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akpp/31TH 2000

1. NSS 1 LLL qQION31O AIVA w l DU te m JATVA 1041405 34155344 YALYIANOD E 47 d A CA Ee INYA HOLNID avid NXNXNNXXXS N3332S o o o OAaas oo o Q YOLVINWNDIV NS NOILvoniam TRANSAXLE AND POWER TRANSFER UNIT SCHEMATICS AND DIAGRAMS Continued 78 21 JILVWA3HOS Y TXVSNVH L HLLE 435012 QNO21S 29112 TIO 300301 RAN S4 er SS 0 066 E z j Nouons dwnd Feu sss w a wa w 2 w s e w w 9 lt gt 2 gt fae 00009 2 54 ss aava ES 544065344 110 55448464680 3ATV N 900900 SSYd A8 Fam mim pir E le NX N NS CET d AVA ups ez Oc i lt rj M RE BE EE E 6 OA33S L3 14033 ONIS 4934 AA 5 d L 1041405 341055344 YILYFANOD 33425 AOLVI
2. NS DISASSEMBLY AND ASSEMBLY Continued PR2224 Fig 47 Install Overrunning Clutch Rollers and Fig 45 Low Reverse Band and Strut Springs 1 11 THRUST WASHER 1 TOOL L 4440 2 LOW REVERSE BAND 2 ROLLER 8 3 STRUT 3 OVERRUNNING CLUTCH CAM ASSEMBLY 4 SPRING 8 removing or installing valves or plugs slide them in or out carefully Do not use force NOTE ALL SPRINGS AS THEY ARE REMOVED FOR REASSEMBLY IDENTIFICATION PR2223A Fig 46 No 11 Thrust Washer 1 11 THRUST WASHER 2 OUTPUT SHAFT ASSEMBLY When rebuilding reverse the above procedure Fig 48 Detent Spring Attaching Screw and Spring VALVE BODY 1 SPECIAL TOOL L 4553 2 DETENT SPRING SCREW NOTE Tighten all valve body screws to 5 40 SCREWDRIVER HANDLE in Ibs CAUTION Do not clamp any portion of valve body or transfer plate in a vise Any slight distortion of the aluminum body or transfer plate will result in sticking valves excessive leakage or both When 5 TRANSAXLE AND POWER TRANSFER 21 31 DISASSEMBLY AND ASSEMBLY Continued 3 Fig 49 Using Tool L 4553 on Valve Body Screw 1 SCREWDRIVER HANDLE 2 VALVE BODY ASSEMBLY 3 SPECIAL TOOL L 4553 PR2186A Fig 51 Transfer Plate and Separator Plate SEPARATOR PLATE TRANSFER PLATE OIL SCREEN VALVE BODY RON A PR2187B Fig 50 Remo
3. Jisd 066 fx awna 54 2555 Speed 10 1028103 asss y SR 77277141 2 43133 L Lp as LLALA D Joo F r N 5 o v lt gt N 4 22 3ATVA 1081405 340155384 3314J3ANOO NN N IASS S YOLVINWNDDY OASIS INON HOLNTD LNOMi 77 21 TRANSAXLE AND POWER TRANSFER UNIT NS SCHEMATICS AND DIAGRAMS Continued 7526 908 SSWd Ad JILVNNAHIS Y TXVSNVH L HLLE 31LLONHL 331113 WO KANN isa 599 33133ANOOD 3nO3OL 72 4 772727772772772 PEN if SS 06 Nouvomam Fx Nouons awna THEN m md LN 285 3NI1 J SIANSSIAd TIO 555554 w 5 MEE e e WI e D IR CECR 5 id B gt D D D Ah A AAA AN 2 A ee 5722777777727277722727 7727 pm
4. HLLE 1541 110 89 0 0 33183ANOO REEE ISa 066 NoLvomam Nouons awna 54 o 53415534 10 mE M S 34fiSS33d 33143ANO5 Sch YOLVINWNDDV HOLNID INOW OAHS H LNTD AVAA NS TRANSAXLE AND POWER TRANSFER UNIT SCHEMATICS AND DIAGRAMS Continued 74 21 12261908 LINDAI NoHvwaNT R 431893 2 INOYOL 355349 YILYAANOD 1 9 e s os ss s s s EN jv zd JILVWA3HOS Or In vHdAH Y TXVSNVH L HLLE JILLOUHL GNO23S NAN iSd 89 9 ONIJAOO 77754 ERE 164 066 Nouvomani awnd 69 895 uannANOO ISd 89 3NI1 518055344 110 X IISI IR sos lt 24 AS SAAN ear wo SSVd A8 sfa mim 5555 431113 10 I a 777776 M SS AN Ta NT Mey 22 HAUT 1NO84 35 LJ1NO34 OA43S 2 onld JATVA D
5. 5 DISASSEMBLY AND ASSEMBLY Continued DX ux SP 80524 70 0 RB749A Fig 156 Differential Bearing Retainer Typical 1 DIFFERENTIAL BEARING CUP Fig 158 Remove or Install Extension Housing 2 DIFFERENTIAL 1 EXTENSION HOUSING 3 DIFFERENTIAL BEARING RETAINER 2 DIFFERENTIAL ASSEMBLY 3 SPECIAL TOOL L 4435 NOTE Use Mopar RTV sealant or equivalent RB750A Fig 159 Differential and Extension Fig 157 Extension Bolts 1 EXTENSION HOUSING 1 EXTENSION HOUSING BOLTS 4 Eeer 2 EXTENSION HOUSING 3 DIFFERENTIAL ASSEMBLY 3 OIL SEAL NS DISASSEMBLY AND ASSEMBLY Continued WARNING HOLD ONTO DIFFERENTIAL ASSEMBLY TO PREVENT IT FROM ROLLING OUT OF HOUSING Use Mopar Silicone Rubber Adhesive Sealant or equivalent when installing extension housing 80524e6e Fig 160 Remove Differential Bearing Cone Extension Housing Side 1 SPECIAL TOOL C 293 2 SPECIAL TOOL C 293 36 3 SPECIAL TOOL C 293 3 TRANSAXLE AND POWER TRANSFER UNIT 21 65 8056d9dd Fig 162 Install Differential Bearing Cone 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL 6536 3 DIFFERENTIAL ASSEMBLY 80524e77 Fig 161 Position Bearing Cone Differential 1 DIFFERENTIAL ASSEMBLY 2 DIFFERENTIAL BEARING 8056d9de Fig 163 Position Button and Collets Onto Differential and Bearing Ring Gear Side 1 SPECIAL TOOL L 4539 2
6. SCRAPING NOISES 2 M Converter Bolts Hitting 2 Dust shield bent L or repair Dust Shield 3 Planetary Gear Set Broken 3 Check for debris in oil pan and repair as Seized required 4 Overrunning Clutch Worn Broken 4 Inspect and check for debris in oil pan Repair as required 5 Oil Pump Components Scored 5 Remove inspect and repair as required Binding 6 Output Shaft Bearing or Bushing 6 Remove inspect and repair as required Damaged 7 Clutch Operation Faulty 7 Perform air pressure check and repair as required 8 Front and Rear Bands 8 Adjust bands Misadjusted DRAGS OR LOCKS UP 1 Fluid Level Low 1 Check and adjust level 2 Clutch Dragging Failed 2 Air pressure check clutch operation and repair as required 3 Front or Rear Band Misadjusted 3 Adjust bands 4 Case Leaks Internally 4 Check for leakage between passages in case 5 Servo Band or Linkage 5 Air pressure check servo operation and Malfunction repair as required 6 Overrunning Clutch Worn 6 Remove and inspect clutch Repair as required 7 Planetary Gears Broken 7 Remove inspect and repair as required look for debris in oil pan WHINE NOISE RELATED 1 Fluid Level Low 1 Add fluid and check for leaks TO ENGINE SPEED 2 Shift Cable Incorrect Routing 2 Check shift cable for correct routing Should not touch engine or bell housing TORQUE CONVERTER Lockup Solenoid Relay or Wiring Test
7. bands The inoperative units clutches bands servos can be located through a series of tests This is done by substituting air pressure for fluid pressure Fig 5 The front and rear dutches kickdown servo and low reverse servo may be tested by applying air pres sure to their respective passages To make air pres sure tests proceed as follows NOTE Compressed air supply must be free of all dirt or moisture Use a pressure of 30 psi Remove oil pan and valve body Refer to Valve Body for removal procedure FRONT CLUTCH Apply air pressure to front dutch apply passage and listen for a dull thud which indicates that front dutch is operating Hold air pressure on for a few seconds and inspect system for excessive oil leaks REAR CLUTCH Apply air pressure to rear dutch apply passage and listen for a dull thud which indicates that rear dutch is operating Also inspect for excessive oil leaks If a dull thud cannot be heard in the dutches place finger tips on dutch housing and again apply air pressure Movement of piston can be felt as the dutch is applied 21 16 TRANSAXLE AND POWER TRANSFER UNIT DIAGNOSIS AND TESTING Continued NS PU142A Fig 5 Air Pressure Tests PUMP SUCTION PUMP PRESSURE FRONT CLUTCH APPLY REAR CLUTCH APPLY TO TORQUE CONVERTER FROM TORQUE CONVERTER TO OIL COOLER KICKDOWN SERVO OFF Jo Q GQ N 9 KICKDOWN SERVO ON 10 ACCUMULATOR OFF 1
8. ROM Kar aen 5694 48 ez D UL 444 JATVA 1 34055344 YALWIANOD HAUT dONUJACO Q 1NOMj 3O01VInWhn25v ONIS NS SPECIFICATIONS 31TH AUTOMATIC TRANSAXLE Type Automatic three speed with torque converter and integral differential Torque Converter Diameter 241 millimeters 9 48 in Oil Mopar ATF 3 Automatic Transmission Fluid Type 7176 Cooling Method Water Heat Exchanger and or air to oil heat exchanger Lubrication Pump internal external gear type Transmission Gear Ratios FirSt Gear oz d CAT 2 69 Second Gear usa u Sale eS 1 55 Third Gear ous 1 00 Reverse Gear 2 10 Band Adjustment Kickdown Backed Off From 8 Nem 72 11 IDS DEE 2 1 4 Turns Low Reverse Backed Off From 5 Nem Alin lbs 3 1 2 Turns Clutch Pack Clearances Front Clutch Not Adjustable 1 27 2 79mm 0 050 0 110 in Rear Clutch 0 71 1 10mm 0 028 0 043 in End Play Input Shaft 0 19 1 50 mm 008 060 in Front Clutch Retainer 0 76 2 69 mm 030 106 in Front Carrier 0 89 1 45 mm 007 057 in Front Annulus Gear 0 09 0 50 mm 0035 020 in Planet Pinion 0 15 0 59 mm 006 023 in Reverse Drum 0 76 3 36 mm 030 132 in O
9. Starter To Trans Bell Bolts 54 N m 40 ft Ibs Stirrup Strap Ret Bolts 23 N m 200 in Ibs Trans To Cyl Block Bolt 95 N m 70 ft Ibs Transfer Shaft Nut 271 N m 200 ft Ibs Transfer Gear Strap Bolts 23 17 ft Ibs Valve Body Assy To Case Bolts 12 105 in 105 Valve Body 5 5 N m 45 in 16 SPECIAL TOOLS 31TH AUTOMATIC TRANSAXLE 293 45 80110408 Adapter Blocks C 293 45 Adapter Blocks 293 52 Puller Press C 293 PA 80119426 Dial Indicator C 3339 Spring Compressor 3575 o T C Band Adjusting Adapter NS NS TRANSAXLE AND POWER TRANSFER 21 83 SPECIAL TOOLS Continued 0 Oil Pump Puller C 3752 Seal Installer C 4193A C Bearing Installer C 4637 Throitle Setting Gauge Z Adapter C 4658 Seal Puller C 3981B Torque Tool C 4995 Universal Handle C 4171 21 84 TRANSAXLE AND POWER TRANSFER UNIT NS SPECIAL TOOLS Continued Adapter C 4996 Gear Puller L 4407A Puller L 4407 6 Remover Kit L 4406 0 Bearing Installer 1 4408 Bearing Remover Cup 1 4406 1 v Bearing Remover Jaws L 4406 2 v Adapter L 4406 3 Bearing Installer L 4410 5 TRANSAXLE AND POWER TRANSFER 21 85 SPECIAL TOOLS Continued
10. 21 22 REMOVAL 1 Screw seal remover Tool 3981 8 into seal Fig 14 then tighten screw portion of tool to with draw the seal oS 9521 154 Fig 14 Remove Pump Oil Seal 1 PUMP OIL SEAL 2 OIL SEAL REMOVER TOOL C 3981 B 3 OIL PUMP TRANSAXLE AND POWER TRANSFER UNIT REMOVAL AND INSTALLATION Continued NS DISASSEMBLY AND ASSEMBLY TRANSAXLE DISASSEMBLY PR2176B Fig 16 Transaxle Oil Pan Bolts 1 TRANSAXLE OIL PAN 2 OIL PAN BOLTS INSTALLATION 1 To install a new seal place seal in opening of the pump housing lip side facing inward Using Tool C 4193 and Handle Tool C 4171 drive new seal into housing until tool bottoms Fig 15 RB718B Fig 15 Install Pump Oil Seal 1 OIL PUMP 2 OIL SEAL INSTALLER TOOL C 4193 3 SPECIAL TOOL HANDLE 4171 Remove all old sealant before applying new seal ant Use only Mopar Silicone Rubber Sealant or equiv alent when installing oil pan Put sealant on the oil pan flange Fig 17 and on all oil pan bolts underside of bolt head 2177 Fig 17 Transaxle Oil Pan 1 TRANSAXLE OIL PAN 2 OIL FILTER 5 TRANSAXLE AND POWER TRANSFER UNIT 21 23 DISASSEMBLY AND ASSEMBLY Continued PR2180 Fig 18 Oil Filter Screws Fig 20 Remove Parking Rod E Clip 1 SCREWDRIVER HANDLE 1 VALVE BODY 2 SPECIAL TOOL L 4553 2 SCREWDRIVER 3 OIL FILTER S
11. 3 Automatic Transmission Fluid Type 7176 should be used A filter change should be made at the time of the transmission oil change The magnet on the inside of the oil pan should also be cleaned with a clean dry cloth NOTE If the transaxle is disassembled for any rea son the fluid and filter should be changed NS FLUID FILTER SERVICE 1 Raise vehide on a hoist See Lubrication Group 0 Place drain container with a large ing 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 Remove oil filter to valve body screws Fig 9 Fig 9 Oil Filter Screws 1 SCREWDRIVER HANDLE 2 SPECIAL TOOL L 4553 3 OIL FILTER SCREWS 2 4 OIL FILTER 4 Remove oil filter and gasket Fig 10 Fig 10 Oil Filler and Gasket 1 OIL FILTER 2 GASKET 3 VALVE BODY 5 Install a new filter and gasket Fig 10 NS SERVICE PROCEDURES Continued 6 Clean the oil pan and magnet Reinstall pan using new Mopar Silicone Adhesive sealant Tighten oil pan bolts to 19 N m 165 in Ibs 7 Pour four quarts of ATF 43 Automatic Transmission Fluid Type 7176 through the dipstick opening 8 Start engine and allow to idle for at least one minute Then with parking and service brakes applied move selector lever momentarily to each position ending in the park or neutral position
12. 99 13 15 94 12 65 1 39 12 65 1 34 12 65 1 29 12 65 1 24 12 65 1 19 12 65 1 14 12 65 1 09 12 65 1 04 12 65 99 12 65 94 The turning torque should be between 5 and 18 inch pounds 5 If the turning torque is within specifications remove tools Setup is complete 6 If turning torque is not within specifications proceed with the following steps a Remove differential bearing retainer from the transaxle case b Remove the bearing cup from the differential bearing retainer using Tool 6062A OUTPUT SHAFT BEARING SHIM CHART Remove the existing shim from under the cup d Measure the existing shim NS ADJ USTMENTS Continued 80a7738e Fig 173 Tool L 4436 and Torque Wrench 1 SPECIAL TOOL L 4436 A 2 TORQUE WRENCH 3 DIFFERENTIAL BEARING RETAINER m Ar 80277390 Fig 174 Checking Differential Bearings Turning Torque 1 SPECIAL TOOL L 4436 A 2 TORQUE WRENCH NOTE If the turning torque was too high when measured install a 05 mm 002 inch thinner shim If the turning torque is was too low install a 05 mm 002 inch thicker shim Repeat until 5 to 18 inch pounds turning torque is obtained Oil Baffle is not required when making shim selection e Install the proper shim under the bearing cup Make sure the oil baffle is installed properly in the bearing retainer below the bearing shim and cup f Install the differen
13. BOLT 2 3 OUTPUT SHAFT GEAR ASSEMBLY To install reverse the above procedure 21 54 TRANSAXLE AND POWER TRANSFER UNIT DISASSEMBLY AND ASSEMBLY Continued Fig 117 Support and Bolts 1 BOLT 2 2 PARKING SPRAG ROD SUPPORT Fig 118 Parking Pawl Return Spring and Pivot Shaft 1 PARKING PAWL 2 RETURN SPRING 3 NOTE SMALL DIAMETER TO REAR 4 PIVOT SHAFT OUTPUT SHAFT REPAIR NOTE Transfer shaft should be removed for repair of output shaft Planetary gear sets must be removed to accurately check output shaft bearing turning torque STIRRUP AND RETAINING STRAP NOTE A stirrup and retaining strap Fig 119 is attached to the output gear The stirrup prevents the output gear retaining nut from turning and NS backing off the output shaft The strap is used to hold the stirrup to the output gear and prevent the stirrup retaining bolts from backing out REMOVAL Sa Fig 119 Stirrup and Retaining Strap Assembly 1 STRAP 2 RETAINING BOLTS 2 3 OUTPUT GEAR 4 STIRRUP 1 Using a punch bend tabs on strap flat against output gear Fig 120 Fig 120 Bend Strap Tabs Flat 1 RETAINING TABS 2 STRAP 2 Remove bolts holding retaining strap to stirrup Fig 121 3 Remove strap from output gear and stirrup Fig 122 NS mY Fig 121 Remove Strap Bolts 1 RETAINING BOLTS 2 STIRRUP
14. 2 FRONT PLANETARY GEAR ASSEMBLY 3 6 THRUST WASHER 21 28 TRANSAXLE AND POWER TRANSFER UNIT 5 DISASSEMBLY AND ASSEMBLY Continued Remove Number 6 thrust washer from sun gear driving shell 80524e5a Fig 39 No 9 Thrust Washer 80524959 4 9 THRUST WASHER 2 OUTPUT SHAFT Fig 37 Sun Gear Driving Shell 3 REAR PLANETARY GEAR ASSEMBLY 1 SUN GEAR DRIVING SHELL 2 REAR PLANETARY GEAR 80524e5b Fig 40 Rear Planetary Gear Assembly 1 REAR PLANETARY GEAR ASSEMBLY Fig 38 Sun Gear Driving Shell Components 1 48 THRUST WASHER STEEL 2 7 SPACER STEEL 3 SUN GEAR 4 SUN GEAR DRIVING SHELL 5 SNAP RING NS nSx F TRANSAXLE AND POWER TRANSFER UNIT 21 29 DISASSEMBLY AND ASSEMBLY Continued 2 D Es PR2219 2221 Fig 41 No 10 Thrust Washer Fig 43 Overrunning Clutch Rollers and Spring 1 OVERRUNNING CLUTCH CAM ASSEMBLY TA ACOVCREVERSE BAND 2 10 THRUST WASHER 2 OVERRUNNING CLUTCH ROLLERS 8 3 OVERRUNNING CLUTCH SPRINGS 8 PR2220A Fig 42 Overrunning Clutch Cam Assembly Fig 44 Loosen or Adjust Low Reverse Band 1 OUTPUT SHAFT 1 LOW REVERSE BAND LEVER 2 OVERRUNNING CLUTCH CAM ASSEMBLY 2 ADJUSTING SCREW 3 STRUT 4 LOW REVERSE BAND 5 LOCK NUT 6 LEVER SHORT 21 30 TRANSAXLE AND POWER TRANSFER UNIT
15. 9 Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm 1 8 in below the ADD mark on the dip stick Fig 11 9321 323 Fig 11 Dipstick Markings 1 TRANSAXLE DIPSTICK 10 Recheck the fluid level after the transaxle has reached normal operating temperature 180 F Refer to Fluid Level and Condition Check in this group for the proper fluid fill procedure 11 To prevent dirt from entering transaxle make certain that dipstick is fully seated into the dipstick opening ALUMINUM THREAD REPAIR Damaged or worn threads in the aluminum tran saxle case and valve body can be repaired by the use of Heli Coils or equivalent This repair consists of drilling out the worn out damaged threads Then tap ping the hole with a Heli Coil tap or equivalent and installing a Heli Coil insert or equivalent into the hole This brings the hole back to its original thread size Heli Coil or equivalent tools and inserts are readily available from most automotive parts suppli ers FLUSHING COOLERS AND TUBES When a transaxle failure has contaminated the fluid the oil cooler s must be flushed The cooler bypass valve in the transaxle must be replaced also The torque converter must also be replaced with an exchange unit This will insure that metal particles TRANSAXLE AND POWER TRANSFER UNIT 21 19 or sludged oil are not later transferred back into the reconditioned or
16. nicks and scratches Minor blemishes may be removed with cro cus doth using only a very light pressure Using a straightedge inspect all mating surfaces for warpage or distortion Slight distortion may be corrected using a surface plate Make sure all metering holes in steel plate are open Using a pen light inspect bores in valve body for scores scratches pits and irregularities Inspect all valve springs for distortion and col lapsed coils Inspect all valves and plugs for burrs nicks and scores Small nicks and scores may be removed with crocus cloth providing extreme is taken not to round off sharp edges The sharpness of these edges is vitally important It prevents foreign matter from lodging between valve and valve body This reduces the possibility of sticking Inspect all valves and plugs for freedom of operation in valve body bores When bores valves and plugs are dean and dry the valves and plugs should fall freely in the bores The valve body bores do not change its dimensions with use Therefore a valve body that was function ing properly when vehicle was new will operate cor if it is properly and thoroughly cleaned There is no need to replace valve body unless it is damaged in handling ADJ USTMENTS GEARSHIFT CABLE ADJUSTMENT Lift and rotate the gearshift hand lever into the park P gate position and remove the ignition key This confirms the shift lever is in the gated park P posit
17. 10 Remove the two gauging shims and install the correct shim combination Install the transfer gear and bearing assembly 11 Install the retaining nut and washer and torque to 271 N m 200 ft 155 Measure transfer shaft end play end play should be 05 to 25 mm 002 to 010 inch 12 Measure bearing end play as outlined in Step 4 End play should be between 05 mm and 25 mm 002 to 010 inch NOTE If end play is too high install a 05 mm 002 inch thinner shim combination If end play is too low install a 05 mm 002 inch thicker shim combi nation Repeat until 05 to 25 mm 002 to 010 inch end play is obtained TRANSAXLE AND POWER TRANSFER UNIT NS End Play with 2 29 mm and 1 39 mm gauging shims Total Thickness Required Shim Combination installed mm 2 29 1 39 2 29 1 39 2 29 1 39 2 29 1 39 2 29 1 34 2 29 1 29 2 29 1 24 2 29 1 19 2 29 1 14 2 29 1 09 2 29 1 04 2 29 99 1 84 1 39 1 84 1 34 1 84 1 29 1 84 1 24 1 84 1 19 1 84 1 14 1 84 1 09 1 84 1 04 1 84 99 1 39 1 39 1 39 1 34 1 39 1 29 1 39 1 24 1 39 1 19 1 39 1 14 1 39 1 09 1 39 1 04 1 39 99 94 1 39 94 1 34 94 1 29 TRANSFER BEARING SHIM CHART SCHEMATICS AND DIAGRAMS 31TH TRANSAXLE HYDRAULIC SCHEMATIC 73 21 TRANSAXLE AND POWER TRANSFER UNIT NS SCHEMATICS AND DIAGRAMS Continued 06263908 JILVNNAHIS
18. 2 SPECIAL TOOL 5048 3 SPECIAL TOOL 5048 4 21 66 TRANSAXLE AND POWER TRANSFER UNIT DISASSEMBLY AND ASSEMBLY Continued 80524e6c Fig 164 Position Tool 5048 Over Button and Collets at Differential Bearing 1 SPECIAL TOOL 5048 2 DIFFERENTIAL 3 SPECIAL TOOL 5048 4 80524e6d Fig 165 Remove Differential Bearing Cone 1 SPECIAL TOOL 5048 2 RING GEAR To install the differential bearing cup and cone on the ring gear side use Special Tool 5052 and Special Tool C 4171 NOTE The differential is serviced as an assembly The only parts that are serviceable within the differ ential are the differential bearing cups and cones If any other part fails within the differential you must replace the differential assembly along with the transfer shaft CAUTION Side gear end play must be BETWEEN 0 001 to 0 013 inch NS MOVE SIDE GEAR UP AND DOWN Fig 166 Checking Side Gear End Play 1 SPECIAL TOOL C 4996 NOTE POSITION 2 DIAL INDICATOR SET 3 DIFFERENTIAL ASSEMBLY 4 SIDE GEAR MOVE SIDE GEAR UP AND DOWN 1 Fig 167 Checking Side Gear End Play Typical 1 SPECIAL TOOL C 4996 NOTE POSITION 2 DIAL INDICATOR SET 3 DIFFERENTIAL ASSEMBLY To remove the differential bearing cup from the extension housing adapter side use Special Tool 6062A Remover To install the differential bearing cup on the extension housing adapter side use Spe cial
19. 3 STRAP TRANSAXLE AND POWER TRANSFER UNIT DISASSEMBLY AND ASSEMBLY Continued Fig 122 Remove Strap From Stirrup and Gear 1 OUTPUT GEAR 2 STRAP 4 Remove stirrup from output gear Fig 123 Fig 124 21 55 d gt Fig 123 Remove Stirrup From Gear 1 OUTPUT GEAR 2 STIRRUP Fig 124 Stirrup and Strap Removed From Output Gear 1 OUTPUT GEAR RETAINING NUT 2 OUTPUT GEAR 21 56 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued OUTPUT GEAR AND SHAFT DISASSEMBLY Fig 125 Remove Output Shaft Retaining Nut and Washer 1 SPECIAL TOOL L 4434 2 OUTPUT SHAFT GEAR Fig 127 Output Shaft Gear and Select Shim 1 BEARING CUP 2 SHIM SELECT 3 BEARING CONE 4 OUTPUT SHAFT GEAR 5 OUTPUT SHAFT PR2289 Fig 128 Remove Output Shaft Gear Bearing Cone d 1 SPECIAL TOOL L 4406 1 WITH ADAPTERS L 4406 2 Fig 126 Remove Output Shaft Gear using L 4407A 2 OUTPUT SHAFT GEAR 1 OUTPUT GEAR 2 TOOL L 4407A NS TRANSAXLE AND POWER TRANSFER UNIT 21 57 DISASSEMBLY AND ASSEMBLY Continued N PR2291B Fig 129 Remove Output Shaft and Rear Annulus Gear Assembly 1 BEARING CUP 2 REAR ANNULUS GEAR 3 OUTPUT SHAFT Fig 130 Remove Output Shaft 1 ARBOR PRESS RAM 2 CAU
20. EN Bearing Installer L 4411 Differential Tool L 4436A Installer Adapter L 4429 3 Housing Remover Adapter L 4437 Starter Nut L 4439 Be Transfer Shaft Remover Installer L 4512 Bearing Puller L 4435 Bearing Cup Remover L 4517 21 86 TRANSAXLE AND POWER TRANSFER UNIT NS SPECIAL TOOLS Continued Special Jaw Set L 4518 Installer L 4520 Bearing Splitter P 334
21. L 4437 Fig 25 Loosen Lock Nut and Tighten Kickdown Band Adjusting Screw 1 KICKDOWN BAND ADJUSTING SCREW lt is 4 PR2206A Fig 28 Oil Pump with No 1 Thrust Washer 1 FRONT CLUTCH 2 OIL PUMP ASSEMBLY Fig 26 Pump Attaching Bolts 1 SEAL 2 PUMP ATTACHING BOLTS 7 3 PUMP HOUSING 21 26 TRANSAXLE AND POWER TRANSFER UNIT 55 DISASSEMBLY AND ASSEMBLY Continued Fig 29 Oil Pump Gasket 1 SPLIT IN GASKET DIFFERENTIAL OIL FEED Fig 31 Kickdown Band and Strut 2 PUMP GASKET 1 FRONT CLUTCH 3 PUMP GASKET DIFFERENTIAL OIL FEED CUTOUT 2 KIOKDOWN BAND 3 OIL RETURN AND FEED HOLE TO DIFFERENTIAL 4 STRUT Fig 30 Loosen Kickdown Band Adjusting Screw 1 KICKDOWN BAND ADJUSTING SCREW Fig 32 Front Clutch Assembly 1 REAR CLUTCH ASSEMBLY 2 FRONT CLUTCH ASSEMBLY 5 TRANSAXLE AND POWER TRANSFER UNIT 21 27 DISASSEMBLY AND ASSEMBLY Continued PR2211A Fig 33 No 2 Thrust Washer and Rear Clutch Fig 35 Front Planetary Gear Snap Ring 1 REAR CLUTCH ASSEMBLY 1 FRONT PLANETARY GEAR SNAP RING 2 2 THRUST WASHER 2 SNAP RING PLIERS 3 FRONT PLANETARY GEAR ASSEMBLY RB722A RB724A Fig 34 No 3 Thrust Washer 1 OUTPUT SHAFT 2 SUN GEAR DRIVING SHELL 3 3 THRUST WASHER SELECT FIT Fig 36 Front Planetary Gear Assembly 1 SUN GEAR
22. PARK NEUTRAL STARTING AND BACK UP LAMP SWITCH TEST The park neutral starting switch is the center ter minal of the terminal switch It provides ground for the starter solenoid circuit through the selector lever in only Park and Neutral positions 1 To test switch remove wiring connector from switch and test for continuity between center pin of switch and transaxle case Continuity should exist only when transaxle is in Park or Neutral 2 Check gearshift cable adjustment before replac ing a switch which tests bad REMOVAL 1 Unscrew switch from transaxle case allowing fluid to drain into a container Move selector lever to Park then to Neutral position and inspect to see the switch operating lever fingers are centered in switch opening INSTALLATION 1 Screw the switch with a new seal into tran saxle case and tighten to 33 N m 24 ft 165 Retest switch with the test lamp 2 Add fluid to transaxle to bring up to proper level 3 The back up lamp switch circuit is through the two outside terminals of the 3 terminal switch 4 To test switch remove wiring connector from switch and test for continuity between the two out side pins 5 Continuity should exist only with transaxle in Reverse position 6 No continuity should exist from either pin to the case TRANSAXLE AND TORQUE CONVERTER REMOVAL NOTE Transaxle removal does NOT require engine removal The transaxle and torque converter must be r
23. POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued 80524e5c Fig 78 Front Planetary Gear 1 FRONT PLANETARY GEAR ASSEMBLY Fig 80 Front Annulus Gear Support and Snap Ring 1 FRONT ANNULUS GEAR 2 FRONT SNAP RING 3 FRONT ANNULUS GEAR SUPPORT 4 REAR SNAP RING Fig 79 Annulus Gear Support Front Snap Ring 1 ANNULUS GEAR SUPPORT 2 FRONT SNAP RING 3 SCREWDRIVER 4 FRONT PLANETARY ANNULUS GEAR Fig 81 Front Annulus Gear Support Snap Ring 1 FRONT ANNULUS GEAR 2 REAR SNAP RING 5 TRANSAXLE AND POWER TRANSFER UNIT 21 45 DISASSEMBLY AND ASSEMBLY Continued LOW REVERSE REAR SERVO RECONDITION DISASSEMBLY 2 D Em 80277397 Fig 84 Remove Retainer Spring and Servo 1 SERVO PISTON 80277395 2 SPRING AND RETAINER Fig 82 Low Reverse Lever 1 LOW REVERSE LEVER 80 77398 Fig 85 Low Reverse Servo Assembly 80a77396 1 SERVO PISTON 2 SPRING Fig 83 Low Reverse Servo Snap Ring 1 SNAP RING PLIERS ASSEMBLY To assemble reverse the above procedure 21 46 DISASSEMBLY AND ASSEMBLY Continued ACCUM ULATOR RECONDITION DISASSEMBLY d PR2251C Fig 86 Accumulator Snap Ring 1 ACCUMULATOR PLATE SNAP RING 2 SNAP RING PLIERS 3 ACCUMULATOR PLATE TRANSAXLE AND POWER TRANSFER UNIT PR2252A
24. Spring Waved Snap Ring Fig 70 Rear Clutch Outer Snap Ring 1 REAR CLUTCH RETAINER 1 SCREWDRIVER 2 PISTON SPRING 2 SNAP RING 3 SCREWDRIVER 3 REAR CLUTCH ASSEMBLY 4 WAVED SNAP RING 9521 105 PR2238A Fig 71 Rear Clutch 4 Disc Shown Fig 73 Rear Clutch Piston and Piston Spring 1 REAR CLUTCH RETAINER 1 INPUT SHAFT 2 CLUTCH PLATES 2 REAR CLUTCH RETAINER 3 THICK STEEL PLATE 3 PISTON SPRING 4 SNAP RING SELECTIVE 4 WAVED SNAP RING 5 DRIVING DISCS 5 PISTON 6 PRESSURE PLATE 6 PISTON SEALS NS 4 PR2239 Fig 74 Remove or Install Input Shaft Snap Ring 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3 SNAP RING PLIERS 4 SNAP RING TRANSAXLE AND POWER TRANSFER UNIT DISASSEMBLY AND ASSEMBLY Continued PR2240 Fig 75 Input Shaft Snap Ring 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3 SNAP RING Press out input shaft if required 21 43 ASSEM BLY To reassemble reverse the above procedure MEASURING PLATE CLEARANCE Fig 76 Measuring Rear Clutch Plate Clearance 1 REAR CLUTCH ASSEMBLY 2 FEELER GAUGE 3 SELECTIVE SNAP RING FRONT PLANETARY AND ANNULUS GEAR RECONDITION Fig 77 Front Planetary Gear Snap Ring and No 4 Thrust Washer Always Install a New Snap Ring 1 SNAP RING 2 4 THRUST WASHER 3 SNAP RING 4 FRONT PLANETARY GEAR ASSEMBLY 21 44 TRANSAXLE AND
25. Tool 6536 Driver and Special Tool C 4171 dle NS TRANSAXLE AND POWER TRANSFER UNIT 21 67 DISASSEMBLY AND ASSEMBLY Continued 80524e73 80524675 Fig 168 Differential Bearing Retainer Fig 170 Remove Bearing Cup 1 DIFFERENTIAL BEARING CUP ASB DIFFERENTIAL BEAMING RETAINER 2 DIFFERENTIAL BEARING RETAINER 80524e74 80524e76 Fig 169 Position Bearing Cup Remover Tool in Retainer Fig 171 Install Bearing Cup 1 SPECIAL TOOL 6062A 1 SPECIAL TOOL C 4171 2 DIFFERENTIAL BEARING RETAINER 2 SPECIAL TOOL 5052 3 DIFFERENTIAL BEARING RETAINER DETERMINING SHIM THICKNESS Shim thickness need be determined only if any of the following parts are replaced Transaxle case Differential carrier Differential bearing retainer e Extension housing e Differential bearing cups and cones Refer to Bearing Adjustment Procedure in rear of this section to determine proper shim thickness 21 68 TRANSAXLE AND POWER TRANSFER UNIT CLEANING AND INSPECTION VALVE BODY Allow all parts to soak a few minutes in a suitable dean solvent Wash thoroughly and blow dry with compressed air Make sure all passages are dean and free from obstructions Inspect manual and throttle valve operating levers and shafts for being bent worn or loose If a lever is loose on its shaft it should be replaced Do not attempt to straighten bent levers Inspect all mating surfaces for burrs
26. and IN 2ND OR GEAR repair as required ONLY 2 Valve Body Malfunction 2 Remove clean and inspect Look for sticking 1 2 shift valve 2 3 shift valve governor plug or broken springs 3 Front Servo Piston Cocked in 3 Inspect servo and repair as required Bore 4 Front Band Linkage Malfunction 4 Inspect linkage and look for bind in linkage NO KICKDOWN OR 1 Throttle Linkage Misadjusted 1 Adjust linkage NORMAL DOWNSHIFT 2 Accelerator Pedal Travel 2 Floor mat under pedal accelerator cable Restricted worn or brackets bent 3 Governor Valve Body Hydraulic 3 Perform hydraulic pressure tests to Pressures Too High or Too Low Due determine cause and repair as required to Sticking Governor Valve Body Correct valve body pressure adjustments as Malfunction or Incorrect Hydraulic required Control Pressure Adjustments 4 Valve Body Malfunction 4 Perform hydraulic pressure tests to determine cause and repair as required Correct valve body pressure adjustments as required 5 Valve Malfunction 5 Sticking 1 2 2 3 shift valves governor plugs 3 4 solenoid 3 4 shift valve 3 4 timing valve STUCK IN LOW GEAR 1 Throttle Linkage Misadjusted 1 Adjust linkage and repair linkage if worn WILL NOT UPSHIFT Stuck or damaged Check for binding cable 2 Gearshift Linkage Misadjusted 2 Adjust linkage and repair linkage if worn or damaged 3 Governor Valve Body Governor 3 Check line and governor pre
27. or adjusting these variables road test the vehicle to determine if the problem has been corrected or that further diagnosis is necessary If the problem still exists refer to the following diagnosis charts to aid in determining the source or cause of failure Hydraulic pressure tests should be performed when a transaxle internal failure is suspected The hydraulic flow charts in the Schematics and Dia grams section of this group outline fluid flow and hydraulic circuitry Circuit operation is provided for all gear ranges Normal working pressures are also supplied for each of the gear ranges 21 6 TRANSAXLE AND POWER TRANSFER UNIT NS DIAGNOSIS AND TESTING Continued TRANSAXLE DIAGNOSIS CHARTS CONDITION POSSIBLE CAUSES CORRECTION HARSH ENGAGEMENT 1 Fluid Level Low 1 Add Fluid FROM NEUTRAL TO 2 Throttle Linkage Misadjusted 2 Adjust linkage setting may be too long DRIVE OR REVERSE 3 Excessive Pinion Backlash 3 Check per Service Manual Correct as needed 4 Hydraulic Pressure Incorrect 4 Check pressure Remove overhaul or adjust valve body as needed 5 Band Misadjusted 5 Adjust rear band 6 Valve Body Check Balls Missing 6 Inspect valve body for proper check ball installation 7 Clutch band or planetary 7 Remove disassemble and repair component Damaged transmission as necessary 8 Converter Clutch if equipped 8 Replace converter and flush cooler a
28. pump ON for two to three minutes to flush cooler and lines 7 Turn pump OFF 8 Disconnect CLEAR suction line from reservoir at cover plate Disconnect CLEAR return line at cover plate and place it in a drain pan 9 Turn pump ON for 30 seconds to purge flush ing solution from cooler and lines Turn pump OFF 10 Place CLEAR suction line into a one quart container of ATF 43 Automatic Transmission Fluid Type 7176 11 Turn pump ON until all transmission fluid is removed from the one quart container and lines This purges any residual cleaning solvent from the trans mission cooler and lines Turn pump OFF 21 20 TRANSAXLE AND POWER TRANSFER UNIT SERVICE PROCEDURES Continued 12 Disconnect alligator clips from battery Recon nec flusher lines to cover plate and remove flushing adapters from cooler lines OIL PUMP VOLUME CHECK Measuring oil pump output volume will determine if sufficient flow to the transmission oil cooler exists and whether or not an internal transmission failure is present Verify that transmission fluid is at the proper level Refer to Fluid Level and Condition in this Group If adding fluid is necessary fill to the proper level with ATF 43 Automatic Transmission Fluid Type 7176 The following procedure is to check oil pump output volume 1 Disconnect the To cooler line at the oil cooler inlet and place a collecting container under the dis connected line CAU
29. replaced transaxle The recommended procedure for cooler flushing is to use Tool 6906 Cooler Flusher WARNING WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI 287 1 1968 WEAR STANDARD INDUSTRIAL RUB BER GLOVES KEEP LIGHTED CIGARETTES SPARKS FLAMES AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTI BLE LIQUIDS AND GASES KEEP A CLASS B FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED KEEP THE AREA WELL VENTILATED DO NOT LET FLUSHING SOLVENT COME IN CON TACT WITH YOUR EYES OR SKIN IF EYE CONTAM INATION OCCURS FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER SEEK MEDICAL ATTENTION 1 Remove cover plate filler plug on Tool 6906 Fill reservoir 1 2 to 3 4 full of fresh flushing solution Flushing solvents are petroleum based solutions gen erally used to dean automatic transmission compo nents DO NOT use solvents containing acids water gasoline or any other corrosive liquids 2 Reinstall filler plug on Tool 6906 3 Verify pump power switch is turned OFF Con nec red alligator clip to positive battery post Connect black alligator dip to a good ground NOTE When flushing transmission cooler and lines ALWAYS reverse flush 4 Connect the BLUE pressure line to the OUT LET From cooler line 5 Connect the CLEAR return line to the INLET To cooler line 6 Turn
30. throt tle This is done during engine warm up and part throttle acceleration TRANSAXLE AND POWER TRANSFER UNIT DESCRIPTION AND OPERATION Continued NS The switch valve directs oil to apply the torque converter clutch in one position The switch valve releases the torque converter clutch in the other posi tion CLUTCHES BAND SERVOS AND ACCUM ULATOR The front and rear dutch pistons and both servo pistons are moved hydraulically to engage the dutches and apply the bands The pistons are released by spring tension when hydraulic pressure is released On the 2 3 upshift the kickdown servo piston is released by spring tension and hydraulic pressure The accumulator controls the hydraulic pressure on the apply side of the kickdown servo during the 1 2 upshift thereby cushioning the kickdown band application at any throttle position GEARSHIFT AND PARKING LOCK CONTROLS The transaxle is controlled by a lever type gear shift incorporated within the steering column The control has six selector lever positions P park R reverse N neutral and D drive 2 second and 1 first The parking lock is applied by moving the selector lever past a gate to the P position Do not apply the parking lock until the vehicle has stopped otherwise a severe ratchet noise will occur GOVERNOR The governor may be serviced by removing the transaxle oil pan and valve body assembly The gov ernor may be unbolted from the govern
31. turning and backing off the transfer shaft The strap is used to hold the stirrup to the transfer gear and prevent the stirrup retain ing bolts from backing out NOTE Remove old sealant before applying new sealant Use Mopar RTV sealant or equivalent when installing cover 21 48 SCH Fig 94 Remove or Install Rear Cover 1 OUTPUT SHAFT GEAR 2 USE MOPAR SILICONE RUBBER ADHESIVE SEALER 3 REAR COVER 4 TRANSFER SHAFT GEAR TRANSAXLE AND POWER TRANSFER UNIT DISASSEMBLY AND ASSEMBLY Continued NS Fig 96 Transfer Shaft Gear Nut and Washer 1 OUTPUT SHAFT GEAR 2 TRANSFER SHAFT GEAR 3 WASHER 4 NUT 1 Using a punch bend tabs on strap flat against transfer gear 2 Remove bolts holding retaining strap to stir rup 3 Remove strap from transfer gear and stirrup 4 Remove stirrup from transfer gear Fig 95 Remove Transfer Shaft Gear Retaining Nut 1 TRANSFER SHAFT GEAR 2 SCREW 2 3 OUTPUT SHAFT GEAR 4 SPECIAL TOOL L 4434 80bdbd29 Fig 97 Remove Transfer Shaft Gear using L 4407A 1 TRANSFER GEAR 2 TOOL L 4407A NOTE Remove or install both governor valves and governor body NS DISASSEMBLY AND ASSEMBLY Continued 9521 122 Fig 98 Transfer Shaft Gear and Select Shim 1 TRANSFER SHAFT GEAR 2 OUTPUT SHAFT GEAR 3 SHIM SELECT 4 BEARING CONE PR2264 Fig 99 Using Tool L 4406 1 with Adapte
32. 1 ACCUMULATOR ON 12 LOW REVERSE SERVO APPLY 13 GOVERNOR PRESSURE 14 LINE PRESSURE TO GOVERNOR 15 GOVERNOR PRESSURE PLUG 16 GOVERNOR PRESSURE KICKDOWN SERVO FRONT Direct air pressure into KICKDOWN SERVO ON passage Operation of servo is indicated by a tighten ing of front band Spring tension on servo piston should release the band LOW AND REVERSE SERVO REAR Direct air pressure into LOW REVERSE SERVO APPLY passage Operation of servo is indicated by a tightening of rear band Spring tension on servo pis ton should release the band If clutches and servos operate properly no upshift indicates that a malfunction exists in the valve body FLUID LEAKAGE TORQUE CONVERTER HOUSING AREA When diagnosing converter housing fluid leaks three actions must be taken before repair 1 Verify proper transmission fluid level 2 Verify that the leak originates from the con verter housing area and is transmission fluid 3 Determine the true source of the leak Fluid leakage at or around the torque converter area may originate from an engine oil leak Fig 6 The area should be examined closely Factory fill fluid is red and therefore can be distinguished from engine oil Some suspected converter housing fluid leaks may not be leaks at all They may only be the result of residual fluid in the converter housing or excess NS DIAGNOSIS AND TESTING Continued 6 9021 35 Fig 6 Converter Hous
33. 8 WASHER NUT Q Fig 144 Checking Output Shaft End Play 1 SPECIAL TOOL L 4432 AND C 4658 2 SCREW 2 3 OUTPUT SHAFT GEAR 4 STEEL BALL GREASE IN PLACE 5 SPECIAL TOOL L 4438 6 DIAL INDICATOR NS TRANSAXLE AND POWER TRANSFER UNIT 21 61 DISASSEMBLY AND ASSEMBLY Continued RY295 Fig 145 Checking Bearing Turning Torque 1 OUTPUT SHAFT GEAR 2 TORQUE WRENCH STIRRUP AND RETAINING STRAP INSTALLATION Once bearing turning torque and shim selection has been adjusted install stirrup and strap assembly onto output gear NOTE Once the stirrup assembly is positioned onto the output gear it is necessary to clock the stirrup against the flats of the output gear retaining nut 1 Position the stirrup on the output gear 2 Position strap 3 Install retaining bolts into output gear Finger tighten bolts 4 Turn stirrup dockwise against the flats of the output gear retaining nut Fig 146 5 Tighten retaining bolts to 23 N m 200 in 105 Fig 147 6 Bend tabs of strap up against flats of retain ing bolts Fig 146 Turn Stirrup Clockwise Against Flats Of Retaining Nut 1 TURN STIRRUP CLOCKWISE 2 STRAP 3 80524e6f Fig 147 Tighten Strap Retaining Nuts 1 STRAP 2 OUTPUT GEAR 3 STIRRUP 21 62 TRANSAXLE AND POWER TRANSFER UNIT 5 DISASSEMBLY AND ASSEMBLY Continued
34. Bear Ret To Case Bolt 34 N m 300 in Ibs Diff Cover To Case Bolt 19 N m 165 in Ibs Exten Hous To Case Bolt 28 N m 250 in 165 Drive Plate To Crankshaft Bolts 95 70 ft Ibs Drive Plate To Torque Conv Bolts 68 50 ft Ibs Fluid Filter Screw 5 N m 45 in Ibs Governor Counterweight Screw 28 250 in 165 Governor To Support Bolt 7 60 in Ibs Kickdown Band Adj Lock Nut 47 N m 35 ft Ibs Left Motor Mount Bolts 54 N m 40 ft Ibs Manual Cable To Trans Case Bolt 28 250 in 165 Manual Control Lever Screw 12 105 in Ibs Oil Pan To Trans Case Screw 19 N m 165 in 165 Output Gear Strap Bolts 23 17 ft Ibs Output Shaft Nut 271 N m 200 ft Ibs Park Neutral Switch 34 N m 25 ft Ibs Pressure Check Plug 5 N m 45 in Ibs Pump To Case Bolts 31 N m 275 in 105 Reaction Shaft Assembly Bolt 28 N m 250 in Ibs Rear Cover To Case Screw 19 N m 165 in Ibs Reverse Band Adj Lock Nut 14 N m 125 in Ibs Reverse Band Shaft Plug 7 N m 60 in Ibs Ring Gear 5 95 N m 70 ft Ibs Speedo To Ext Hous Screw 7N m 60 in Ibs 21 82 TRANSAXLE AND POWER TRANSFER UNIT SPECIFICATIONS Continued DESCRIPTION TORQUE Sprag Ret To Transfer Case Bolt 28 250 in 105
35. CREWS 2 4 OIL FILTER 4 PARKING ROD Remove neutral starting and back up lamp switch PR2181 Fig 19 Oil Filter 1 OIL FILTER 2 GASKET 3 VALVE BODY Fig 21 Parking Rod 1 VALVE BODY 2 PARKING ROD Measuring input shaft end play before disassembly will usually indicate if a thrust washer change is required Fig 24 The 43 thrust washer is located between input and output shafts 21 24 TRANSAXLE AND POWER TRANSFER UNIT 5 DISASSEMBLY AND ASSEMBLY Continued PR2183 Fig 23 Valve Body and Governor Tubes 1 VALVE BODY ASSEMBLY 2 GOVERNOR TUBES Cooler Bypass Valve and Seal If Equipped 1 TRANSFER PLATE 2 BYPASS VALVE 3 SEAL 80bdbd18 Fig 24 Measure Input Shaft End Play using End Play Set 8266 Fig 22 Valve Body Attaching Bolts 1 TOOL 8266 8 1 VALVE BODY 2 TOOL 8266 2 2 VALVE BODY ATTACHING BOLTS 7 3 TOOL C 3339 3 GOVERNOR TUBES NS s oa N R A F W n TRANSAXLE AND POWER TRANSFER UNIT 21 25 DISASSEMBLY AND ASSEMBLY Continued Move input shaft in and out to obtain end play reading End play specifications are 0 19 to 1 50 mm 0 008 to 0 060 inch Record indicator reading for reference when reas sembling the transaxle Fig 27 Install Tool C 3752 with Adapters L 4437 1 PUMP 2 PULLERS TOOL C 3752 3 ADAPTERS TOOL
36. DIFFERENTIAL REPAIR NOTE The transfer shaft should be removed for differential repair and bearing turning torque check ing RB747A Fig 150 Differential Cover Bolts 1 DIFFERENTIAL COVER 2 DIFFERENTIAL COVER BOLT Fig 148 Remove Extension Seal EXTENSION HOUSING SMALL CHISEL HAMMER OIL SEAL I 4 RB748 Fig 151 Remove or Install Differential Cover GOVERNOR PRESSURE PLUG DIFFERENTIAL COVER 1 8 INCH BEAD OF R T V SEALANT DIFFERENTIAL ASSEMBLY A PR2307A Fig 149 Install New Seal into Extension SPECIAL TOOL L 4520 INVERTED HANDLE C 4171 HAMMER EXTENSION HOUSING NS NOTE Use Mopar RTV sealant or equivalent when installing differential cover 80524 71 Fig 152 Remove Bearing Retainer Axle Seal 1 SPECIAL TOOL 7794A 2 SPECIAL TOOL C 637 3 DIFFERENTIAL BEARING RETAINER TRANSAXLE AND POWER TRANSFER UNIT DISASSEMBLY AND ASSEMBLY Continued 21 63 PR2310 Fig 154 Differential Bearing Retainer Bolts 1 DIFFERENTIAL BEARING RETAINER 2 DIFFERENTIAL BEARING RETAINER BOLTS 6 Fig 153 Install Bearing Retainer Axle Seal 1 SPECIAL TOOL L 4520 2 SPECIAL TOOL C 4171 PR2311 Fig 155 Remove or Install Bearing Retainer 1 GOVERNOR PRESSURE PLUG 2 DIFFERENTIAL BEARING RETAINER 3 SPECIAL TOOL L 4435 21 64 TRANSAXLE AND POWER TRANSFER UNIT
37. EVERSE PRESSURE 5 GOVERNER PRESSURE BELOW DIFFERENTIAL COVER ON RIGHT SIDE 6 LINE PRESSURE 7 KICKDOWN APPLY AT ACCUMULATOR 8 TO COOLER 9 KICKDOWN RELEASE FRONT CLUTCH 10 KICKDOWN APPLY 11 CONVERTER CLUTCH SOLENOID CONNECTOR 12 FROM COOLER 13 KICKDOWN BAND ADJUSTING SCREW 3 Move selector lever on transaxle one detent for ward from full rearward position This is selector 2 position 4 Read pressures on both gauges as throttle lever on transaxle is moved from full clockwise position to full counterdockwise position 5 Line pressure should read 52 to 58 psi with throttle lever dockwise Pressure should gradually increase to 80 to 88 psi as lever is moved counter clockwise 6 Lubrication pressure should be 10 to 25 psi with lever clockwise and 10 to 35 psi with lever at full counterclockwise 7 This tests pump output pressure regulation and condition of rear clutch and lubrication hydraulic circuits TEST THREE SELECTOR IN D 1 Attach gauges to line and kickdown release ports 2 Operate engine at 1600 rpm for test 3 Move selector lever on transaxle two detents forward from full rearward position This is selector D position 4 Read pressures on both gauges as throttle lever on transaxle is moved from full clockwise to the full counterclockwise position 5 Line pressure should read 52 to 58 psi with throttle lever clockwise Pressure should gradually
38. Fig 87 Accumulator Plate and Snap Ring NS PR2253 Fig 88 Accumulator Spring and Piston 1 ACCUMULATOR SPRING 2 ACCUMULATOR PISTON 3 SEAL RINGS KICKDOWN SERVO CONTROLLED LOAD RECONDITION DISASSEMBLY Fig 89 Kickdown Servo Snap Ring 1 SNAP RING 2 SNAP RING PLIERS 3 ACCUMULATOR PLATE 1 SNAP RING 2 ACCUMULATOR PLATE 3 Or RING ASSEMBLY To assemble reverse the above procedure 4 KICKDOWN LEVER 5 KICKDOWN PISTON ROD GUIDE ASSEMBLY To assemble reverse the above procedure 5 TRANSAXLE AND POWER TRANSFER UNIT 21 47 DISASSEMBLY AND ASSEMBLY Continued RB742A Fig 90 Kickdown Servo Rod Guide and Snap Ring Fig 92 Controlled Load Kickdown Servo 1 SNAP RING 1 KICKDOWN PISTON 2 ACCUMULATOR PLATE 2 O RING 3 RETURN SPRING 3 SNAP RING 4 O RING 4 PISTON ROD GUIDE 5 PISTON ROD GUIDE 5 SNAP RING 6 O RING 7 PISTON RETURN SPRING 8 PISTON ROD 9 SEAL RINGS Fig 91 Kickdown Piston Return Spring and Piston 1 RETURN SPRING 2 KICKDOWN LEVER 3 PISTON ROD 4 KICKDOWN SERVO PISTON PR2258B Fig 93 Rear Cover Bolts 1 REAR COVER 2 REAR COVER BOLTS 10 TRANSFER SHAFT REPAIR DISASSEMBLY STIRRUP AND STRAP REMOVAL NOTE A stirrup and retaining strap is attached to the transfer gear The stirrup prevents the transfer gear retaining nut from
39. G 4 ADJUSTING SCREW 10 MANUAL VALVE 5 SCREW 11 THROTTLE VALVE 6 GUIDE 21 34 TRANSAXLE AND POWER TRANSFER UNIT 55 DISASSEMBLY AND ASSEMBLY Continued 6 UI RB714 Fig 60 Governor Plugs 1 SHUTTLE VALVE SECONDARY SPRING 5 SCREW 4 2 SHUTTLE VALVE 6 END COVER 3 1 2 SHIFT VALVE GOVERNOR PLUG 7 2 3 SHIFT VALVE GOVERNOR PLUG 4 END COVER 8 E CLIP NS TRANSAXLE AND POWER TRANSFER UNIT 21 35 DISASSEMBLY AND ASSEMBLY Continued 80bdbd32 Fig 61 Torque Converter Clutch Solenoid and Regulator Control Valves 1 CONVERTER PRESSURE CONTROL VALVE 4 REGULATOR VALVE THROTTLE PRESSURE PLUG SPRING 2 END COVER 5 REGULATOR VALVE THROTTLE PRESSURE PLUG 3 SCREW 3 6 SWITCH VALVE 21 36 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued gt 80bdbd30 Fig 62 Shift Valves and Shuttle Valve 1 SHUTTLE VALVE E CLIP 9 BY PASS VALVE SPRING 2 SHUTTLE VALVE SECONDARY SPRING 10 1 2 SHIFT VALVE SPRING 3 SHUTTLE VALVE 11 1 2 SHIFT VALVE 4 2 3 SHIFT VALVE 12 BY PASS VALVE 5 SHUTTLE VALVE PRIMARY SPRING 13 TORQUE CONVERTER CLUTCH SOLENOID 6 2 3 SHIFT VALVE SPRING 14 VALVE BODY 7 SHUTTLE VALVE PLUG 15 SPRING GUIDES 2 8 SCREWS NS TRANSA
40. IT DESCRIPTION AND OPERATION 31TH TRANSAXLE D NS 80507000 31TH Transaxle 1 TORQUE CONVERTER CLUTCH 2 TORQUE CONVERTER 3 OIL PUMP 4 FRONT CLUTCH 5 REAR CLUTCH 6 OVER RUNNING CLUTCH 7 PLANETARY GEARS 8 TRANSFER GEARS 9 TRANSFER SHAFT 10 GOVERNOR 11 DIFFERENTIAL This transaxle combines torque converter three speed transmission final drive gearing and differen tial into a front wheel drive system Within this transaxle there are three primary areas NS DESCRIPTION AND OPERATION Continued 1 Main center line plus valve body 2 Transfer shaft center line includes governor and parking sprag 3 Differential center line Center distances between the main rotating parts in these three areas are held precise to maintain a low noise level The torque converter transaxle area and differen tial are housed in an integral aluminum die casting The differential oil sump is common with the transaxle sump Separate filling of the differen tial is NOT necessary The torque converter is attached to the crankshaft through a flexible driving plate Cooling of the con verter is accomplished by circulating the transaxle fluid through a remote cooler There are two types of coolers used oil to water type cooler located in the radiator side tank and or an oil to air heat exchanger The torque converter assembly is a sealed unit that cannot be disass
41. IUS 7 ess MTN N 75 21 TRANSAXLE AND POWER TRANSFER UNIT NS SCHEMATICS AND DIAGRAMS Continued JILVWA3HOS Y TXVSNVH L HLLE 2646 308 033201 LON 10 300301 med VAZA Sd 80 0 6 NOuvomam F Nouons awnd SS 8 2255 3NI1 534055344 10 4799 X XXX TIT TYT sss sss gqu CPA LAL LD 9 gt x d N S 5 uwa sJ i 7 222 d ON310S e N ww 6777714177777 GION oes 2 OIL eA N lt S Se S 4 NN 1 d z onid Ei N E eeneg EE n SANS SSN OS EEE SS 4 0 LN e 0 M p R bh HOLD 938 3ATVA OA43S 4 34 HON33AOO YOLVINWNDDV 5 INON HDIM 1NO33 NS TRANSAXLE AND POWER TRANSFER UNIT SCHEMATICS AND DIAGRAMS Continued 76 21 JILVWA3HOS Y TIXVSNVH L HLLE 802263908 33114 WO Nisa 280 4
42. L 21 DISASSEMBLY AND ASSEMBLY TRANSAXLE 22 TRANSAXLE AND POWER TRANSFER UNIT 21 1 page POWER TRANSFER 225 page VALVE BODY e e RET REP 30 RR Rey tete 37 FRONT GLUTGH ia eR RR RD 38 REAR CLUTCH ASSEMBLY 41 FRONT PLANETARY AND ANNULUS 43 LOW REVERSE REAR SERVO REGONDITION nere een oa Ag 45 ACCUMULATOR RECONDITION 46 KICKDOWN SERVO CONTROLLED LOAD RECONDITION 46 TRANSFER SHAFT REPAIR 47 PARKING 53 OUTPUT SHAFT 54 DIFFERENTIAL REPAIR 62 CLEANING AND INSPECTION VALVE 68 ADJUSTMENTS GEARSHIFT CABLE ADJUSTMENT 68 THROTTLE PRESSURE LINKAGE 68 BAND ADJUSTMENT 69 HYDRAULIC CONTROL PRESSURE ADJUSTMENTS 69 BEARING ADJUSTMENT PROCEDURES 69 OUTPUT SHAFT BEARING DIFFERENTIAL BEARING TRANSFER SHAFT BEARING SCHEMATICS AND DIAGRAMS 31TH TRANSAXLE HYDRAULIC SCHEMATIC SPECIFICATIONS 31TH AUTOMATIC TRANSAXLE 31TH TRANSAXLE TORQUE SPECIFICATIONS SPECIAL TOOLS 31TH AUTOMATIC TRANSAXLE 21 2 TRANSAXLE AND POWER TRANSFER UN
43. M THICKNESS Shim thickness need be determined only if any of the following parts are replaced Transaxle case Output shaft Rear planetary annulus gear e Output shaft gear Rear annulus and output shaft gear bearing cones e Overrunning clutch race cups Refer to Bearing Adjustment Procedure at the rear of this section to determine proper shim thickness Check output shaft bearing turning torque using an inch pound torque wrench If turning torque is 3 to 8 inch pounds the proper shim has been installed TRANSAXLE AND POWER TRANSFER UNIT DISASSEMBLY AND ASSEMBLY Continued 21 59 Z Fig 139 Install Output Shaft Assembly 1 OUTPUT SHAFT ASSEMBLY 2 USE GREASE TO HOLD SHIMS IN POSITION 3 BEARING CONE 4 LUBRICATION HOLE 5 SELECT SHIMS N in ds s Fig 140 Output Shaft and Select Shims in Position 1 BEARING CUP 2 SELECT SHIM 3 OUTPUT SHAFT ASSEMBLY 21 60 TRANSAXLE AND POWER TRANSFER UNIT 5 DISASSEMBLY AND ASSEMBLY Continued Fig 141 Start Output Shaft Gear onto Output Shaft 1 OUTPUT SHAFT GEAR 2 OUTPUT SHAFT 3 SPECIAL TOOL L 4439 Fig 143 Tighten Output Shaft Retaining Nut to 271 N m 200 ft Ibs 1 OUTPUT SHAFT GEAR 2 SPECIAL TOOL L 4434 AND C 4658 3 SCREW 2 m 8 4 PR2303B Fig 142 Holding Output Shaft Gear OUTPUT SCREW 2 SPECIAL TOOL L 4434 AND C 465
44. NS TRANSAXLE AND POWER TRANSFER UNIT TABLE OF CONTENTS page 31TH AUTOMATIC 1 41TE AUTOMATIC TRANSAXLE 87 31TH AUTOMATIC TRANSAXLE TABLE OF CONTENTS page DESCRIPTION AND OPERATION 31TH TRANSAXLE 2 FLUID REQUIREMENT 3 TORQUE CONVERTER 3 HYDRAULIC CONTROL SYSTEM 3 PRESSURE SUPPLY SYSTEM 4 PRESSURE REGULATING VALVES 4 FLOW CONTROL anaa 4 CLUTCHES BAND SERVOS AND 4 GEARSHIFT AND PARKING LOCK CONTROLS 4 GOVERNOR usaq aaa bu EE EE 4 COOLER BYPASS VALVE 4 DIAGNOSIS AND TESTING TRANSAXLE PRELIMINARY DIAGNOSIS 4 ROAD TEST Ade P tei eun ec 12 HYDRAULIC PRESSURE TESTS 13 CLUTCH AND SERVO AIR PRESSURE TESTS 15 FLUID LEAKAGE TORQUE CONVERTER 5 16 SERVICE PROCEDURES FLUID LEVEL AND 17 TRANSAXLE FLUID AND FILTER SERVICE 18 ALUMINUM THREAD REPAIR 19 FLUSHING COOLERS AND TUBES 19 OIL PUMP VOLUME CHECK 20 REMOVAL AND INSTALLATION VEHICLE SPEED SENSOR PINION GEAR 20 PARK NEUTRAL STARTING AND BACK UP LAMP SWITCH 20 TRANSAXLE AND TORQUE CONVERTER REMOVAL Des ie D 20 FRONT PUMP OIL SEA
45. NWNIDV 79 21 TRANSAXLE AND POWER TRANSFER UNIT NS SCHEMATICS AND DIAGRAMS Continued JILVWA3HOS Y TIXVSNVH L 92261308 35012 IVANWW 43114 10 ZZAsao nuoxn Cem 055 X z Nouons awna gt LL 2222164 ses xanaANOO 534165344 110 GEET a a 99 e runden 5 Ext SSVd A8 3ATYA nno SSVd A8 HAE 5 DEIXXEREEEEEKFEEEEREIX odnio d 7 Ki JU TN 34055344 YILYIANOD GH Kelt En En 3 Q dj o 8 A e dO01vinwnoov 7 HAUT 1NO H 0143 Lo1NO 3 JAVA 1081905 N N 21012 QA43S N3ONN3JAOO NS TRANSAXLE AND POWER TRANSFER UNIT SCHEMATICS AND DIAGRAMS Continued 80 21 JILVWA3HOS Y TIXVSNVH L HLLE 1016808 3Su3A33 31113 10 2 30301 HERE ISd 001 06 gt OL ANI 001 09 Nouvommm lt Nouons awna Z Qu aatva Saanssasd Lee LINDA D y H NOILVvORIS T1 W 5 d a 8 y x B
46. TION SUPPORT ANNULUS GEAR UNDERNEATH NEAR GEAR CENTER 3 BEARING 4 REAR ANNULUS GEAR 5 OUTPUT SHAFT PR2292C PR2293 Fig 131 Remove Rear Planetary Annulus Gear Bearing Cone 1 SPECIAL TOOL L 4406 1 WITH ADAPTERS L 4406 2 2 REAR PLANETARY ANNULUS GEAR PR2296 Fig 132 Remove Output Shaft Gear Bearing 1 OUTPUT SHAFT GEAR BEARING CUP 2 SPECIAL TOOL L 4518 21 58 TRANSAXLE AND POWER TRANSFER UNIT 5 DISASSEMBLY AND ASSEMBLY Continued RB744 Fig 133 Remove Rear Planetary Annulus Gear Fig 135 Install Rear Planetary Annulus Gear Bearing Cup Bearing Cone 1 REAR PLANETARY ANNULUS GEAR BEARING CUP 1 ARBOR PRESS RAM 2 SPECIAL TOOL L 4518 2 SPECIAL TOOL C 4637 3 REAR PLANETARY ANNULUS GEAR 4 CUP FROM TOOL L 4518 ASSEMBLY 5 BEARING CONE PR2290A Fig 134 Install Output Shaft Gear Bearing Cone PR2295A 1 PRE EN ud C471 Fig 136 Install Output Shaft into Rear Planetary J Annulus Gear 3 SPECIAL TOOL L 4408 4 OUTPUT SHAFT GEAR PRESS 5 BEARING CONE 1 2 INCH SOCKET OUTPUT SHAFT REAR ANNULUS GEAR SPACER Q Q NS PR2298A Fig 137 Install Output Shaft Gear Bearing Cup 1 OUTPUT SHAFT GEAR BEARING CUP 2 SPECIAL TOOL L 4429 3 PR2299 B Fig 138 Install Rear Planetary Annulus Gear Bearing Cup 1 SPECIAL TOOL L 4429 3 DETERMINING SHI
47. TION With the fluid set at the proper level fluid collection should not exceed 1 quart or inter nal damage to the transmission may occur 2 Start engine and run at curb idle speed with the shift selector in neutral 3 If one quart of ATF is collected in 20 seconds or less flow is within acceptable limits If fluid flow is intermittent or it takes more than 20 seconds to col lect one quart of ATF refer to Hydraulic Pressure Tests in this Group 4 Inspect the cooler hose for damage Replace if necessary 5 Connect the To cooler hose to the oil cooler inlet and torque clamp to 2 20 in Ibs torque 6 Refill the transaxle to proper level with ATF 43 Automatic Transmission Fluid Type 7176 REMOVAL AND INSTALLATION VEHICLE SPEED SENSOR PINION GEAR When the sensor is removed for any reason a NEW O ring must be installed on its outside diame ter REMOVAL 1 Remove harness connector from sensor Make sure weatherseal stays on harness connector 2 Remove bolt securing the sensor in the exten sion housing 3 Carefully pull sensor and pinion gear assembly out of extension housing 4 Remove pinion gear from sensor NS INSTALLATION 1 To install reverse the above procedure Make sure extension housing and sensor flange are dean prior to installation Always use a NEW sensor O ring 2 Tighten bolt to 7 60 Ibs Tighten speedometer cable to 4 N m 35 in 106
48. XLE AND POWER TRANSFER UNIT 21 37 DISASSEMBLY AND ASSEMBLY Continued OIL PUMP 80646950 Fig 63 Oil Pump Assembly 1 REACTION SHAFT SUPPORT 2 INNER GEAR 3 PUMP BODY 4 PUMP BUSHING 5 OUTER GEAR 1 Remove reaction shaft support to pump body bolts 2 Remove reaction shaft support and the inner and outer pump gears Fig 63 3 Visually inspect gears for excessive wear 4 Inspect pump bushing for excessive wear 5 Reinstall gears and measure outer gear to pocket dearance Clearance should be within 0 045 0 141 mm 0 0018 0 0056 in 6 Measure both inner and outer gear side dear ance using a straight edge and feeler gauge across the pump face Inner and outer gear side dearance should be within 0 020 0 046 mm 0 0008 0 0018 in 80596900 Measuring Pump Outer Gear to Pocket Clearance 1 FEELER GAUGE 2 OUTER GEAR 21 38 TRANSAXLE AND POWER TRANSFER UNIT DISASSEMBLY AND ASSEMBLY Continued FRONT CLUTCH p 1 SNAP RING WAVE 2 REACTION PLATE 3 CLUTCH DISC 4 CLUTCH PLATE 5 SEAL 6 CLUTCH RETAINER 80bdbd40 Front Clutch Assembly 7 SEAL 8 PISTON 9 SPRING 10 SNAP RING 11 SPRING RETAINER NS NS TRANSAXLE AND POWER TRANSFER UNIT 21 39 DISASSEMBLY AND ASSEMBLY Continued DISASSEMBLY 3 9521 109 Fig 66 Front Clutch 4 Disc Shown Fig 64 Front Clutch Waved Snap R
49. aft bearing retainer Retainer snap ring Governor support Refer to Bearing Adjustment Procedure in rear of this section to determine proper shim thickness Fig 114 Tighten Transfer Shaft Gear Retaining Nut to 271 N m 200 ft Ibs 1 TRANSFER SHAFT GEAR 2 TORQUE WRENCH 3 SPECIAL TOOL L 4434 AND ADAPTER C 4658 TRANSAXLE AND POWER TRANSFER UNIT DISASSEMBLY AND ASSEMBLY Continued STIRRUP AND STRAP INSTALLATION Once bearing shim selection has been adjusted install stirrup and strap assembly onto transfer gear NOTE Once the stirrup assembly is positioned onto the transfer gear it is necessary to clock the stirrup against the flats of the transfer gear retain ing nut 1 Position the stirrup on the transfer gear 2 Position strap 3 Install retaining bolts into transfer gear Fin ger tighten bolts 4 Turn stirrup dockwise against the flats of the transfer gear retaining nut 5 Tighten retaining bolts to 23 N m 200 in 105 6 Bend tabs of strap up against flats of retain ing bolts 21 53 Fig 115 Checking Transfer Shaft End Play 1 SPECIAL TOOL L 4432 AND C 4658 2 TRANSFER SHAFT GEAR 3 STEEL BALL USE GREASE TO HOLD IN PLACE 4 DIAL INDICATOR 5 SCREW 2 ASSEM BLY To install transfer shaft reverse the above proce dure PARKING PAWL DISASSEMBLY 2921 116 Fig 116 Parking Sprag Rod Support 1 PARKING SPRAG ROD SUPPORT 2
50. ailed components as needed Remove and disassemble transmission Repair or replace failed components as needed 7 Park Sprag not Releasing Check 7 Remove disassemble repair Stall Speed Worn Damaged Stuck 8 Torque Converter Damage 8 Inspect and replace as required 21 8 TRANSAXLE AND POWER TRANSFER UNIT NS DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION SHIFTS DELAYED OR 1 Fluid Level Low High 1 Correct fluid level and check for leaks if ERRATIC ALSO SHIFTS low HARSH AT TIMES 2 Fluid Filter Clogged 2 Replace filter If filter and fluid contained clutch material or metal particles an overhaul may be necessary Perform lube flow test 3 Throttle Linkage Misadjusted 3 Adjust linkage as described in service section 4 Throttle Linkage Binding 4 Check cable for binding Check for return to closed throttle at transmission 5 Gearshift Linkage Cable 5 Adjust linkage cable as described in Misadjusted service section 6 Governor Valve Sticking 6 Inspect clean or repair 7 Governor Seal Rings Worn 7 Inspect replace Damaged 8 Clutch or Servo Failure 8 Remove valve body and air test clutch and band servo operation Disassemble and repair transmission as needed 9 Front Band Misadjusted 9 Adjust band 10 Pump Suction Passage Leak 10 Check for excessive foam on dipstick after normal driving Che
51. c Pressure Too Low 5 Perform hydraulic pressure tests to determine cause 6 Rear Servo Leaking 6 Air pressure check clutch servo operation and repair as required 7 Band Linkage Binding 7 Inspect and repair as required SLIPS IN FORWARD 1 Fluid Level Low 1 Add fluid and check for leaks DRIVE RANGES 2 Fluid Foaming 2 Check for high oil level bad pump gasket or seals dirt between pump halves and loose pump bolts Replace pump if necessary 3 Throttle Linkage Misadjusted 3 Adjust linkage 4 Gearshift Linkage Misadjusted 4 Adjust linkage 5 Rear Clutch Worn 5 Inspect and replace as needed 6 Low Hydraulic Pressure Due to 6 Perform hydraulic and air pressure tests Worn Pump Incorrect Control to determine cause Pressure Adjustments Valve Body Warpage or Malfunction Sticking Governor Leaking Seal Rings Clutch Seals Leaking Servo Leaks Clogged Filter or Cooler Lines 7 Rear Clutch Malfunction Leaking 7 Air pressure check clutch servo operation Seals or Worn Plates and repair as required 8 Overrunning Clutch Worn Not 8 Replace Clutch Holding Slips in 1 Only SLIPS IN LOW GEAR Overrunning Clutch Faulty Replace overrunning clutch ONLY BUT NOT IN 1 POSITION 5 TRANSAXLE AND POWER TRANSFER UNIT 21 11 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION GROWLING GRATING OR 1 1 Drive Plate Broken Plate Broken 1 1 Replace
52. ck for loose pump bolts defective gasket Replace pump assembly if needed NO REVERSE D RANGES 1 Gearshift Linkage Cable 1 Repair or replace linkage parts as OK Misadjusted Damaged needed 2 Rear Band Misadjusted Worn 2 Adjust band replace 3 Valve Malfunction 3 Remove and service valve body Replace valve body if any valves or valve bores are worn or damaged 4 Rear Servo Malfunction 4 Remove and disassemble transmission Replace worn damaged servo parts as necessary 5 Direct Clutch in Overdrive Worn 5 Disassemble overdrive Replace worn or damaged parts 6 Front Clutch Burnt 6 Remove and disassemble transmission Replace worn damaged clutch parts as required HAS FIRST REVERSE 1 Governor Valve Shaft Weights or 1 Remove governor assembly and clean or ONLY NO 1 2 OR 2 3 Body Damaged Stuck repair as necessary UPSHIFT 2 Valve Body Malfunction 2 Stuck 1 2 shift valve or governor plug 3 Front Servo Kickdown Band 3 Repair replace Damaged Burned MOVES IN 2ND OR 3RD 1 Valve Body Malfunction 1 Remove clean and inspect Look for GEAR ABRUPTLY stuck 1 2 valve or governor plug DOWNSHIFTS TO LOW 2 Governor Valve Sticking 2 Remove clean and inspect Replace faulty parts NS 31RANSAXLE AND POWER TRANSFER 21 9 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION NO LOW GEAR MOVES 1 Governor Valve Sticking 1 Remove governor clean inspect
53. cuit leakage 3 Low pressure in D and R but correct pressure in 1 indicates front clutch circuit leakage 4 Low pressure in R and 1 but correct pressure in 2 indicates rear servo circuit leakage 5 Low line pressure in all positions indicates a defective pump a clogged filter or a stuck pressure regulator valve 21 15 GOVERNOR PRESSURE Test only if transaxle shifts at wrong vehicle speeds when throttle cable is correctly adjusted 1 100 psi gauge to governor pressure port It is located at lower right side of case below differential cover Fig 4 2 Operate transaxle in third gear to read pres sures The governor pressure should respond smoothly to changes in mph and should return to 0 to 3 psi when vehide is stopped High pressure above 3 psi at standstill will prevent the transaxle from downshifting THROTTLE PRESSURE No gauge port is provided for throttle pressure ncor rect throttle pressure should be suspected if part throt tle upshift speeds are either delayed or occur too early in relation to vehicle speed Engine runaway on shifts can also be an indicator of low throttle pressure setting or misadjusted throttle cable In no case should throttle pressure be adjusted until the transaxle throttle cable adjustment has been verified to be correct CLUTCH AND SERVO AIR PRESSURE TESTS A no drive condition might exist even with correct fluid pressure because of inoperative clutches
54. d filter change inter vals for this transaxle NOTE Refer to Service Procedures in this group for fluid level checking procedures NOTE The transmission and differential sump have a common oil sump with an opening between the two DESCRIPTION Mopar ATF 3 Automatic Transmission Fluid Type 7176 is required in this transaxle Substitute fluids can induce torque converter dutch shudder Automatic Transmission Fluid Type 7176 when new is red in color The ATF is dyed red so it can be identified from other fluids used in the vehide such as engine oil or antifreeze The red color is not permanent and is not an indicator of fluid condition As the vehide is driven the ATF will begin to look darker in color and may eventually become brown This is normal A dark brown black fluid accompanied with a burnt odor and or deterioration in shift quality may indicate fluid deterioration or transmission component failure FLUID ADDITIVES DaimlerChrysler strongly recommends against the addition of any fluids to the transmission other than those automatic transmission fluids listed above Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks Various special additives and supplements exist that claim to improve shift feel and or quality These additives and others also claim to improve converter clutch operation and inhibit overheating oxidation varnish and sludge These clai
55. e and shift cable from tran saxle levers so they can be controlled from outside the vehicle Attach 100 psi gauges C 3292 to ports required for test being conducted A 300 psi gauge C 3293SP is required for reverse pressure test at rear servo Test port locations are shown in Fig 3 TEST ONE SELECTOR IN 1 1 Attach gauges to line and low reverse ports 2 Operate engine at 1000 rpm for test 3 Move selecor lever on transaxle all the way rearward 1 position 4 Read pressures on both gauges as throttle lever on transaxle is moved from full clockwise position to full counterclockwise position 5 Line pressure should read 52 to 58 psi with throttle lever clockwise Pressure should gradually increase to 80 to 88 psi as lever is moved counter clockwise 6 Low reverse pressure should read the same as line pressure within 3 psi 7 This tests pump output pressure regulation and condition of rear clutch and rear servo hydraulic circuits TEST TWO SELECTOR IN 2 1 Attach one gauge to line pressure port and tee another gauge into lower cooler line fitting This will allow lubrication pressure readings to be taken 2 Operate engine at 1000 rpm for test 21 14 TRANSAXLE AND POWER TRANSFER UNIT DIAGNOSIS AND TESTING Continued D NS lt gt 8050053 Fig 3 Test Port Locations 1 ACCUMULATOR VENT 2 MANUAL THROTTLE LEVER SHAFT 3 MANUAL SHIFT LEVER SHAFT 4 LOW R
56. embled The transaxle fluid is filtered by an internal filter attached to the lower side of the valve body assembly Engine torque is transmitted to the torque con verter and then through the input shaft to multiple disc dutches in the transaxle The power flow depends on the application of the dutches and bands Refer to Elements in Use Chart in Diagnosis and Tests section The transaxle consists of e Two multiple disc clutches An overrunning clutch Two servos A hydraulic accumulator Two bands Two planetary gear sets This provides three forward ratios and a reverse ratio The common sun gear of the planetary gear Sets is connected to the front dutch by a driving shell The driving shell is splined to the sun gear and front dutch retainer The hydraulic system consists of an oil pump and a single valve body which con tains all of the valves except the governor valves The transaxle sump and differential sump are both vented through the dipstick Output torque from the main center line is delivered through helical gears to the transfer shaft This gear set is a factor in the transaxle final drive axle ratio The shaft also car ries the governor and parking sprag An integral heli cal gear on the transfer shaft drives the differential ring gear FLUID REQUIREM ENT NOTE Refer to the maintenance schedules in Group 0 Lubrication and Maintenance for the rec TRANSAXLE AND POWER TRANSFER UNIT 21 3 ommended maintenance flui
57. emoved as an assembly otherwise the torque con verter drive plate pump bushing or oil seal may be damaged The drive plate will not support a load NS REMOVAL AND INSTALLATION Continued therefore none of the weight of the transaxle should be allowed to rest on the plate during removal REMOVAL 1 Disconnect negative battery cable 2 Remove air cleaner and hoses 3 Disconnec throttle linkage and shift linkage from transaxle 4 Unplug torque converter clutch connector located near the dipstick Unplug the gear position switch 5 Remove transaxle dipstick tube 6 Remove the transaxle cooler lines and plug 7 Install engine support fixture Fig 12 9521 153 Fig 12 Engine Support Fixture 1 ENGINE FIXTURE TRANSAXLE AND POWER TRANSFER UNIT 8 Remove bell housing upper bolts 9 Raise vehide Remove front wheels Refer to Group 2 Suspension to remove or install wheel hub nut and both drive shafts CAUTION The exhaust flex joint must be discon nected from the exhaust manifold anytime the engine is lowered If the engine is lowered while the flex pipe is attached damage will occur 10 Remove bolts securing exhaust flex joint to exhaust manifold Disconnect exhaust pipe from manifold 11 Remove torque converter dust cover Mark torque converter and drive plate with chalk for reas sembly Rotate engine clockwise and remove torque converter mounting bolts 12 Remove engine m
58. ft Ibs LOW REVERSE BAND REAR To adjust low reverse band proceed as follows 1 Loosen and back off locknut approximately 5 turns 2 Using an inch pound torque wrench tighten adjusting screw to 5 41 in Ibs true torque 3 Back off adjusting screw the number of turns listed under Specifications This chart is located at the rear of this section 4 Tighten locknut to 14 N m 10 ft 105 HYDRAULIC CONTROL PRESSURE ADJUSTMENTS LINE PRESSURE An incorrect throttle pressure setting will cause incorrect line pressure readings even though line pressure adjustment is correct Always inspect and correct throttle pressure adjustment before adjusting the line pressure The approximate adjustment for line pressure is 1 5 16 inches measured from valve body to inner edge of adjusting nut However due to manufactur ing tolerances the adjustment can be varied to obtain specified line pressure The adjusting screw may be turned with an Allen wrench One complete turn of adjusting screw changes closed throttle line pressure approximately 1 2 3 psi Turning adjusting screw counterclockwise increases pressure and clockwise decreases pressure TRANSAXLE AND POWER TRANSFER UNIT 21 69 THROTTLE PRESSURE Throttle pressures cannot be tested accurately therefore the adjustment should be measured if a malfunction is evident 1 Insert gauge pin of Tool C 3763 between the throttle lever cam and kickdown valve 2 By
59. id level check is accurate The engine should be running at idle speed for at least one minute with the vehicle on level ground This will assure complete oil level sta bilization between differential and transmis sion The fluid should be at 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 fluid level indicator Fig 8 D 80b04ee2 Fig 8 Fluid Level Indicator Markings 1 TRANSAXLE DIPSTICK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid As in any hydraulic system air bubbles make the fluid spongy therefore pressures will be low and build up slowly Improper filling can also raise the fluid level too high When the transaxle has too much fluid the 21 18 TRANSAXLE AND POWER TRANSFER UNIT SERVICE PROCEDURES Continued gears churn up foam and cause the same conditions which occur with a low fluid level In either case the air bubbles can cause overheat ing fluid oxidation and varnishing This can inter fere with normal valve dutch and servo operation Foaming can also result in fluid escaping from the transaxle dipstick where it may be mistaken for a leak Along with fluid level it is important to check the condition of the fluid When the fluid smells burned and is contaminated with metal or friction material particles a complete transaxle o
60. if the transaxle slips in any two forward gears the rear clutch is slipping Using the same procedure the rear dutch and front dutch are applied in D third gear If the tran saxle slips in third gear either the front clutch or the rear dutch is slipping By selecting another gear that does not use one of those units the unit that is slip ping can be determined If the transaxle also slips in reverse the front clutch is slipping If the transaxle does not slip in reverse the rear clutch is slipping The process of elimination can be used to detect any unit that slips and to confirm proper operation of good units Road testing can usually diagnose slip ping units although the actual cause of the problem may not be detected Practically any condition can be caused by leaking hydraulic circuits or sticking valves Therefore unless the condition is obvious the tran saxle should never be disassembled until hydraulic pressure tests have been performed HYDRAULIC PRESSURE TESTS Pressure testing is a very important step in the diagnostic procedure These tests usually reveal the cause of most transaxle problems Before performing pressure tests check fluid level and condition as well as control cable adjustments Fluid must be at operating temperature 150 200 degrees F Install an engine tachometer Raise vehicle on a hoist that allows front wheels to turn and position tachometer so it can be read Disconnect throttle cabl
61. il Pump Clearances Outer Gear To Pocket 0 045 0 141mm 0 0018 0 0056 in Outer Gear Side Clearance 0 020 0 046mm 0 0008 0 0018 in Inner Gear Side Clearance 0 020 0 046mm 0 0008 0 0018 in Tapered Roller Bearing Settings Differential Assembly 6 to 12 165 Drag Torque Output Hub 0 to in Ibs Drag Torque Transfer Shaft 0 002 to 0 010 in End Play Overall Drag At Output Hub 16 Ibs Drag Torque Thrust Washers Reaction Shaft Support No 1 1 55 1 60 mm 061 063 in TRANSAXLE AND POWER TRANSFER UNIT 21 81 Thrust Washers Rear Clutch Retainer No 2 1 55 1 60 mm 061 063 in Output Shaft No 3 Select 1 98 2 03 mm 077 080 in Output Shaft No 3 Select 2 15 2 22 mm 085 087 in Output Shaft No 3 Select 2 34 2 41 mm 092 095 in Front Annulus No 4 2 95 3 05 mm 116 120 in Front Carrier Nos 5 amp 6 1 22 1 28 mm 0948 050 in Sun Gear Front No 7 0 85 0 91 mm 033 036 in Sun No 8 0 85 0 91 mm 033 036 in Rear Carrier Nos 9 amp 10 1 22 1 28 mm 0948 050 in Rev Drum No 11 1 55 1 60 mm 061 063 in 31TH TRANSAXLE TORQUE SPECIFICATIONS DESCRIPTION TORQUE Bell Housing Cover Bolts 12 105 in Ibs Cooler Line Clamps 2 N m 18 in Ibs Diff
62. increase to 80 to 88 psi as lever is moved counter clockwise 6 Kickdown release is pressurized only in direct drive and should be same as line pressure within 3 psi up to kickdown point NS DIAGNOSIS AND TESTING Continued Fig 4 Governor Pressure Tap 1 GOVERNOR PRESSURE PLUG TRANSAXLE AND POWER TRANSFER UNIT 7 This tests pump output pressure regulation and condition of rear clutch front clutch and hydraulic circuits TEST FOUR SELECTOR IN REVERSE 1 Attach 300 psi gauge C 3292SP to low reverse port 2 Operate engine at 1600 rpm for test 3 Move selector lever on transaxle four detents forward from full rearward position This is selector R position 4 Low reverse pressure should read 180 to 220 psi with throttle lever clockwise Pressure should gradually increase to 260 to 300 psi as lever is moved counterclockwise 5 This tests pump output pressure regulation 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 This tests for leakage into rear servo due to case porosity which can cause reverse band burn out TEST RESULT INDICATIONS 1 If proper line pressure minimum to maximum is found in any one test the pump and pressure reg ulator are working properly 2 Low pressure in D 1 and 2 but correct pres sure in R indicates rear clutch cir
63. ing 1 FRONT CLUTCH RETAINER 1 WAVED SNAP RING 2 CLUTCH PLATES 2 SCREWDRIVER 3 DRIVING DISCS 3 FRONT CLUTCH ASSEMBLY PR2232 PR2230 Fig 65 Thick Steel Plate and Waved Snap Ring Fig 67 Front Clutch Return Spring Snap Ring 1 WAVED SNAP RING 1 COMPRESSOR TOOL C 3575 A 2 THICK STEEL PLATE 2 FRONT CLUTCH RETAINER 3 FRONT CLUTCH RETAINER 3 SNAP RING 4 SNAP RING PLIERS 21 40 TRANSAXLE AND POWER TRANSFER UNIT OH n T NS DISASSEMBLY AND ASSEMBLY Continued MEASURING PLATE CLEARANCE Fig 68 Front Clutch Return Spring and Piston PR2234 1 LIP SEALS 2 PISTON Fig 69 Measuring Front Clutch Plate Clearance 3 RETURN SPRING RETAINER 1 FEELER GAUGE 4 SNAP RING 2 FRONT CLUTCH ASSEMBLY 5 PISTON RETURN SPRING 6 FRONT CLUTCH RETAINER ASSEMBLY To reassemble reverse the above procedure NS n TA R TRANSAXLE AND POWER TRANSFER UNIT 21 41 DISASSEMBLY AND ASSEMBLY Continued REAR CLUTCH ASSEMBLY 80bdbd41 Rear Clutch Assembly 1 SNAP RING SELECT 8 SNAP RING 2 REACTION PLATE 9 PISTON 3 CLUTCH DISC 10 SPRING 4 CLUTCH PLATE 11 SNAP RING WAVE 5 REACTION PLATE 12 SEAL 6 CLUTCH RETAINER 13 SEAL 7 INPUT SHAFT 21 42 TRANSAXLE AND POWER TRANSFER UNIT r F h h o sn 5 DISASSEMBLY AND ASSEMBLY Continued DISASSEMBLY Fig 72 Piston
64. ing Leak Paths 1 PUMP SEAL 2 PUMP VENT 3 PUMP BOLT 4 PUMP GASKET 5 CONVERTER HOUSING 6 CONVERTER 7 REAR MAIN SEAL LEAK TRANSAXLE AND POWER TRANSFER UNIT fluid spilled during factory fill or fill after repair Converter housing leaks have several potential sources Through careful observation a leak source can be identified before removing the transmission for repair Pump seal leaks tend to move along the drive hub and onto the rear of the converter Fig 6 Pump o ring or pump body leaks follow the same path as seal leak Pump attaching bolt leaks are generally deposited on the inside of the converter housing and not on the converter itself Pump seal or gasket leaks usually travel down the inside of the converter hous ing Fig 6 TORQUE CONVERTER LEAKAGE Possible sources of torque converter leakage are e Torque converter weld leaks at the outside diam eter weld Fig 7 e Torque converter hub weld Fig 7 SERVICE PROCEDURES FLUID LEVEL AND CONDITION NOTE The transmission and differential sump have a common oil sump with a communicating opening between the two 21 17 RH254 Fig 7 Converter Leak Points Typical 1 OUTSIDE DIAMETER WELD 2 TORQUE CONVERTER HUB WELD 3 STARTER RING GEAR 4 LUG FLUID LEVEL CHECK The torque converter fills in both the P Park and N Neutral positions Place the selector lever in P Park to be sure that the flu
65. ion After confirming the park gate position turn the ignition switch If the starter will operate the park gate position is correct Move the shift lever into the neutral N position If the starter will operate in this position the linkage is properly adjusted If the starter fails to operate in either position linkage adjustment is required 1 Park the vehicle on level ground and set the parking brake NS 2 Place the gearshift lever in park P gate posi tion and remove key 3 Loosen the cable adjustment screw at the tran saxle operating lever Fig 172 4 Pull the transaxle operating lever fully forward to the park detent position 5 Release the park brake then rock the vehide to assure it is in park lock Reset the park brake 6 Tighten the cable adjustment screw to 8 70 in 106 Gearshift cable should now be properly adjusted 7 Verify PRNDL indicator still displays the corre sponding gear completely If not readjustment of PRNDL may be required 8 Check adjustment by using the preceding pro cedure 9521 159 Fig 172 Gearshift Cable Adjustment 1 SHIFT CABLE ADJUSTMENT 2 SHIFT CABLE THROTTLE PRESSURE LINKAGE ADJUSTM ENT The throttle pressure rod adjustment is very important to proper transaxle operation This adjust ment positions a valve which controls shift speed shift quality and part throttle downshift sensitivity If the setting is too short early shifts a
66. ms have not been sup ported to the satisfaction of DaimlerChrysler and these additives must not be used The use of trans mission sealers should also be avoided since they may adversely affect the integrity of transmission Seals TORQUE CONVERTER CLUTCH A torque converter dutch is standard on all vehi des The torque converter clutch is activated only in direct drive and is controlled by the engine electron ics A solenoid on the valve body is powered by the powertrain control module to activate torque con verter dutch HYDRAULIC CONTROL SYSTEM The hydraulic control system makes the transaxle fully automatic and has four important functions to 21 4 perform The components of any automatic control system may be grouped into the following basic groups The pressure supply system the pressure regulat ing valves the flow control valves the clutches and band servos Taking each of these basic groups or systems in turn the control system may be described as follows PRESSURE SUPPLY SYSTEM The pressure supply system consists of an oil pump driven by the engine through the torque converter The single pump furnishes pressure for all the hydraulic and lubrication requirements Oil pump housing assemblies are available with prese lected pump gears PRESSURE REGULATING VALVES The pressure regulating valve controls line pres sure dependent on throttle opening The governor valve transmits regulated pressure to
67. nd Faulty line before installing new converter DELAYED ENGAGEMENT 1 Fluid Level Low 1 Correct level and check for leaks FROM NEUTRAL TO 2 Filter Clogged 2 Change filter DRIVE OR REVERSE 3 Gearshift Linkage Misadjusted 3 Adjust linkage and repair linkage if worn or damaged 4 Rear Band Misadjusted 4 Adjust band 5 Valve Body Filter Plugged 5 Replace fluid and filter If oil pan and old fluid were full of clutch disc material and or metal particles overhaul will be necessary 6 Oil Pump Gears Worn Damaged 6 Remove transmission and replace oil pump 7 Hydraulic Pressure Incorrect 7 Perform pressure test remove transmission and repair as needed 8 Reaction Shaft Seal Rings 8 Remove transmission remove oil pump Worn Broken and replace seal rings 9 Rear Clutch Input Shaft Rear 9 Remove and disassemble transmission Clutch Seal Rings Damaged and repair as necessary 10 Governor Valve Stuck 10 Remove and inspect governor components Replace worn or damaged parts 11 Regulator Valve Stuck 11 Clean 5 5 AND POWER TRANSFER UNIT 21 7 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION NO DRIVE RANGE 1 Fluid Level Low 1 Add fluid and check for leaks if drive is REVERSE OK restored 2 Gearshift Linkage Cable 2 Repair or replace linkage components Loose Misadjusted 3 Rear Clutch Burnt 3 Remove and disassemble transmi
68. nd slippage between shifts may If the setting is too long shifts may be delayed and part throttle downshifts may be very sensitive With engine at operating temperature adjust idle speed of engine using a tachometer Refer to Group 14 Fuel System for idle speed Specifications and adjustment ROD ADJUSTMENT PROCEDURE 1 Perform transaxle throttle pressure adjustment while engine is at normal operating temperature 2 Loosen adjustment swivel lock screw 3 To insure proper adjustment swivel must be free to slide along flat end of throttle rod Disassem NS ADJ USTMENTS Continued ble and clean or repair parts to assure free action if necessary 4 Hold transaxle throttle lever firmly toward engine against its internal stop Tighten swivel lock screw to 11 100 in Ibs 5 The adjustment is finished and linkage back lash was automatically removed by the preload spring 6 If lubrication is required see Group 0 Lubrica tion BAND ADJUSTM ENT KICKDOWN BAND FRONT The kickdown band adjusting screw is located on left side top front of the transaxle case 1 Loosen locknut and back off nut approximately five turns Test adjusting screw for free turning in the transaxle case 2 Using wrench tighten adjusting screw to 8 72 in 105 3 Back off adjusting screw the number of turns listed in Specifications Hold adjusting screw in this position and tighten locknut to 47 N m 35
69. nsfer shaft and out put shaft bearings 11 Use Tool L 4434 to remove the retaining nut and washer To remove the output shaft gear use Tool L 4407 12 Remove the two gauging shims and install the proper shim combination making sure to install the 12 65 13 15 or 13 65 mm shim first Use grease to hold the shims in place Install the output shaft gear and bearing assembly 13 Install the retaining nut and washer and torque to 271 N m 200 ft 105 14 Using an inch pound torque wrench check the turning torque The torque should be between 3 and 8 inch pounds 15 If the turning torque is too high install a 05mm 002 inch thicker shim If the turning torque is too low install a 05 mm 002 inch thinner shim Repeat until the proper turning torque is 3 to 8 inch pounds DIFFERENTIAL BEARING 1 Position the transaxle assembly vertically on the support stand differential bearing retainer side up 2 Install Tool L 4436A into the differential and onto the pinion mate shaft 3 Rotate the differential at least one full revolu tion to ensure the tapered roller bearings are fully seated 4 Using Tool L 4436A and an inch pound torque wrench check the turning torque of the differential mm 13 65 1 34 13 65 1 24 13 65 1 19 13 65 1 14 13 65 1 09 13 65 1 04 13 65 99 13 65 94 13 15 1 39 13 15 1 34 13 15 1 29 13 15 1 24 13 15 1 19 13 15 1 14 13 15 1 09 13 15 1 04 13 15
70. or support and removed from the transaxle for reconditioning or replacement When cleaning or assembling the governor make sure the governor valves move freely in the bores of the governor body COOLER BYPASS VALVE The cooler bypass valve Fig 1 is designed to bypass the transaxle oil cooler circuit in cold weather conditions or when circuit restriction exceeds 25 30 p s i The valve consists of an integrated check ball and spring and a return tube to carry bypassed oil back to the pump The bypass valve is mounted to the valve body transfer plate and is sealed with a rubber o ring seal Fig 2 DIAGNOSIS AND TESTING TRANSAXLE PRELIMINARY DIAGNOSIS Automatic transaxle malfunctions are usually caused by the following general conditions NS DIAGNOSIS AND TESTING Continued 806596426 Fig 1 Cooler Bypass Valve 1 BYPASS VALVE 2 TUBE Improper fluid level condition Poor engine performance Improper engine or transaxle adjustments Transaxle hydraulic malfunctions e Transaxle mechanical malfunctions Diagnosis of transaxle problems should always begin with checking the easily accessible variables e Fluid level and condition e Gearshift cable adjustment e Throttle valve cable adjustment TRANSAXLE AND POWER TRANSFER UNIT 21 5 2 80bdbd19 Fig 2 Bypass Valve Location If Equipped 1 TRANSFER PLATE 2 BYPASS VALVE 3 SEAL After verifying
71. ount bracket from front crossmember 13 Remove front mount insulator through bolt and bellhousing bolts 14 Position transaxle jack Fig 13 15 Remove rear engine mount shield 21 21 9321 228 Fig 13 Transaxle Jack 1 DIFFERENTIAL COVER 2 ENGINE 3 TRANSMISSION JACK 4 TRANSAXLE 16 Remove rear engine mount bracket bolts and bracket 17 Remove left engine mount thru bolt 18 Remove left engine mount from transaxle 19 Remove starter Remove lower bell housing bolts 20 Carefully work transaxle and torque converter assembly rearward off engine block dowels and dis engage converter hub from end of crankshaft Attach a small C clamp to edge of bell housing This will hold torque converter in place during tran saxle removal Lower transaxle and remove assem bly from under the vehicle 21 To remove torque converter assembly remove C clamp from edge of bellhousing and slide converter out of transaxle INSTALLATION 1 When installing transaxle reverse the above procedure 2 torque converter was removed from transaxle be sure to align pump inner gear pilot flats with torque converter impeller hub flats 3 Adjust gearshift and throttle cables 4 Refill transaxle with Mopar ATF 3 Automatic Transmission Fluid Type 7176 FRONT PUMP OIL SEAL The pump oil seal can be replaced without remov ing the pump and reaction shaft support assembly from the transaxle case
72. pushing in on tool compress kickdown valve against its spring so throttle valve is com pletely bottomed inside the valve body 3 While compressing spring turn throttle lever Stop screw with adapter C 4553 Turn until head of screw touches throttle lever tang with throttle lever cam touching tool and throttle valve bottomed Be sure adjustment is made with spring fully com pressed and valve bottomed in the valve body BEARING ADJUSTMENT PROCEDURES 1 Take extreme care when removing and install ing bearing cups and cones Use only an arbor press for installation as a hammer may not properly align the bearing cup or cone Burrs or nicks on the bearing seat will give a false end play reading while gauging for proper shims Improperly seated bearing cup and cones are subject to low mile age failure 2 Bearing cups and cones should be replaced if they show signs of pitting or heat distress 3 If distress is seen on either the cup or bearing rollers both cup and cone must be replaced NOTE Bearing end play and drag torque specifica tions must be maintained to avoid premature bear ing failures 4 Used original bearing may lose up to 50 per cent of the original drag torque after break in NOTE bearing adjustments must be made with no other component interference or gear inter mesh except the transfer gear bearing 5 Refer to the conversion chart in specifications to convert inches to millimeter measuremen
73. r L 4406 3 Remove Transfer Shaft Gear Bearing Cone 1 SPECIAL TOOL L 4406 1 2 TRANSFER SHAFT GEAR TRANSAXLE AND POWER TRANSFER UNIT 21 49 PR2265A Fig 100 Install Transfer Shaft Gear Bearing Cone 1 PRESS 2 HANDLE C 4171 3 SPECIAL TOOL L 4410 4 TRANSFER SHAFT GEAR 5 BEARING CONE 9521 113 Fig 101 Governor Support Retainer 1 TRANSFER SHAFT 2 OUTPUT SHAFT GEAR 3 BEARING CUP 4 GOVERNOR SUPPORT RETAINER 21 50 PR2267A Fig 102 Remove Governor Support Retainer Bearing Cup 1 PRESS 2 HANDLE C 4171 WITH SPECIAL TOOL L 4517 3 GOVERNOR SUPPORT RETAINER TRANSAXLE AND POWER TRANSFER UNIT DISASSEMBLY AND ASSEMBLY Continued NS Fig 104 Low Reverse Band Anchor Pin 1 LOW REVERSE BAND ANCHOR PIN 2 OUTPUT SHAFT GEAR PR2268A Fig 103 Install Governor Support Retainer Bearing Cup 1 PRESS 2 HANDLE C 4171 3 SPECIAL TOOL L 4520 4 GOVERNOR SUPPORT RETAINER 5 BEARING CUP 9521 117 Fig 105 Governor Assembly 1 TRANSFER SHAFT 2 OUTPUT SHAFT GEAR 3 GOVERNOR ASSEMBLY 5 TRANSAXLE AND POWER TRANSFER UNIT 21 51 DISASSEMBLY AND ASSEMBLY Continued D lt NSS SY 2 9521 112 Fig 106 Transfer Shaft Bearing Snap Ring 1 SNAP RING PLIERS 2 SNAP RING 3 OUTPUT SHAFT GEAR 4 TRANSFER SHAFT Fig 108 Remo
74. rt Plug Loose 3 Tighten to correct torque Replace plug Loose Damaged or reseal if leak persists 4 Pan Gasket Leaks 4 Tighten pan screws to 150 inch pounds If leaks persist replace gasket Do no over tighten screws 5 Valve Body Manual Lever Shaft 5 Replace shaft seal Seal Leaks Worn 6 Rear Bearing Access Plate Leaks 6 Replace gasket Tighten screws OIL LEAKS ITEMS LISTED REPRESENT POSSIBLE LEAK POINTS AND SHOULD ALL BE CHECKED 7 Gasket Damaged or Bolts are 7 Replace bolts or gasket or tighten both Loose 8 Adapter Extension Gasket 8 Replace gasket Damaged Leaks Damaged 9 Neutral Switch Leaks Damaged 9 Replace switch and gasket 10 Converter Housing Area Leaks 10 Check for leaks at seal caused by worn seal or burr on converter hub cutting seal worn bushing missing oil return oil in front pump housing or hole plugged Check for leaks past O ring seal on pump or past pump to case bolts pump housing porous oil coming out vent due to overfill or leak past front band shaft access plug 11 Pump Seal Leaks Worn 11 Replace seal Damaged 12 Torque Converter Weld 12 Replace converter Leak Cracked Hub 13 Case Porosity Leaks 13 Replace case ROAD TEST Prior to performing a road test check the fluid level and throttle valve cable adjustments During the road test the transaxle should be oper ated in each position to check for slipping and any variation in shifting If
75. solenoid relay and wiring for LOCKS UP IN SECOND Shorted Open continuity shorts or grounds Replace AND OR THIRD GEAR solenoid and relay if faulty Repair wiring and connectors as necessary HARSH 1 2 OR 2 3 Lockup Solenoid Malfunction Remove valve body and replace solenoid SHIFTS assembly NO START IN PARK OR 1 Gearshift Linkage Cable 1 Adjust linkage cable NEUTRAL Misadjusted 2 Neutral Switch Wire Open Cut 2 Check continuity with test lamp Repair as required 3 Neutral Switch Faulty 3 Refer to service section for test and replacement procedure 4 Neutral Switch Connect Faulty 4 Connectors spread open Repair 5 Valve Body Manual Lever 5 Inspect lever assembly and replace if Assembly Bent Worn Broken damaged 21 12 TRANSAXLE AND POWER TRANSFER UNIT NS DIAGNOSIS AND TESTING Continued POSSIBLE CAUSES CORRECTION 1 Direct Clutch Pack front clutch 1 Disassemble unit and rebuild clutch pack CONDITION NO REVERSE OR SLIPS IN REVERSE Worn 2 Rear Band Misadjusted 2 Adjust band 3 Front Clutch Malfunctioned Burnt 3 Air pressure test clutch operation Remove and rebuild if necessary 1 Fluid Lines and Fittings Loose 1 Tighten fittings If leaks persist replace Leaks Damaged fittings and lines if necessary 2 Filler Tube where tube enters 2 Replace tube seal Inspect tube for cracks in tube case Leaks Damaged 3 Pressure Po
76. ssion and rear clutch and seals Repair replace worn or damaged parts as needed 4 Valve Body Malfunction 4 Remove and disassemble valve body Replace assembly if any valves or bores are damaged 5 Transmission Overrunning Clutch 5 Remove and disassemble transmission Broken Replace overrunning clutch 6 Input Shaft Seal Rings Worn 6 Remove and disassemble transmission Damaged Replace seal rings and any other worn or damaged parts 7 Front Planetary Failed Broken 7 Remove and repair NO DRIVE OR REVERSE 1 Fluid Level Low 1 Add fluid and check for leaks if drive is VEHICLE WILL NOT restored MOVE 2 Gearshift Linkage Cable 2 Inspect adjust and reassemble linkage Loose Misadjusted as needed Replace worn damaged parts 3 Filter Plugged 3 Remove and disassemble transmission Repair or replace failed components as needed Replace filter If filter and fluid contained clutch material or metal particles an overhaul may be necessary Perform lube flow test Flush oil Replace cooler as necessary 4 Oil Pump Damaged 4 Perform pressure test to confirm low pressure Replace pump body assembly if necessary 5 Valve Body Malfunctioned 5 Check press and inspect valve body Replace valve body as assembly if any valve or bore is damaged Clean and reassemble correctly if all parts are in good condition 6 Transmission Internal Component 6 Remove and disassemble transmission Damaged Repair or replace f
77. ssures to Valve Stuck Closed Loose Output determine cause Correct as required Shaft Support or Governor Housing Bolts Leaking Seal Rings or Valve Problem i e Stuck 1 2 Shift Valve Gov Plug 4 Front Band Out of Adjustment 4 Adjust Band 5 Clutch or Servo Malfunction 5 Air pressure check operation of clutches and bands Repair faulty component CREEPS IN NEUTRAL 1 Gearshift Linkage Misadjusted 1 Adjust linkage 2 Rear Clutch Dragging Warped 2 Disassemble and repair Welded 3 Valve Malfunction 3 Perform hydraulic pressure test to determine cause and repair as required 21 10 TRANSAXLE AND POWER TRANSFER UNIT 5 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION BUZZING NOISE 1 1 Fluid Level Low 00000 Level Low 1 Add 1 Add fluid and check for leaks and check for leaks 2 III M Cable Misassembled 2 Route cable away ILE engine and bell housing 3 Valve Body Misassembled 3 Remove disassemble inspect valve body Reassemble correctly if necessary Replace assembly if valves or springs are damaged Check for loose bolts or screws 4 Pump Passages Leaking 4 Check pump for porous casting scores on mating surfaces and excess rotor clearance Repair as required Loose pump bolts 5 Cooling System Cooler Plugged 5 Flow check cooler circuit Repair as needed S Replace SLIPS IN REVERSE ONLY 5 Hydrauli
78. the valve body in conjunction with vehicle speed to control upshift and downshift The throttle valve transmits regulated pressure to the transaxle dependent on throttle position to con trol upshift and downshift FLOW CONTROL VALVES The manual valve provides the different transaxle drive ranges as selected by the vehide operator The 1 2 shift valve automatically shifts the tran saxle from first to second or from second to first depending on the vehicle operation The 2 3 shift valve automatically shifts the tran saxle from second to third or from third to second depending on the vehicle operation The kickdown valve makes possible a forced down shift from third to second second to first or third to first depending on vehicle speed This can be done by depressing the accelerator pedal past the detent feel near wide open throttle The shuttle valve has two separate functions and performs each independently of the other The first is providing fast release of the kickdown band and smooth front clutch engagement when a lift foot upshift from second to third is made The second function is to regulate the application of the kick down servo and band when making third to second kickdown The by pass valve provides for smooth application of the kickdown band on 1 2 upshifts The torque converter clutch solenoid allows for the electronic control of the torque converter clutch It also disengages the torque converter at closed
79. tial bearing retainer using Tool 5052 and C 4171 Seal the retainer to the TRANSAXLE AND POWER TRANSFER UNIT 21 71 housing with MOPAR Adhesive Sealant and torque bolts to 28 250 in Ibs DIFFERENTIAL BEARING SHIM CHART SHIM THICKNESS MM INCH 0 0386 0 0402 0 0418 0 0434 0 0449 0 0465 0 0481 0 0497 0 0512 0 0528 7 Using Tool L 4436A and an inch pound torque wrench recheck the turning torque of the differen tial The turning torque should be between 5 and 18 inch pounds TRANSFER SHAFT BEARING 1 Use Tool L 4434 to remove the retaining nut and washer Remove the transfer shaft gear using Tool L 4407 2 Install a 2 29 mm 090 inch and a 1 39 mm 055 inch gauging shims on the transfer shaft behind the governor support 3 Install transfer shaft gear and bearing assem bly and torque the nut to 271 N m 200 ft 5 4 To measure bearing end play 4 Attach Tool L 4432 to the transfer gear 5 Mount a steel ball with grease into the end of the transfer shaft 6 Push and pull the gear while rotating back and forth to insure seating of the bearing rollers 21 72 ADJ USTMENTS Continued 7 Using a dial indicator measure transfer shaft end play 8 Refer to the Transfer Bearing Shim Chart for the required shim combination to obtain the proper bearing setting 9 Use Tool L 4434 to remove the retaining nut and washer Remove the transfer shaft gear using Tool L 4407
80. ts Refer to bearing shim chart for proper shim thicknesses OUTPUT SHAFT BEARING 1 With output shaft gear removed install a 13 65 mm 537 inch and a 1 34 mm 053 inch gauging shims on the planetary rear annulus gear hub using grease to hold the shims in place The 13 65 mm shim has a larger inside diameter and must be installed over the output shaft first The 1 34 mm shim pilots on the output shaft 2 Install output shaft gear and bearing assembly torque to 271 N m 200 ft Ibs 3 To measure bearing end play 4 Attach Tool L 4432 to the output shaft gear 21 70 TRANSAXLE AND POWER TRANSFER UNIT NS ADJ USTMENTS Continued 5 Mount a steel ball with grease into the end of End Play the output shaft i with 13 65 6 Push and pull the gear while rotating back and forth to insure seating of the bearing rollers 7 Using a dial indicator mounted to the tran saxle case measure output shaft end play 8 Once bearing end play has been determined mm and 1 34 mm gauging shims Required Shim Total installed Combination Thickness refer to the output shaft bearing shim chart 9 The 12 65 mm 498 inch 13 15 mm 518 inch or 13 65 mm 537 inch shims are always installed first These shims have lubrication slots which are necessary for proper bearing lubrica tion 10 Shims thinner than 12 65 mm listed in the chart are common to both the tra
81. ve or Install Transfer Shaft and Bearing Retainer Assembly Using Tool L 4512 1 OUTPUT SHAFT GEAR 2 O RING 3 SPECIAL TOOL L 4512 4 BEARING RETAINER ASSEMBLY 5 TRANSFER SHAFT Q 9521 119 Fig 107 Remove Transfer Shaft and Bearing 9521 111 Retainer Assembly 1 SPECIAL TOOL L 4512 Fig 109 Transfer Shaft and Bearing Retainer 2 SPECIAL TOOL L 4437 1 O RING 3 SPECIAL TOOL C 3752 2 TRANSFER SHAFT 3 BEARING CONE 4 TRANSFER SHAFT BEARING RETAINER 21 52 PR2275 Fig 110 Remove Transfer Shaft Bearing Cone 1 TOOL C 293 52 2 TRANSFER SHAFT 3 TOOL C 293 PA 4 VISE TRANSAXLE AND POWER TRANSFER UNIT DISASSEMBLY AND ASSEMBLY Continued PR2276A Fig 111 Install Transfer Shaft Bearing Cone PRESS SPECIAL TOOL L 4411 BEARING CONE TRANSFER SHAFT NS PR2279C 3 Fig 112 Remove Transfer Shaft Bearing 1 SPECIAL TOOL L 4518 2 TRANSFER SHAFT BEARING RETAINER 3 O RING 4 BEARING CUP PR2280C Fig 113 Install Transfer Shaft Bearing Cup PRESS HANDLE C 4171 SPECIAL TOOL L 4520 TRANSFER SHAFT BEARING RETAINER Oo Q I O RING NS DETERMINING SHIM THICKNESS Shim thickness need be determined only if any of the following parts are replaced Transaxle case Transfer shaft Transfer shaft gear Transfer shaft bearings Governor support retainer Transfer sh
82. ve or Install Valve Body Screws SCREWDRIVER HANDLE 1 2 VALVE BODY SCREWS 16 Fig 52 Steel Ball Locations 3 VALVE BODY 1 MANUAL VALVE 4 SPECIAL TOOL L 4553 2 STEEL BALLS 8 3 STEEL BALLS 21 32 TRANSAXLE AND POWER TRANSFER UNIT DISASSEMBLY AND ASSEMBLY Continued NS 4 PR2190 Fig 53 Remove or Install Throttle Shaft E Clip 1 MANUAL VALVE LEVER ASSEMBLY 2 THROTTLE VALVE LEVER ASSEMBLY 3 SCREWDRIVER 4 E CLIP Fig 55 Manual Valve Lever Assembly 1 THROTTLE VALVE LEVER ASSEMBLY 2 MANUAL VALVE LEVER ASSEMBLY 3 VALVE BODY e PR2191 Fig 54 Throttle Shaft E Clip Washer and Seal MANUAL VALVE LEVER ASSEMBLY OIL SEAL E CLIP THROTTLE VALVE LEVER ASSEMBLY WASHER Qn Q N PR2193 3 Fig 56 Throttle Valve Lever Assembly 1 THROTTLE VALVE LEVER ASSEMBLY 2 MANUAL VALVE 3 VALVE BODY NS 1 TRANSAXLE AND POWER TRANSFER UNIT 21 33 DISASSEMBLY AND ASSEMBLY Continued Fig 57 Manual Valve 1 MANUAL VALVE 2 VALVE BODY Fig 58 Pressure Regulator and Adjusting Screw Bracket 1 SCREWDRIVER HANDLE 2 PRESSURE REGULATOR SPRING RETAINER AND ADJUSTING SCREW BRACKET 3 VALVE BODY 4 SCREWS PR2196A Fig 59 Pressure Regulators and Manual Controls 1 VALVE BODY 7 SPRING 2 LINE PRESSURE VALVE 8 KICKDOWN VALVE 3 SPRING 9 SPRIN
83. vehicle operates at high speeds but has poor acceleration the converter s overrunning clutch may be slipping If acceleration is normal but high throt tle opening is needed for high speeds the stator clutch may have seized 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 condition is far advanced an overhaul will probably be necessary to restore normal operation In most cases the dutch or band that is slipping can be determined by noting the transaxle operation in all selector positions and then comparing which internal units are applied in those positions The Ele ments in Use Chart provides a basis for road test analysis NS DIAGNOSIS AND TESTING Continued TRANSAXLE AND POWER TRANSFER UNIT 21 13 CLUTCHES BANDS LEVER POSITION START SAFETY PARK SPRAG FRONT REAR OVER RUNNING KICKDOWN FRONT LOW REV REAR LOCKUP PARK X X R REVERSE N NEUTRAL D DRIVE First Second Third 2 SECOND First Second 1 Low The rear dutch is applied in both the D first gear and 1 first gear positions Also the overrunning dutch is applied in D first gear and the low reverse band is applied in 1 first gear position If the tran saxle slips in D range first gear but does not slip in 1 first gear the overrunning dutch is slipping Simi larly
84. verhaul is needed Be sure to examine the fluid on the dipstick closely If there is any doubt about its condition drain out a sample for a double check FLUID CONDITION Along with fluid level it is important to check the condition of the fluid When the fluid smells burned and is contaminated with metal or friction material particles a complete transaxle recondition is needed Be sure to examine the fluid on the dipstick closely If there is any doubt about its condition drain out a sample for a double check ATF43 Automatic Transmission Fluid Type 7176 when new is red in color The is dyed red so it can be identified from other fluids used in the vehide such as engine oil or antifreeze The red color is not permanent and is not an indicator of fluid condition As the vehicle is driven the ATF will begin to look darker in color and may eventually become brown This is normal A dark brown black fluid accompanied with a burnt odor and or deterioration in shift quality may indicate fluid deterioration or transmission component failure After the fluid has been checked seat the dipstick fully to seal out water and dirt TRANSAXLE FLUID AND FILTER SERVICE NOTE Refer to the maintenance schedules in Group 0 Lubrication and Maintenance or the vehi cle owner s manual for the recommended mainte nance fluid filler change intervals for this transaxle NOTE Only fluids of the type labeled

akpp/31TH 2000

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