f r om
the governor support and removed.Wh e n cle a n in g or a sse m blin g t h e g over n or , m a k e
sure the governor valves move freely in the bores of
the governor body.
ALUMINUM THREAD REPAIRD a m a g e d o r w o r n t h r e a d s i n t h e a l u m i n u m t r a n -
sa x le ca se a n d va lve bod y ca n be r e pa ir e d by t h e u se
of H eli-Coils, or equiva lent. This repair consists of
drilling out the worn-out damaged threads. Then tap-
ping the hole with a Heli-Coil tap, or equivalent, and
in st a l l in g a He li-Co il in ser t , or e q u iva le n t , in t o t h e
hole. This brings the hole back to its original thread
size.
H e li -C oi l, or eq u iv a len t , t ool s a n d i ns er t s a r e
readily available from most automotive parts suppli-
ers.
OIL COOLERS AND TUBES REVERSE FLUSHINGWh en a t r a n sa x le f a il ur e h a s con t a m in a t ed t h e
f luid , t h e oi l cooler (s) m u st be f lush e d. Th e t o r q u e
con ver t e r m u st be r e pla ced w it h a n e xch a n g e u n it .
Th is w ill in su r e t h a t m e t a l p a r t icles or s lu d ge d o i l
a r e n ot t r a n sf e r r ed ba ck in t o t h e r e con d it ion e d (or
replaced) tra nsa xle.
CAUTION: If vehicle is equipped with two oil cool-
ers (one in the radiator tank, one in front of the ra-
diator) they must be flushed separately. Do not
attempt to flush both coolers at one time.
(1) Disconnect the cooler lines at the transmission.
(2) U s in g a h a n d s u ct i on g u n f il le d w i t h m i n er a l
spirits, reverse flush the cooler. Force mineral spirits
in t o t h e From Cooler l ine of the cooler (Fig. 9) and
ca t c h t h e ex it i n g s pi ri t s f r om t h e To Cooler line.
O bs er v e f or t h e p re se nce of d eb r is i n t h e e xi t in g
f luid . Co n t in u e u n t i l f lu id e xit in g is cle a r a n d f r ee
from debris.
(3) U sin g com p r essed a ir in in t e rm it t e n t sp ur t s ,
blow a n y r e m a in in g m in er a l sp ir i t s f r om t h e cooler ,
again in the reverse direction.
(4) To remove any remaining mineral spirits from
t h e cooler , on e (1) q u a r t of a u t o m a t ic t r a n sm ission
fluid should be pumped through the cooler before re-
connecting.
(5) I f a t a n y s t a g e o f t h e cl ea n i ng pr oces s, t h e
cooler does not freely pa ss fluid, the cooler m ust be
replaced.
OIL COOLER FLOW CHECKAf t e r t h e n e w or r e pa ir e d t r a n sm ission h a s bee n
i n st a l l ed a n d f il le d t o t h e p rop er l ev el w i t h a u t o-
ma tic t ran smission fluid. The flow should be checked
using the following procedure:
(1) Disconnect the From cooler l i n e a t t h e t r a n s -m ission a n d p la ce a col le ct in g con t a in e r u n d er t h e
disconnected line.
(2) Ru n t h e e n g in e at curb idle speed, w i t h t h eshift selector in neutral.
(3) If the fluid flow is intermittent or it takes more
t h a n 20 s econ 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,
fluid collection should not exceed (1) quart or inter-nal damage to the transmission may occur.
(4) I f f lo w is f o u n d t o be w it h in a cce p t a ble l im it s ,
reconnect the cooler line. Then fill tra nsmission to
t h e p r op er leve l, u sin g t h e a p p r oved t y p e o f a u t o -
m a t ic t r a n sm ission f luid .
TRANSAXLE AND TORQUE CONVERTER REMOVALTransaxle removal does NOT require engine
removal.(1) The transaxle and torque converter must be re-
m ov ed a s a n a s s em b ly ; ot h er w i s e, t h e t or q u e c on -
ve r t e r d r ive p la t e , p u m p bu sh in g , o r o i l se a l m a y be
d a m a g e d. Th e d r iv e p l a t e w i l l n o t s u pp or t a l oa d ;
therefore, none of the weight of the transaxle should
be a l low e d t o r e st o n t h e p la t e d u r in g r e m ova l .
(2) Disconnect battery negative cable.(3) D iscon n e ct t h r o t t le l in k a g e a n d sh ift l in k a g e
f r om t r a n sa x le .
Fig. 9 Cooler Line Identification
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If equipped, unplug torque converter clutchplug, located near the dipstick.
CAUTION: Raise vehicle. Remove front wheels. Refer
to Suspension, Group 2 to remove or install wheel
hub nut and both drive shafts.
Remove torque converter dust cover. Marktorque converter and drive plate with chalk, for
reassembly. Remove torque converter mountingbolts.
Fig. 1 Remove Upper and Lower Oil Cooler Hoses
Fig. 2 Engine Support Fixture
Fig. 3 Remove Bell Housing Upper Bolts
Fig. 4 Remove or Install Left Splash Shield
Fig. 5 Remove or Install Access Plug in RightSplash Shield to Rotate Engine Crankshaft
Fig. 6 Remove or Install Wire to Neutral/Park SafetySwitch
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Re m ove o r in st a l l s t a r t e r . Re m ove o r in st a l l low e r
bell housing bolts.
Ca r e f u lly w o r k t r a n sa x le a n d t o r q u e co n ve r t e r a s-
se m bly r e a r w a r d o f f e n g in e blo ck d o w e ls a n d d ise n -
gage converter hub from end of crankshaft . Attach a
small Cclamp to edge of bell housing. This will
hold torque converter in place during transaxle
removal. Lower transaxle and remove assembly from
under the vehicle.
When inst alling tra nsa xle, reverse the above proce-
dure.
I f t o r q u e con ver t e r w a s r e m oved f r om t r a n sa x le be
su r e t o a l ig n p u m p in n e r g e a r p i lo t f la t s w it h t o r q u e
converter impeller hub flats.Adjust gearshift and thrott le cables.
Re fi ll t r a n sa x le w it h MO PAR ATF P LU S (Auto-
ma tic Tra nsmiss ion F luid) Type 7176.
DISASSEMBLY SUBASSEMBLY REMOVALP r i or t o r em ov in g a n y t r a n s a x le s u ba s s em b li es ,
p lu g a l l op en in g s a n d t h o r ou g h ly cle a n e xt e r ior of
t h e u n it , p re fer a b l y b y s t ea m . C l ea n l in es s t h r ou g h
e n t ir e d isa ssem bly a n d a sse m bly ca n n ot be o ver e m -
p h a siz ed . Wh e n d isa ssem blin g , e a ch p a r t sh ou ld be
Fig. 7 Remove or Install Engine Mount Bracket from
Front Crossmember
Fig. 8 Remove or Install Front Mount InsulatorThrough-Bolt and Bell Housing Bolts
Fig. 9 Positioning Transmission Jack
Fig. 10 Remove or Install Left Engine Mount
Fig. 11 Remove or Install Left Engine Mount fromEngine
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w a s h ed i n a s ui t a bl e s ol ven t , t h en d r ied b y com -
p r e sse d a ir . D o n o t w ip e p a r t s w it h sh o p t o w e ls. All
m a t in g su r f a ce s in t h e t r a n sa x le s a r e a ccu r a t e ly m a -
ch in e d ; t h e r e f o r e , ca r e f u l h a n d lin g o f a l l p a r t s m u st
be exercised to avoid nicks or burrs.
Re m ove a l l o ld se a la n t bef or e a p ply in g n e w MO -
P AR Adhesive Sealant .Use only MOPAR Ad h e sive Se a la n t w h e n in st a l l-
in g o i l p a n .
P u t M OP AR Ad h es iv e S ea l a n t on t h e oi l pa n
flange (Fig. 2) and on all oil pan bolts (underside ofbolt head).
Fig. 12 Raise or Lower Transaxle
Fig. 13 Pry Engine for Clearance
Fig. 1 Transaxle Oil Pan Bolts
Fig. 2 Transaxle Oil Pan
Fig. 3 Oil Filter Screws
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R em ov e or i n st a l l n eu t r a l s t a r t i n g a n d b a ck -u p
la m p sw it ch .
Measuring input shaft end play before disassembly
w il l u su a lly in d ica t e w h e n a t h r u st w a sh e r ch a n g e is
required, (except when major parts are replaced). The
t h r u st w a s h e r i s l oca t e d b et w e en i n pu t a n d ou t pu t
sh a f t s .
At t a c h a d ia l i n di ca t o r t o t r a n s a x le b el l h ou s in g
w i t h i t s p l un g er s ea t e d a g a i n s t en d of i n pu t s h a f t
(Fig. 9).