MANUAL DE TRANSMISIONES CHRYSLER AÑOS 90 PRINCIPALMENTE

8/13/2019 MANUAL DE TRANSMISIONES CHRYSLER AOS 90 PRINCIPALMENTE

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TRANSAXLE

CONTENTS

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41TE FOUR SPEED AUTOM ATIC TRANSAXLE . 8541TE FOUR SPEED TRANSAXLE HYDRAULIC

SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 17 041TE ON-BOARD DIAGNOSTICS . . . . . . . . . . 14 5A-523, A-543, and A-568 MANUAL

TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 18 3THREE SPEED TORQUEFLITE AUTOMATIC

TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . .. 35THREE SPEED TRANSAXLE HYDRAULIC

SCHEM ATICS . . . . . . . . . . . . . . . . . . . . . . . . 162

A-523, A-543, and A-568 MANUAL TRANSAXLE

INDEX

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Bearing Adjustment Procedure . . . . . . . . . . . . .. 31Differential Bearing Preload Adjustment . . . . . . .. 33Gearshift Linkage Adjustment (Cable Operated) . . 2General Information . . . . . . . . . . . . . . . . . . . . . . . . 1

In-Car Transaxle Disassemble/Assemble . . . . . . . . 4Out of Car TransaxleDisassemble and Assemble . 6Subassembly-Recondition . . . . . . . . . . . . . . . . . . 15Transaxle Removal and Installation . . . . . . . . . . .. 5

GENERAL INFORMATIONSafety goggles should be worn at all times

when working on these transaxles. A l l m a n u a l

t r a n sa x le s u se SAE 5W-30 e n g in e o i l, m e et in g SG

an d/or SG -CC qua lifications, as the lubricant in orderto reduce wear.

This 5-speed manual transaxles combine gear reduc-

tion, rat io selection, and differential functions in one

unit . I t is housed in a die-cast aluminum case (Fig. 1).

All shift forks are cast iron.Do not interchange 1-2

or 5th shift fork padswith the 3-4 shift fork pads.

All sy n ch r on iz er s u se a winged strut d es ig n t h a t

prevents the struts from popping out of position.

If any synchronizer is to bedisassembled,markall parts so that they will be reassembled in the

same position.

CAUTION: 1-2 synchronizer assembly components

must NOT be interchanged with any other synchro-

nizer assembly. Do not interchange with previous

model years transaxles; they will NOT function cor-

rectly.

A-523 AND A-543 MANUAL TRANSAXLE

The A-523 ma nua l tr a nsa xle is used in a ll 4-cylinder

applications, except high output turbocharged engines.Th e A-543 m a n u a l t r a n sa x le is u sed on ly w it h V-6

engines.

To r ed u ce w e a r, t h e m a n u a l t r a n s a x le u s es S AE

5W-30 engine oil as the lubricant.

G ear rat ios for the A-523 a nd A-543 a re a s follows:

1st3.31, 2cd2.06, 3rd1.36, 4th0.97, 5t h0.71,

Reverse3.14. The final drive ratio is 3.77.

CAUTION: All gears and shafts must not be inter-

changed with previous model years; they will not

function correctly.

Fig. 1 External Transaxle Components

TRANSAXLE 21 - 1


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s h i f t l e v e r t h r o u g h a l l g e a r r a n g e s . I f t h e g e a r s h i f t

lever moves smoothly, the cable(s) should NOT be re-

p la ced . I f t h e g e a r lever bin ds r e pla ce t h e ca ble t h a t

is causing the binding condition.

(1) Working over the left front fender, remove the

lock pin from the transaxle gearshift (selector shaft)

housing (Fig. 4).

(2) Reverse the lock pin (so long end is down) and

insert lock pin int o sam e threa ded hole. A hole in these le ct o r sh a f t w il l a l ig n w it h t h e lo ck p in , a l lo w in g

the lock pin to be screwed into the housing. This op-

eration locks the selector shaft in the 3-4 neutral po-

sition.

(3) Remove or install gearshift knob (Fig. 5 or 6).

(4) Remove or install boot (Fig. 7) or console.

(5) Remove or install selector and crossover cables

(Fig. 8 or 9).

Cable attachment clips must be installed fromthe side. Install cable fittings to shifter pins bypushing with thumb.

Fig. 4 Manual Transaxle Pinned in the Neutral

Position to Adjust Gearshift

Fig. 5 Remove Gearshift Knob

Fig. 6 Install Gearshift Knob

Fig. 7 Remove or Install Boot

Fig. 8 Remove Cables

TRANSAXLE 21 - 3


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CAUTION: Be sure crossover bellcrank does NOT

move when tightening adjusting screw (Fig. 10).

CAUTION: Proper torque to the crossover cable ad-justing screw is very important (Fig. 10).

(6) Remove lock pin from gearshift housing a nd re-

install lock pin (so long end is up) in gear shift hous-

ing. Tighten lock pin to 8 Nm (70 in. lbs.).

(7) Check for shift into first and reverse.

(8) Ge a r sh if t m e ch a n ism a n d ca ble s a r e n o w f u n c-

tioning properly.

IN- CAR TRANSAXLE DISASSEM BLE/ASSEM BLEThe following items can be serviced without remov-

in g t h e t r a n sa x le f r o m t h e ve h icle:

Ge a r sh if t h o u sin g

Synchronizers

I n t e r m e d ia t e sh a f t sp e e d g e a r s

I n p u t sh a f t

Re ve r se id le r g e a r a n d sh a f t

Sh if t f o r k s a n d p a d s

Sh if t r a i ls

Roller detents

Speedometer pinion

All external covers

Observe follow ing procedure:

(1) Disconnect negative cable from battery.

(2) Remove both shift cables from shift cover levers.

(3) Re m ove le ft f r on t w h e e l a n d t ir e a ssem bly a n d

left splash shield.(4) P l a c e d r a i n p a n u n d er t r a n s a x le a n d r em ov e

tra nsaxle rear end cover.

(5) P ush out th e fifth fork roll pin a nd slide the fifth

fork an d s ynchronizer sleeve off the ra il/hub.

(6) Re m o ve t h e f i f t h h u b sn a p r in g , h u b a sse m bly

and speed gear.

(7) Remove fifth gear nut and fifth input gear.

(8) Re m ove t h e bea r in g r e t a in er p la t e , in t er lock

p la t e a n d sh u t t les.

CAUTION: Before removing the gearshift housing

assembly, reverse the lock pin (so the long end is

down) and insert lock pin into the same threaded

hole. This procedure will save time when the gear

shift housing assembly is reinstalled.

(9) Remove selector sha ft housing bolts (note the tw o

pilot bolts) and remove housing.

(10) Remove roller detents a nd springs, noting t hat

the rollers align with the shift rails.

(11) Push out the 1-2 and 3-4 lug roll pins, remove

the reverse pivot lever and fifth rail C-Clip. If a roll

pin or C-Clip falls, be sure to remove it from the

bottom of the case.

(12) P ull out t he fifth shift ra il and r emove the fifthshift lug and interlock pin.If the pin falls, be sureto

remove it from the bottom of the case.

(13) R e m ov e t h e i n t er m ed ia t e s h a f t b a l l b ea r i n g

snap ring and the bearing support plate.

(14) Remove reverse shift ra il a nd lug assembly.

(15) Remove the reverse idler sha ft a nd gear assem-

bly.

(16) Rotate the 1-2 shift lug and rail , and 3-4 shift

lug towa rds t he front of the vehicle.

(17) F ir m ly g r a sp bot h t h e in p u t a n d in t er m e d ia t e

shaft assemblies and pull them out of the tra nsmission

with the 1-2 and 3-4 shift ra ils, lugs and forks.The differential assembly can only be serviced

by removing the complete transaxle from the

vehicle because bearing preload must be reset.

The component s listed in the first pa ra gra ph can now

be se r vice d . Re f e r t o t h e a p p r o p r ia t e subassembly

recondition section.

To reassemble t he t ran saxle in the vehicle, reverse

the a bove procedure using t he proper sea lant s. Fill th e

tra nsaxle w ith SAE 5W-30 engine oil to t he bottom of

the fill hole in the end cover.

Fig. 9 Install Cables

Fig. 10 Adjusting Crossover Cable

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TRANSAXLE REMOVAL AND INSTALLATIONTransaxle removal does not require engine re-

moval.After insta lling tra nsa xle, f ill tran saxle to bott om of

fill plug hole wit h SAE 5W-30 engine oil before lower-

ing vehicle to floor.

(1) Disconnect or connect negative battery cable.

(2) Install a lifting eye on batt ery ground strap bolton left side of engine. Then install the engine supportfixture as shown in Figure 1.

(3) Disconnect or connect gearshift cables at tran-

saxle. Disconnect speedometer. Disconnect or connect

gearshift cables bracket at transaxle.

(4) R em ov e or i n st a l l b ot h f r on t w h e el a n d t i r e

assemblies.

(5) Remove or install left front splash shield.(6) Remove or install engine left mount from tran-

saxle.

CAUTION:Left engine mounting bolts used in posi-tion number 1 and number 3 are the same length. Thebolt in the number 2 position is longer. If bolt number2 is used in position number 3 it can damage the

selector shaft housing when the bolt is seated (Fig.2).

(7) Re m ove or in st a l l a n t i-r ot a t ion a l l in k (or a n t i-

hop damper) from crossmember bracket. Do not re-

move bracket from transaxle.(8) R e fe r t o G r o up 2 Suspension, t o r em ov e or

in st a l l bot h d r ive sh a f t s .

When removing or installing the transaxle, itmay be helpful to use locating pins in placeof the

top transaxle to engine bolts (Fig. 3).

Ma k e t h e lo ca t in g p in s f r o m t w o st o ck ( t r a n sa x le

case to engine block) bolts as follows: Using a hacksaw,

remove bolt heads, cut slot in end of bolts for a screw

driver, and remove burrs with a grinding wheel.

I n st a l l t h e lo ca t in g p in s in t o t h e e n g in e blo ck a n d

proceed with transaxle installat ion. After transaxle is

in place, insta ll bolts an d r emove locating pins before

removing t ra nsmission jack.

Fig. 1 Engine Support Fixture

Fig. 2 Left Engine Mount Bolt Location

Fig. 3 Remove or Install Bolts

TRANSAXLE 21 - 5


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OUT OF CAR TRANSAXLE DISASSEMBLE ANDASSEMBLE

DIFFERENTIAL

Fig. 1 Remove or Install 2 Extension Outer Bolts

Fig. 2 Remove or Install 3 Differential Bearing

Retainer Outer Bolts

Fig. 3 Remove or Install Differential Cover Bolts

Fig. 4 Remove Differential Cover

Fig. 5 Differential Cover Removed

Fig. 6 Remove or Install 2 Extension Bolts

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GEAR SET

CAUTION: Tool 6252 must be used to remove or in-

stall this nut. Always install a NEW nut and tighten

to 258 Nm (190 ft. lbs.).

Fig. 7 Remove or Install Extension

Fig. 8 Remove or Install 3 Differential BearingRetainer Bolts

Fig. 9 Remove or Install Differential BearingRetainer

Fig. 10 Differential Assembly Removed

Fig. 1 Rear End Cover Bolts

Fig. 2 Rear End Cover Removed

TRANSAXLE 21 - 7


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Fig. 3 Remove 5th Fork Roll Pin

Fig. 4 Install 5th Fork Roll Pin

Fig. 5 5th Fork and Sleeve

Fig. 6 Snap Ring

Fig. 7 Remove 5th Synchronizer Hub

Fig. 8 Install 5th Synchronizer Hub

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Fig. 9 Remove or Install 5th Gear Nut

Fig. 10 Bearing Retainer Plate Bolts

Fig. 11 Bearing Retainer Plate

Fig. 12 Interlock Shuttles

Fig. 13 Interlock Plate

TRANSAXLE 21 - 9


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CAUTION: Before removing the gearshift housing,

reverse the lock pin (so the long end is down) andinsert lock pin into the same threaded hole. Thisprocedure will save time when the gearshift hous-ing assembly is reinstalled.

Fig. 14 A-523/A-543/A-568 Shift Forks and Shift Rail Components

Fig. 15 Gearshift Housing Bolts

Fig. 16 Gearshift Housing Removed

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To install gearshift housing, be sure to reversethe lock pin in the housing to lock the selectorshaft in the 3-4 neutral position.

CAUTION: Install roller detents so roller and slots are

parallel with shift rails.

Remove or install 3-4 lug roll pin, 3-4 fork roll pin,

an d reverse lug roll pin using the above procedure.

CAUTION: If any roll pin falls out, retrieve roll pin from

bottom of case.

Fig. 19 Install 1-2 Shift Lug Roll Pin

Fig. 20 Remove 1-2 Shift Fork Roll Pin

Fig. 21 Reverse Pivot Lever

Fig. 17 Remove Roller Detents

Fig. 18 Remove 1-2 shift Lug Roll Pin

TRANSAXLE 21 - 11


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Fig. 22 5th Shift Rail C-Clip

Fig. 23 5th Shift Rail and Shift Lug

Fig. 24 5th Shift Lug with Interlock Pin

Fig. 25 5th Shift Lug Properly Installed

Fig. 26 Reverse Shift Rail and Shift Lug

Fig. 27 3-4 Shift Rail and Shift Lug

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CAUTION: Pry only at slot as shown (Fig. 30).

Fig. 28 1-2 Shift Rail and Shift Lug

Fig. 29 Remove or Install Large Snap Ring

Fig. 30 Pry Bearing Retainer Plate to Remove

Fig. 31 Bearing Support Plate

Fig. 32 Remove or Install Reverse Idler Gear

Fig. 33 Reverse Idler Gear Assembly

TRANSAXLE 21 - 13


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CLUTCH RELEASE BEARING INPUT SHAFT OIL SEAL

Fig. 34 Remove or Install Gear Set

Fig. 35 Gear Set

Fig. 1 Remove Retaining E-Clip

Fig. 2 Remove or Install Clutch Release Shaft

Fig. 3 Clutch Release Shaft Components

Fig. 4 Remove or Install Input Shaft Seal Retainer

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REVERSE SHIFT LEVER

SUBASSEMBLY-RECONDITION

TRANSAXLE CASE

Fig. 6 Install New Input Shaft Seal

Fig. 7 Remove or Install Reverse Shift Lever E-Clip

Fig. 8 Reverse Shift Lever Components

Fig. 1 Remove Input Shaft Front Bearing Cup

Fig. 2 Install Input Shaft Front Bearing Cup

Fig. 5 Input Shaft Seal Retainer

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Use Tool C-4660-2A Screw. The screw has a larger

hole in the lower end to fit over the larger oil feeder

nipple (Fig. 5).

INTERMEDIATE SHAFT ASSEMBLY

Intermediate shaft ball bearing seal color:A-525/A-523/A-543 B la ck, A-568 B lu e.

Fig. 3 Remove or Install Bearing Retaining Strap

Fig. 4 Remove Intermediate Shaft Front Bearing

Fig. 5 Oil Feeder

Fig. 6 Install Intermediate Shaft Front Bearing

Fig. 1 Intermediate Shaft Bearing Snap Ring

Fig. 2 Remove Intermediate Shaft Rear Bearing

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When assembling intermediate shaft, makesure all speed gears turn freely.

1-2 SYNCHRONIZER (DUAL-CONE)

Fig. 6 Install 3-4 Synchronizer Hub and 3rd SpeedGear

Fig. 1 2nd Speed Gear

Fig. 2 1-2 Synchronizer Hub Snap Ring

Fig. 3 Install Intermediate Shaft Rear Bearing

Fig. 4 3-4 Synchronizer Hub Snap Ring

Fig. 5 Remove 3-4 Synchronizer Hub and 3rd SpeedGear

TRANSAXLE 21 - 17


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Fig. 3 1st Speed Gear and 1-2 Synchronizer

Assembly

Fig. 4 Split Thrust Washer

Fig. 5 Intermediate Shaft Assembly

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SYNCHRONIZERS

Fig. 1 1-2 and 3-4 Synchronizer Sleeves and Hubs

Fig. 2 5th Speed Synchronizer

TRANSAXLE 21 - 19


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CAUTION: 1-2 synchronizer assembly componentsmust NOT be interchanged with any other synchro-

nizer assembly, or with previous model years tran-saxles; they will NOT function correctly.

Fig. 3 Synchronizer Identification

Fig. 4 Synchronizers

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GEARSHIFT HOUSING

Roll pin must be flush with top of lever.

Fig. 1 Gearshift Housing Disassembled

Fig. 2 Remove or Install Roll Pin and Lever Fig. 3 Dust Boot

TRANSAXLE 21 - 21


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For Disassembly: Drive roll pin out far enoughto clear the selector shaft, but not through. Thepin must remain in the selector so not to breakthe housing.

Fig. 10 Crossover Shaft

Fig. 11 Selector Shaft C-Clip

Fig. 12 Selector Shaft C-Clip

Fig. 13 Selector Assembly Roll Pin

Fig. 14 Remove or Install Selector Shaft

Fig. 15 Disassembled View

TRANSAXLE 21 - 23


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DIFFERENTIAL BEARING RETAINER

Fig. 1 Remove Differential Bearing Retainer Seal

Fig. 2 Install Differential Bearing Retainer Seal

Fig. 3 Remove Differential Bearing Retainer Cup

Fig. 4 Differential Bearing Retainer

Fig. 5 Install Oil Baffle

Fig. 6 Insert (Select) Shim and Differential BearingRetainer Cup

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INPUT SHAFT

Sh im t h ick n e ss n e e d o n ly be d e t e r m in e d i f a n y o f

the following parts are replaced:

Transaxle case

I n p u t sh a f t se a l r e t a in e r

B e a r in g r e t a in e r p la t e

Rear end cover

I n p u t sh a f t

I n p u t sh a f t be a r in g s

Re f e r t o Bearing Adjustment Procedure in r e a r

of this section t o determine proper shim thickness for

correct bearing end play and proper turning torque.

Fig. 1 Remove Input Shaft Rear Bearing Cone

Fig. 2 Install Input Shaft Rear Bearing Cone

Fig. 3 Remove Input Shaft Front Bearing Cone

Fig. 4 Install Input Shaft Front Bearing Cone

Fig. 5 Remove Input Shaft Rear Bearing Cup

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CAUTION: Bolt on bearing support plate before in-

stalling input shaft rear bearing cup.

A-523, A-543 DIFFERENTIALSh im t h ick n e ss n e e d o n ly be d e t e r m in e d i f a n y o f

the following parts are replaced:

Transaxle case

Differential bearing retainer

Extension housing

Differential case

Differential bearings

CAUTION: Differential covers are not interchange-

able from case to case.

Re f e r t o Bearing Adjustment Procedure in r e a r

of this section t o determine proper shim thickness for

cor r e ct bea r in g p r eloa d a n d p r op er bea r in g t u r n in g

torque.

Fig. 6 Install Input Shaft Rear Bearing Cup

Fig. 1 Remove Differential Bearing Cone

Fig. 2 Install Differential Bearing Cone

Fig. 3 Remove Differential Bearing Cone


TRANSAXLE 21 - 27


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CAUTION: Always install new ring gear bolts. Bolts

must be properly torqued (See Tightening Refer-ence).

After assembling the differential side gears, pinion

gears and pinion gears with the pinion gear washers,bu t without t h e sid e g ea r t h r u st w a sh e r s. Rot a t e t h ea s s em b ly t w o f u ll r ev ol ut i on s b ot h cl ock w i se a n d

counterclockwise.

Se t u p d ia l in d ica t or a s sh o w n a n d r e cor d e n d p la y .

Ro t a t e sid e g e a r 90 d e g r e e s a n d r e co r d a n o t h e r e n d

play. Again, rotate side gear 90 degrees and record a

f in a l e n d p la y .U s i n g t h e s m a l les t e nd p la y r ecor d ed , s h im t h a t

side gear to within .001 to .013 inch. The other side

gear should be checked using the same procedure.

Fig. 5 Remove or Install Ring Gear Bolts and Ring

Gear

Fig. 6 Remove Pinion Shaft Roll Pin

Fig. 7 Remove or Install Pinion Shaft

Fig. 8 Remove or Install Pinion Gears, Side Gears,and Thrust Washers by Rotating Side Gears to

Opening in Case

Fig. 9 Differential Gears

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CAUTION: Always install new ring gear bolts. Boltsmust be properly torqued (See Tightening Refer-ence).


Fig. 5 Remove or Install Ring Gear Bolts

Fig. 6 Remove Ring Gear

Fig. 7 Remove 3 Roll Pins

Fig. 8 Install 3 Roll Pins

Fig. 9 Ring Gear and Side Gear Removed

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CAUTION: See Figure 14 to determine side gear

thrust washer thickness. Side gear end play must be

within.001 to .013 inch.

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

.042, and .047 inch.

Side gear thrust washers are available in 4

select thicknesses: .032, .037, .042, and .047 inch.

Me a su r e t h e d e p t h f r om t h e d if f er e n t ia l ca se t o t h e

machined surface in 3 places, as shown in Figure 13.

Then measure the height of raised step o n t h e r in g

gear. The difference, minus the proper side gear end

p la y ( .001 t o .013 in ch ) is t h e p r o p e r t h r u st w a sh e r

thickness.

For the other side gear: After a ssembling t he differ-

ential side gears, pinion gears, and pinion gears with

t h e p in io n g e a r w a sh e r s bu t without t h e sid e g e a r

t h r u st w a sh e r s. Ro t a t e t h e a sse m bly t w o f u l l r e vo lu -

tions both clockwise and counterclockwise.

S e t u p d i a l i n d ica t o r a s s h ow n i n F i g u re 1 4 a n d

r ecor d e nd p la y. R ot a t e s id e g ea r 90 d eg r ee s a n d

r e co r d a n o t h e r e n d p la y . Ag a in , r o t a t e sid e g e a r 90

degrees a nd record a f inal end play.

Using t he smallest end play recorded, shim tha t sidegear to w ithin .001 to .013 inch.

CAUTION: After reassembly of the differential assem-

bly, insert the inner joint housing spline from a drive

shaft into the side gear. By hand, turn the side gear

with the joint housing spline. If the side gear will NOT

turn, or it feels very tight, remove the ring gear and

install a thinner side gear thrust washer.

Side gear thrust washers are available in four

select thicknesses: .032, .037, .042, and .047 inch.

BEARING ADJUSTMENT PROCEDURE

GENERAL RULES ON SERVICING BEARINGS

(1) Ta ke extreme car e when removing and inst a lling

be a r in g cu p s a n d co n e s. U se o n ly a n a r bo r p r e ss f o r

in st a l la t io n , a s a h a m m e r m a y n o t p r o p e r ly a l ig n t h e

b ea r i n g cu p or con e. B u r r s or n i ck s on t h e b ea r -

Fig. 12 Differential Gears

Fig. 13 Determine Proper Side Gear Thrust WasherThickness

Fig. 10 Remove or Install Pinion Shafts

Fig. 11 Remove or Install 4 Pinion Gears and 2 SideGears

TRANSAXLE 21 - 31


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i ng s ea t w i ll g iv e a f a ls e e n d pl a y r ea d in g w h i le

gauging for proper shims. Improperly seated bearing

cups a nd cones a re subject to low mileage failure.(2) B earin g cups an d cones should be replaced if they

show signs of pitting or heat distress. If distress is seen

on either the cup or bearing rollers, both cup and cone

must be replaced.

(3) Bearing preload and drag torque specifications

must be maintained t o a v oi d p re ma t u r e b ea r i n gfailures. Used (original) bearing may lose up to 50%of

t h e o r ig in a l d r a g t o r q u e a f t e r br e a k in . All bearingadjustments must be made with no other compo-nent interference or gear intermesh.

(4) Replace bearings as a pair . For example, if one

differential bearing is defective, replace both differen-

t ia l be a r in g s. I f o n e in p u t sh a f t be a r in g is d e f e ct ive ,replace both input shaft bearings.

(5) B earing cones must not be reused if removed.(6) Tu r n in g t o r q u e r e a d in gs sh ou ld be obt a in e d

w h ile sm oot h ly r ot a t in g in e it h e r d ir ect ion (br ea k -

a w a y r ea d i n g i s n ot i n di ca t i v e o f t h e t r u e t u r n i ng

torque).

(7) Replace oil baffle, if da ma ged.

INPUT SHAFT BEARING END PLAY ADJUST-

MENT

(1) U sing Tool C-4656 w ith Ha ndle C-4171, press

input shaft front bearing cup slightly forward in case.

Then, using Tool C-4655 w ith Ha ndle C-4171, pressbe a r in g cu p ba ck in t o ca se f r o m t h e f r o n t . Pr o p e r ly

posit ion bearing cup, before checking input sha ft end

p la y (s ee i n pu t s h a f t f r on t b ea r i n g cu p r ep la c e i n

Subassembly Recondition section). This step isnot necessary if Tool C-4655 was previously usedto install input shaft front bearing cup in thecase. Also no input shaft shim has been installedsince pressing cup into case.

(2) Select a gauging shim which will give 0.025 to

0.254mm (.001 to .010 inch) end pla y. SUGGESTION:Measure original shim from input shaft

seal retainer and select a shim 0.254mm (.010

inch) thinner than original for the gauging shim.

(3) I n st a l l g a u g in g sh im o n be a r in g cup a n d in st a l l

input shaft seal retainer.

CAUTION: The input shaft seal retainer is used to

draw the input shaft front bearing cup the proper

distance into the case bore during this step. Alter-nately tighten input shaft seal retainer bolts until

input shaft seal retainer is bottomed against case.

Tighten bolts to 28 Nm (21 ft. lbs.).

(4) Oil input shaft bearings with SAE 5W-30 engine

oi l a n d i n st a l l i n pu t s h a f t i n c a s e. I n s t a l l b e a r in g

r et a i ner pl a t e w i t h i np ut s h a ft r ea r b ea r in g cu p

pressed in and bearing support plate installed. Tighten

a ll bo lt s a n d n u t s t o 28 Nm (21 ft. lbs.).

(5) Posit ion dial indicator to check input shaft end

p la y . Ap ply m od e ra t e lo a d , by h a n d , t o in p u t sh a f t

splines (Fig. 1). P ush towa rd rear while rotating input

sh a f t ba ck a n d f o r t h a n u m be r o f t im e s t o se t t le o u t

bea r in g s. Z e ro d ia l in d ica t or. P u ll in p ut sh a f t t o w a r d

t h e f r o n t w h ile r o t a t in g in p u t sh a f t ba ck a n d f o r t h a

num ber of times to settle out bear ings. Record end play.

(6) The shim required for proper bea ring end pla y is

the t otal of the ga uging shim t hickness, plus end play,

minus (consta nt) end play of 0.051mm (.002 inch).Combine shims, if necessary, to obtain a shim within

.04mm (.0016 inch) of the required shim (see Sh im

Cha rt for proper sh im).

(7) Rem ove in p ut sh a f t se a l r e t a in e r a n d g a u g in g

shim. I nst a ll shim(s) selected in step (6). Then reinst a ll

i n pu t s h a f t s ea l r et a i n er w i t h a 1/16 i n ch b ea d of

MOPAR Ga sk e t Ma k e r , L o ct i t e , o r e q u iva le n t f o r a

g a sk e t . Re co r d e n d p la y . O bse r ve t h e CAUTION in

step (3). Tighten input shaft seal retainer bolts to 28

Nm (21 ft. lbs.).

Fig. 14 Checking Side Gear End Play

Fig. 1 Checking Input Shaft Bearing End Play to De-termine Shim Thickness

21 - 32 TRANSAXLE


33/188

(8) Verify tha t a preload condition does not exist .

Use Special Tool L-4508 a nd an inch-pound torque

w r e n ch t o ch e ck in p u t sh a f t t u r n in g t o r q u e (F ig . 2) .

The turning torque should be less than 5 in. lbs.

CAUTION: Step (1) MUST be repeated every time a

thinner shim is installed. This will assure that the

input shaft bearing cup is pressed the proper dis-tance into the case. If the turning torque is too high,

install a .04mm (.0016 inch) thinner shim.

(9) Recheck input sha ft t urning torque. Repeat step

(8) until the proper bearing turning torque is obtained.

Observe CAUTION in step (8).

DIFFERENTIAL BEARING PRELOAD ADJUSTMENT(1) R e mov e b ea r i n g cu p a n d e xi st i n g s h im f r om

differential bearing reta iner. (See Differential B earing

Retainer in Subassembly Reconditionsecti on).

(2) S e le ct a g a u g in g sh im w h ich w ill g ive 0.025 t o

0.254mm (.001 to .010 inch) end pla y. SUGGESTION:

Measure original shim from differential bearing

retainer and select a shim 0.381mm (.015 inch-

)thinner than original for the gauging shim.I n -

stall gauging shim in differential bearing retainer and

press in bearing cup. Installation of oil baffle is not

necessary when checking differential assembly

end play.

(3) Oil differential bearings with SAE 5W-30 engineoil and install differential assembly in transaxle case.

Check extension housing O-ring for damage (replace if

necessa ry). Add a 1/16 inch bead of MOPAR Ga sk e t

Maker, Loctite 518, or equiva lent to extension flange.

Install extension housing and differential bearing re-

ta iner. Torque b olts (see Tight ening Reference).

(4) P osit ion tra nsa xle with bell housing facing down

on w orkbench with C-clam ps. P osit ion dia l indicator.

(5) Apply a medium load to differentia l w ith Tool

C-4995 and a T-Ha ndle, in the downwa rd direction.

Roll differential assembly back and forth a number of

times. This will settle the bearings. Zero dial indicator.

To obta in end play readings, a pply a medium load in

the upward direction while rolling differential assem-

bly back and forth (Fig. 3). Record end play.

(6) The shim required for proper bearing preload is

total of gauging shim thickness, plus end play,

Fig. 2 Checking Input Shaft Bearing Turning Torque

INPUT SHAFT SHIM CHART

Fig. 3 Checking Differential Bearing End Play to De-termine Shim Thickness

TRANSAXLE 21 - 33


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plus (constant) preload of 0.254mm (.010 in.).

Combine shims, if necessary, to obtain a shim within

.05m m (.002 in ch ) o f t h e r e q u ir e d sh im (se e S h im

Cha rt for proper sh ims).

(7) Re m ove d iff er e n t ia l bea r in g r e t a in er . Re m ove

b ea r i n g cu p a n d g a u g in g s h im . P r o pe rl y i n st a l l oi l

baffle. Be sure oil baffle is not damaged. I n st a l l

shim(s) selected in step (6). Then press in the bearingcup into differential bearing r etainer.

(8) U sin g a 1/16 in ch bea d of MO PAR Ga sk e t

Ma k e r, L oct it e 518, o r e q u iva le n t f or g a sk e t , in st a l l

d i ff er e n t ia l bea r in g r e t a in er . Tor q u e a l l bolt s (Se e

Tightening Reference).

(9) U sing Special Tool C-4995 a nd an inch-pound

torque w rench, check t urning t orque of th e differential

assembly in clockwise and counterclockwise directions

(Fig. 4). The turning torque should be 9 to 14 in.

lbs. for new bearings or a minimum of 6 in. lbs.

for used bearings. If the turning torque is too

high, install a .05mm (.002 inch) thinner shim. Ifthe turning torque is too low, install a .05mm

(.002 inch) thicker shim.

(10) Recheck turning torque. Repeat Step (9) until

the proper turning torque is obtained.

Fig. 4 Checking Differential Bearing Turning Torque

DIFFERENTIAL BEARING SHIM CHART

21 - 34 TRANSAXLE


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THREE SPEED TORQUEFLITE AUTOMATIC TRANSAXLE

INDEX

page page

Accumulator-Recondition . . . . . . . . . . . . . . . . . . . 67

Aluminum Thread Repair . . . . . . . . . . . . . . . . . . . 48Assembly Subassembly Installation . . . . . . . . . . . 57Band Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 47Bearing Adjustment Procedures . . . . . . . . . . . . . . 81Clutch and Servo Air Pressure Tests . . . . . . . . . . 43Differential Repair . . . . . . . . . . . . . . . . . . . . . . . . 76Disassembly Subassembly Removal . . . . . . . . . . 50Fluid and Filter Change . . . . . . . . . . . . . . . . . . . . 40Fluid Drain and Refill . . . . . . . . . . . . . . . . . . . . . 40Fluid Leakage-Transaxle Torque Converter

Housing Area . . . . . . . . . . . . . . . . . . . . . . . . . . 44Fluid Level and Condition . . . . . . . . . . . . . . . . . . 40Front Clutch-Recondition . . . . . . . . . . . . . . . . . . . 62Front Planetary & Annulus Gear-Recondition . . .. 65Gearshift Linkage Adjustment . . . . . . . . . . . . .. . 46

General Information . . . . . . . . . . . . . . . . . . . . . . . 35Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Hydraulic Control Pressure Adjustments . . . . .. . 47Hydraulic Pressure Tests . . . . . . . . . . . . . . . . . . . 42Kickdown Servo (Controlled Load)-Recondition . . 67

Low/Reverse Servo-Recondition . . . . . . . . . . . . . . 66

Oil Cooler Flow Check . . . . . . . . . . . . . . . . . . . . 48Oil Coolers and Tubes Reverse Flushing . . . . . . 48Oil Pump-Recondition . . . . . . . . . . . . . . . . . . . . . 62Output Shaft Repair . . . . . . . . . . . . . . . . . . . . . . 71Park/Neutral Position and Back-Up Lamp Switch . 47Parking Pawl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Pump Oil Seal-Replacement . . . . . . . . . . . . . . . . 61Rear Clutch-Recondition . . . . . . . . . . . . . . . . . . . 64Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Selection of Lubricant . . . . . . . . . . . . . . . . . . . . . 40Special Additives . . . . . . . . . . . . . . . . . . . . . . . . . 40Three Speed Torqueflite General Diagnosis . . . . . 36Throttle Pressure Linkage Adjustment . . . . . . . .. 46Torque Converter Clutch Solenoid Wiring

Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Transaxle and Torque Converter Removal . . . .. . 48Transfer Shaft Repair . . . . . . . . . . . . . . . . . . . . . 68Valve Body-Recondition . . . . . . . . . . . . . . . . . . . . 57Vehicle Speed Sensor Pinion Gear . . . . . . . . . .. 47

GENERAL INFORMATIONSafety goggles should be worn at all times

when working on these transaxles.Th is t r a n sa x le com bin es a f u lly a u t o m a t ic 3 sp e ed

transmission, f inal drive gearing, and differential into

a f r on t w h e el d r iv e s y s t em . Th e u n i t i s a Metricdesign. The identification markings and usage of the

tra nsa xle ar e cha rted in D iagnosis and Tests.

Transaxle operation requirements are differ-ent for each vehicle and engine combination andsome internal parts will be different to providefor this. Therefore,when replacingparts, refer tothe seven digit part number stamped on rear ofthe transaxle oil pan flange.

Wit h in t h is t r a n sa x le , t h e r e a r e 3 p r im a r y a r e a s:

(1) Main center line plus valve body.

(2) Tra nsfer sha ft center line (includes governor an d

parking sprag).

(3) D if fe r en t ia l ce n t er l in e . Ce n t e r d ist a n ces be-

tw een the main rota ting parts in these 3 area s are held

p r ecise. Th is m a in t a in s a low n oise le vel t h r o ug hsmooth accurate mesh of the gears.

The torque converter, transaxle area, and differential

a r e h ou sed in a n in t eg r a l a lu m in u m d ie ca st in g . Th e

differential oil sump is common with the transaxlesump. Separa te filling of the differential is NOT nec-essary.

Th e t or q u e con ve rt e r is a t t a ch ed t o t h e cr a n k sh a f t

t h r o ug h a f lex ible d r ivin g p la t e . C oolin g o f t h e con -

ver t e r is a ccom p lish ed by cir cu la t in g t h e t r a n sa x le

fluid through an oil-to-water type cooler located in the

r a d ia t or s id e t a n k a n d /or a n oi l-t o a i r h ea t ex -

ch a n g e r . Th e t o r q u e con ve rt e r a sse m bly is a se a led

u n it t h a t ca n n o t be d isa sse m ble d .

Th e t r a n sa x le f luid is f il t e re d by a n in t er n a l f i lt e r

a t t a ch e d t o t h e lo w e r sid e o f t h e va lve bo d y a sse m -

bly.

E n g in e t or q u e i s t r a n s m i t t ed t o t h e t or q u e c on -

verter then, through the input shaft to multiple-disc

clutches in the tra nsa xle. The power flow depends ont h e a p pl ica t i on of t h e cl ut ch es a n d b a n d s . R ef er t o

Elements in Use Chart in Diagnosis and Tests sec-

t i on . Th e t r a n s a x le con s is t s of t w o m u lt i pl e-d i sc

clu t ch e s, a n over r u n n in g clut ch , t w o se r vos, a h y -

d r a u li c a ccu m u la t o r , t w o b a n d s , a n d t w o p la n e t a r y

gear sets. They provide three forward ratios and a re-

ve r se r a t io . T h e co m m o n su n g e a r o f t h e p la n e t a r y

gear sets is connected to the front clutch by a driving

sh e ll . T h e d r ive sh e ll is sp lin e d t o t h e su n g e a r a n d

t o t h e f r on t cl ut ch r et a i n er . Th e h y d r a u li c s y s t em

con s is t s of a n oi l pu m p, a n d a s in gl e v a lv e b od y

which contains all of the valves except the governor

valves. The transaxle sump and differential sump are

b ot h v en t ed t h r ou g h t h e dipstick. Ou t p u t t o r q u e

from the main center line is delivered through heli-

c a l g e a r s t o t h e transfer shaft. Th i s g e a r s et i s a

f a ct or of t h e f in a l d r ive (a x le ) r a t io. Th e sh a f t a lso

ca r r ie s t h e g o ve r n o r a n d p a r k in g sp r a g . An in t e g r a l

h e lica l g ea r on t h e t r a n sf e r sh a f t d r ive s t h e d iff er e n -

t ia l r in g g e a r . T h e f in a l d r ive g e a r in g is co m p le t e d

with one of th ree gear sets producing overall t op gear

ratios of 2.78, 3.02, or 3.22 depending on model and

application.

TRANSAXLE 21 - 35


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37/188

DIAGNOSIS GUIDEABNORMAL NOISE

TRANSAXLE 21 - 37


38/188

DIAGNOSIS GUIDEVEHICLE WILL NOT MOVE

DIAGNOSIS GUIDEFLUID LEAKS

21 - 38 TRANSAXLE


39/188

DIAGNOSTICCHART

TRANSAXLE 21 - 39


40/188

FLUID LEVEL AND CONDITIONThe transmission and differential sump have a

common oil sump with a communicating opening

between the two.

B efore removing t he dipstick, w ipe all dirt off of the

protective disc and t he dipstick ha ndle.

The torqu e converter will fill in both the P Pa r k or N

Neutral positions. Place the selector lever in PP a r k t ocheck fluid level.

I n sp ect f luid level on d ipst ick e ver y six m on t h s.

Allow the engine to idle for at least one minutewith vehicle on level ground. This will assurecomplete oil level stabilization between differen-tial and transmission. A properly filled tra nsa xlewill read near t headd ma rk when fluid temperature is21 degrees Celsius (70 degrees Fahrenheit). When the

t r a n s a x le r ea c h es op er a t i n g t e mp er a t u r e t h e f lu id

should be in the HOT region.L ow f luid leve l ca n ca u se a va r ie t y o f con d it ion s

because it a llows t he pump to ta ke in a ir along with t he

fluid. As in a ny hydr aulic system, air bubbles make th efluid spongy, th erefore, pressures w ill be low a nd build

up slowly.

I m p r op er f i ll in g ca n a lso r a ise t h e f luid leve l t o o

high. When the t ran saxle ha s too much fluid, the gears

ch u r n u p f o a m a n d ca u se t h e sa m e co n d it io n s w h ich

occur with a low fluid level.

In either case, the a ir bubbles can ca use overheating,

f lu id o x id a t io n , a n d va r n ish in g , w h ich ca n in t e r f e r e

with normal va lve, clutch, a nd servo operat ion. Foam-

ing can a lso result in fluid escaping from the tr ansa xle

vent (dipstick ha ndle) where it ma y be mista ken for a

leak.

Along with fluid level, it is important to check the

condition of the fluid. When the fluid smells burned,

a n d i s con t a m i n a t e d w i t h m et a l or f r ict i on m a t e r ia l

part icles, a complete t ra nsa xle overhaul is needed. B e

su r e t o e x a m in e t h e f lu id o n t h e d ip st ick clo se ly . I f

t h er e i s a n y d ou b t a b ou t i t s con d it i on , d r a i n o u t a

sample for a double check.

After the fluid has been checked, seat the dipstick

f u lly t o sea l o u t w a t e r a n d d ir t .

SELECTION OF LUBRICANTI t is im p or t a n t t h a t t h e p r op er lu br ica n t be u sed in

these transmissions. MOPAR ATF PLUS (AutomaticTra nsm ission F luid-Type 7176) should be used t o a id in

assuring optimum transmission performance. Fluids of

the type labeled DE XRON II Automat ic Tran smission

Fluid should be used only if the recommended fluid is

n o t a v a i l a b l e . I t i s i m p o r t a n t t h a t t h e t r a n s m i s s i o n

f luid be m a in t a in e d a t t h e p r e scr ibed level u sin g t h e

recommended fluids.

SPECIAL ADDITIVESChry sler C orporation does not recommend the a ddi-

t io n o f a n y f lu id s t o t h e t r a n sm issio n , o t h e r t h a n t h e

a u t om a t i c t r a n s m i ss ion f lu id l is t ed a b ov e. An e x-

ception to th is policy is th e use of special dyes t o aid in

detecting fluid leaks. The use of transmission sealers

sh ou ld be a void ed , s in ce t h e y m a y a d ve r sely a f f ect

seals.

FLUID AND FILTER CHANGEWhen the factory fill fluid is changed, only

fluids of the type labeled MOPAR ATF PLUS(Automatic Transmission fluid) Type7176 should

be used. A band adjustment and filter change

should be madeat the time of the oil change. The

magnet (on the inside of the oil pan) should also

be cleaned with a clean, dry cloth.

If the transaxle is disassembled for any reason,

the fluid and filter should be changed, and theband(s) adjusted.

FLUID DRAIN AND REFILL(1) Ra ise vehicle on a hoist (See Lubrication, G roup

0). P lace a dra in conta iner with a large opening, under

t r a n sa x le oi l p a n .(2) Loosen pan bolts and tap the pan at one corner to

break it loose allowing fluid to dra in, then remove the

oil pa n.

(3) I n st a l l a n e w f i l t er a n d g a sk et on bo t t om of t h e

valve body and t ighten retaining screws to 5 Nm (40

in. lbs.).

(4) C l ea n t h e o il p a n a n d m a g n et . R ei n st a l l p a n

using new MOPAR Adhesive sealant. Tighten oil panbolts to 19 Nm (165 in. lbs.).

(5) Pour four quarts of MOPAR ATF PLUS (Auto-m a t ic Tr a n sm ission F lu id) Ty p e 7176 t h r o ug h t h e

dipstick opening.

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

m in u t e . T h e n , w it h p a r k in g a n d se r vice br a k e s a p -

plied, move selector lever momentarily to each posi-

tion, ending in the pa rk or neutra l posit ion.

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

below the ADD mark.

R ech eck f lu id l ev el a f t er t r a n s a x le i s a t n or m a l

operat ing tempera tur e. The level should be in the H OT

region (Fig. 1).

To prevent dirt from entering tr ansa xle, m ake cer-

ta in tha t d ipstick is full seated into th e dipstick open-

ing.

TORQUE CONVERTER CLUTCH SOLENOID WIRINGCONNECTOR

I f w ir in g con n e ct o r is u n p lu g g ed , t h e t o r q u e con -

verter clutch will not operate (Fig. 2).

ROAD TESTPr io r t o p e r f o r m in g a r o a d t e st , be ce r t a in t h a t t h e

fluid level and condition, an d cont rol cable a djustment s

ha ve been checked a nd approved.

D u r in g t h e r oa d t e st , t h e t r a n sa x le sh o u ld be o pe r-

a t e d in e a ch p osit ion t o ch eck f or sl ip pin g a n d a n y

variat ion in shift ing.

21 - 40 TRANSAXLE


41/188

If vehicle operates properly at highway speeds, but

h a s p oor a c ce le ra t i on , t h e t or q u e con v er t er s t a t o r

overrunning clutch may be slipping. If through-gear

a cce le r a t io n is n o r m a l , bu t h ig h t h r o t t le o p e n in g isrequired to maintain highway speeds, the torque con-

ve r t e r st a t o r clu t ch m a y h a ve se iz e d . B o t h o f t h e se

stator defects require replacement of the torque con-

verter.

Observe closely for slipping or engine speed flare-

up. Slipping or flare-up in any gear usually indicates

clutch, band, or overrunning clutch problems. If the

con d it ion is f a r a d va n ce d , a n ove rh a u l w il l p r oba bly

be necessary to restore normal operation.

Th e clut ch o r ba n d t h a t is s l ipp in g ca n be d e t er -

mined by noting the transaxle operation in all selec-

t o r p osit ion s. Th e n com p a r in g w h ich in t er n a l u n it sare applied in those posit ions. The Elements in Use

Chart p r o vid e s a ba sis f o r r o a d t e st a n a ly sis .

The rear clutch is applied in both the D f i rst g ea r

a n d 1 fi r st g ea r p os it i on s . Al so t h e ov er r u n ni n g

clutch is applied in D f irst gear and the low/reverse

ba n d is a p p lie d in 1 f i r st g e a r p o sit io n . I f t h e t r a n -

saxle slips in D r a n g e f ir st g e a r , bu t d oe s n o t s l ip in

1 f irst gear, the overrunning clutch is slipping. Sim-

i la r ly , if t h e t r a ns a xle s lips in a n y t w o for w a rd

gears, the rear clutch is slipping.

U s in g t h e s a m e pr oced ur e, t h e r ea r cl ut ch a n d

front clutch are applied in D t h i r d g e a r . I f t h e t r a n -sa x le sl ip s in t h ir d g ea r , e it h e r t h e f r o n t clu t ch or

the rear clutch is slipping. By selecting another gear

which does not use one of those units, the unit which

is sl ip p in g ca n be d e t e r m in e d . I f t h e t r a n sa x le a lso

sl ip s in r e ve r se , t h e f r on t clu t ch is s l ip pin g . I f t h e

t r a n sa x le d o e s n o t s l ip in r e ve r se , t h e r e a r clu t ch is

slipping.

Th e p r oce ss of e lim in a t ion ca n be u sed t o d e t ect

any unit which slips and to confirm proper operation

of g ood u n it s . R oa d t e st a n a l y s is ca n u s ua l l y d i a g -

n o se sl ip p in g u n it s , bu t t h e a ct u a l ca u se o f t h e m a l-

f u n ct ion u su a lly ca n n o t be d e cid ed . P r a ct ica l ly a n y

condition can be caused by leaking hydraulic circuits

or st icking valves.

ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER

Fig. 1 Dipstick and Transaxle Vent

Fig. 2 Torque Converter Clutch Solenoid WiringConnector

TRANSAXLE 21 - 41


42/188

Unless the condition is obvious, like no drive in Dr a n g e f ir st g ea r on ly . Th e t r a n sa x le sh o u ld n e ve r be

d i sa s s em b le d u n t il h y d ra u l ic p re ss u r e t e st s h a v e

been performed.

HYDRAULIC PRESSURE TESTSP r e ssu r e t e st in g is a ver y im p or t a n t st e p in t h e d i-

a g n o st ic p r oced u r e. Th e se t e st s u su a lly r e ve a l t h e

cause of most transaxle problems.

B e f or e p er f or m in g p r essu r e t e st s , be cer t a in t h a t

f luid leve l a n d con d it ion , a n d con t r o l ca ble a d ju st -

ments have been checked and approved.

Fluid must be at operating temperature (150 to 200

degrees F.).

Install an engine tachometer, raise vehicle on hoist

w h i ch a l l ow s f r on t w h e el s t o t u r n , a n d p os it i on t a -

ch om e t er so i t ca n be r e a d .

Disconnect thrott le cable and shift cable from tran-

sa x le le ver s so t h e y ca n be con t r o lled f r om ou t sid e

the vehicle.

Attach 150 psi gauges to ports required for test be-ing conducted. A 300 psi gauge (C-3293) is required

for reverse pr e ssu r e t e st a t r e a r se rvo.Test port locations are shown in (Fig. 3).

TEST ONE (SELECTOR IN 1)

(1) At t a ch g a u g e s t o line a n d low-reverse ports(Fig. 3).

(2) Operate engine at 1000 rpm for test .

(3) Move se lect or lever on t r a n sa x le a l l t h e w a y

r e a r w a r d (1posit ion).(4) Read pressures on both gauges as thrott le lever

on transaxle is moved from full clockwise posit ion tofull counterclockwise position.

(5) L i n e p re ss u r e s h ou ld r ea d 52 t o 58 p si w i t h

thrott le lever clockwise and gradually increase, as le-

ver is moved counterclockwise, to 80 to 88 psi.

(6) L o w - r e ve r se p r e ssu r e sh o u ld r e a d t h e sa m e a s

line pressure within 3 psi.

(7) Th is t e st s p u m p ou t p u t , p r essu r e r e gu la t ion ,

and condition of rear clutch and rear servo hydraulic

circuits.

TEST TWO (SELECTOR IN 2)

(1) At t a ch on e g a u g e t o line pressure por t a n d

tee another gauge into lower cooler line fit t ing. Thisw il l a l lo w y o u t o r e a d lubrication pressure (Fig 3).(2) Operate engine at 1000 rpm for test .

Fig. 3 Transaxle (Left Side)

21 - 42 TRANSAXLE


43/188

(3) Move se le ct o r lever on t r a n sa x le on e detent

forward from full rearward posit ion. This is selector

2 position.

(4) Read pressures on both gauges as thrott le lever

on transaxle is moved from full clockwise posit ion to

full counterclockwise position.

(5) L i n e p re ss u re s h ou ld r ea d 52 t o 58 p si w i t h

thrott le lever clockwise and gradually increase, as le-ver is moved counterclockwise, to 80 to 88 psi.

(6) L u b r ica t i on p re ss u re s h ou ld b e 10 t o 25 p si

with lever clockwise and 10 to 35 psi with lever full

counterclockwise.


a n d co n d it io n o f r e a r clu t ch a n d lu br ica t io n h y d r a u -

lic circuits.

TEST THREE (SELECTOR IN D)

(1) At t a ch g a u g e s t o line a n d kickdown release

ports (Fig. 3).


(3) Move se le ct o r leve r on t r a n sa x le t w o detents


D position.

(4) Read pressures on both gauges as thrott le lever

on transaxle is moved from full clockwise posit ion to

full counterclockwise position.

(5) L i n e p re ss u re s h ou ld r ea d 52 t o 58 p si w i t h

thrott le lever clockwise and gradually increase, as le-

ver is moved counterclockwise to 80 to 88 psi.

(6) Kickdown release is pressurized only in direct

d r iv e a n d s h ou ld b e s a m e a s l in e p r es s ur e w i t h in 3

psi, up to kickdown point .

(7) Th is t e st s p u m p ou t p u t , p r essu r e r e gu la t ion ,a n d con d it i on of r ea r cl ut ch , f r on t cl ut c h, a n d h y -

dra ulic circuits.

TEST FOUR (SELECTOR IN REVERSE)

(1) Attach 300 psi gauge to low-reverseport (Fig.

3).


(3) Move selector lever on t ra nsa xle four detents


R position.

(4) L ow -r e ve r se p r essu r e sh ou ld r e a d 180 t o 220

p si w i t h t h r ot t l e l ev er cl ock w i se a n d g r a d u a l ly i n -crease, as lever is moved counterclockwise to 260 to

300 psi.


and condition of front clutch and rear servo hydraulic

circuits.

(6) Move selector lever on transaxle to D position

to check that low-reverse pressure drops to zero.

(7) Th is t e st s f or lea k a g e in t o r e a r ser vo, d u e t o

ca s e p or os i t y, w h i ch ca n ca u s e r ev er s e b a n d b u rn

out.

TEST RESULT INDICATIONS

(1) If proper line pressure, minimum t o ma ximum, is

found in a ny one test , the pump a nd pressure regulat or

are working properly.

(2) Low pressure in D, 1, and 2 but correct pressure

in R indicat es rear clutch circuit leaka ge.

(3) Low pressure in D and R but correct pressure in

1 indicat es front clutch circuit leakage.(4) Low pressure in R and 1 but correct pressure in

2 indicat es rear servo circuit leakage.

(5) L ow l ine p r essu r e in a l l p osi t ion s in d ica t e s a

defective pump, a clogged filter, or a stuck pressure

regulator valve.

GOVERNOR PRESSURE

Test only if t ran saxle shifts at wrong vehicle speeds

wh en thr ott le cable is correctly adjusted.

(1) Connect a 0-150 psi pressure gauge to governor

pressure take-off point , located at lower right side of

case, below differential cover (Fig. 3).

(2) O p er a t e t r a n s a x le i n t h i rd g ea r t o r ea d p res -sures. The governor pressure s hould respond sm oothly

t o ch a n g es in m p h a n d sh ou ld r e t u r n t o

0 to 3 psi w hen vehicle is st opped. H igh pressure at

sta ndstill (above 3 psi) will prevent the t ra nsaxle from

downshift ing.

THROTTLE PRESSURE

N o g a u g e p or t is p r ovid ed f or t h r o t t le p r e ssu r e.

Incorrect throttle pressure should only be suspected if

part throttle upshift speeds are either delayed or occur

t oo ea r l y, w i t h a cor r ect l y a d ju s t ed t h r ot t l e ca b l e.

En g in e r u n a w a y on e it h e r u p sh if t s o r d o w n sh ift s ca n

also be an indicator of incorrect (low) throttle pressure

sett ing, or misa djusted thrott le cable.

In no case should t hrott le pressure be adjusted unt il

the transaxle thrott le cable adjustment has been veri-

fied t o be correct.

CLUTCH AND SERVO AIR PRESSURE TESTSAno drive condition might exist even with correct

f luid p r essu r e, beca u se of in op er a t ive clu t ch es or

ba n d s. Th e in op er a t ive u n it s , c lu t ch es, ba n d s, a n d

s er v os ca n b e l oca t e d t h r ou g h a s er i es of t e st s b y

substituting air pressure for fluid pressure (Fig. 4).

Th e f r on t a n d r e a r clu t ch e s, k ick d ow n ser vo, a n d

low-reverse servo may be tested by applying air pres-

sure to th eir respective passa ges aft er

the va lve body a ssembly ha s been removed. To make

air pressure t ests, proceed as follows:

Compressed air supply must be free of all dirtor moisture. Use a pressure of 30 psi.

Re m o ve o i l p a n a n d va lve bo d y Se e Disassembly-Subassembly Removal.

FRONT CLUTCH

Apply air pressure to front clutchapply p a ssa g e a n dl is t en f or a d ul l thud w h ich i n di ca t e s t h a t f r on t

TRANSAXLE 21 - 43


44/188

clu t ch is op er a t in g . Ho ld a ir p r essu r e on f or a f ew

seconds and inspect system for excessive oil leaks.

REAR CLUTCH

Ap ply a ir p r essu r e t o r e a r clu t ch apply p a ssa g e

a n d l ist e n f o r a d u ll thud w h ich in d ica t e s t h a t r e a r

clu t ch is op er a t in g . Also in spe ct f or e xcessive oi l

le a k s. I f a d u ll thud cannot be heard in the clutches,

p la ce f in g e r t ip s o n clu t ch h o u sin g a n d a g a in a p p ly

a ir p r e ssu r e . Mo ve m e n t o f p ist o n ca n be f e l t a s t h e

clutch is applied.

KICKDOWN SERVO (FRONT)

D ir e ct a ir p r essu r e in t o k ickd ow n se r vo ON p a s-

sa g e . O p er a t ion of ser vo is in d ica t e d by a t ig h t e n in g

of front band. Spring tension on servo piston shouldr e le a se t h e ba n d .

LOW AND REVERSE SERVO (REAR)

D ir e ct a ir p r essu r e in t o L O W-REV ERSE SERV O

APPLY passage. Operation of servo is indicat ed by a

t ightening of rear band. Spring tension on servo pis-

t o n sh o u ld r e le a se t h e ba n d .

If clutches a nd servos opera te properly, no upshift

or erratic shift conditions indicate t ha t ma lfunctions

e xist in t h e va lve bod y .

FLUID LEAKAGE-TRANSAXLE TORQUECONVERTER HOUSING AREA

(1) Check for Source of Leakage.S i n ce f lu id l ea k a g e a t or a r ou n d t h e t or q u e c on -

v er t er a r e a m a y or i gi n a t e f r om a n e ng in e o il l ea k ,

t h e a r e a s h ou ld b e ex a m in ed cl os el y. F a c t or y f il l

f luid is dyed red and, therefore, can be dist inguished

from engine oil.

(2) Pr ior t o r e m ovin g t h e t r a n sa x le , p e r for m t h e

following checks:

When leakage is determined to originate from the

t r a n sa x le, ch eck f luid level p r ior t o r e m ova l of t h e

t r a n sa x le a n d t o r q u e con ver t e r .

H ig h oi l l e ve l c a n r es u lt i n oi l l e a k a g e o ut t h e

ve n t in t h e d ip st ick . I f t h e f lu id le ve l is h ig h , a d ju st

to proper level.

After performing this operation, inspect for leak-

a g e . I f a lea k p er sist s , p e rf or m t h e f ol low in g op er a -

t i on on t h e v eh i cl e t o d et e rm i n e i f i t i s t h e t or q u e

con ver t e r o r t r a n sa x le t h a t is le a k in g.

LEAKAGE TEST PROBE

(1) Remove torque converter housing dust shield.

(2) Clea n t h e in sid e of t o r q u e con ver t e r h ou sin g

(lo w e r a r e a ) a s d r y a s p o ssible . A so lve n t sp r a y f o l-

lowed by compressed air drying is preferable.

Fig. 4 Air Pressure Tests

21 - 44 TRANSAXLE


45/188

(3) Fa bricat e a nd fast en test probe (Fig. 5) securely

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

torque converter is cleared by test probe. Tool must

be cle a n a n d d r y .

(4) Ru n e n gin e a t a p p r ox im a t e ly 2,500 r p m w it h

t r a n sa x le in n e u t r a l , f or a bo u t 2 m in u t es. Tr a n sa x lem u st be a t o p e r a t in g t e m p e r a t u r e .

(5) Stop engine and carefully remove tool.

(6) If upper surface of test probe is dry, there is no

t o r q u e con ver t e r lea k . A p a t h of f lu id a cr oss p r obe

indicat es a torque converter leak. Oil leaking under

t h e p r o be is co m in g f r o m t h e t r a n sa x le p u m p a r e a .

(7) Re m o ve t r a n sa x le a n d t o r q ue con ver t e r a sse m -

bly from vehicle for further investigation.The fluid

sh ou ld be d r a in e d f r o m t h e t r a n sa x le . Re in st a l l o il

p a n (w i t h M OP AR Ad h e sive Se a la n t ) a t sp ecif ied

torque.

Possible sources of transaxle torque converter areaf luid lea k a g e a r e :

(1) Torque converter hub seal.

(a ) Se a l l ip cu t , ch e ck t o r q u e co n ve r t e r h u b f in -

ish.

(b) B ushing moved and /or w orn.

(c) O il r e t u r n h ole in p u m p h o u sin g p lu g g ed or

omitted.

(d) Seal worn out (high-mileage vehicles).

(2) F lu id l ea k a g e a t t h e ou t s id e d ia m e t er f r om

pump housing O-ring.

(3) F lu id lea k a g e a t t h e p u m p t o ca se bo lt s . C h e ck

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

necessary.

(4) Fluid leakage due to case or pump housing po-

rosity.

TORQUE CONVERTER LEAKAGE

Possible sources of torque converter leakage are:

Torque converter weld leaks at the outside diame-

ter (peripheral) weld.

Torque converter hub weld.

Torque converter impeller shell cracked adjacent

t o h u b.

At drive lug welds.

Hub weld is inside and not visible. Do not

attempt to repair. Replace torque converter.

AIR PRESSURE TEST OF TRANSAXLE

F a br ica t e e q u ip m en t n e ed e d f or t e st a s sh ow n in

figures 6 and 7.

The tra nsa xle should be prepared for pressure test a s

follows aft er removal of th e torque converter:

(1) Inst all a dipstick bore plug a nd plug oil cooler

line fitting (lower fitting).

(2) Wit h r ot a r y m ot ion , in st a l l con ver t e r h u b se a l

cup over input sha ft . I t must go through the converter

h u b se a l u n t i l t h e cu p bot t o m s a g a in st t h e p u m p g e a r

lugs. B efore use, inspect h ub sea l cup (Fig. 6) for n icks

or b u rr s t h a t cou ld d a m a g e s ea l . S e cu r e w i t h cu pr e t a in e r st r a p (F ig . 7) u sin g st a r t e r u p p e r h o le a n d

opposite bra cket hole.

(3) Atta ch a nd cla mp hose from n ozzle of Tool C-4080

to the upper cooler line fitting position in case.

CAUTION: Do not, under any circumstances, pressur-

ize a transaxle to more than 10 psi.

(4) P ressurize t he tr a nsa xle using Tool C-4080 until

t h e p re ss u re g a u g e r e a d s 8 p si . P o s it i on t r a n s a x le

Fig. 5 Leak Locating Test Probe Tool

Fig. 6 Torque Converter Hub Seal Cup

Fig. 7 Hub Seal Cup Retaining Strap

TRANSAXLE 21 - 45


46/188

so t h a t p u m p h ou sin g a n d ca se f r on t m a y be cover e d

w it h soa p y solu t ion or w a t e r . L e a k s a r e som e t im e s

caused by porosity in the case or pump housing.

I f a le a k so u r ce is lo ca t e d , t h a t p a r t a n d a l l a sso ci-

a t e d se a ls , O -r in g s, a n d g a sk et s sh ou ld be r e p la ce d

w i t h n e w p a r t s .

GEARSHIFT LINKAGE ADJUSTMENTN or m a l op er a t i on of t h e P a r k /N eu t r a l P o s it i onS w i t ch p rov id es a q u ick ch eck t o con f ir m p rop er

m a n u a l l in k a g e a d ju st m e n t .

M ov e t h e s el ect or l ev el s l ow l y u pw a r d u n t il i t

clicks into the P Park notch in the selector gate. I f

the starter will operate the P posit ion is correct .

After checking P posit ion, move selector slowly

toward N Neutral posit ion until lever drops in the

N stop. If the starter will also operate at this point

t h e g ea r s h i ft l in k a g e i s p rop er ly a d ju s t ed . I f t h e

starter fails to operate in either posit ion, linkage ad-

justment is required.

CAUTION: When it is necessary to disassemblelinkage cable from levers, which use plastic grom-mets as retainers, the grommets should be replacedwith new grommets. Use a prying tool to force rod

from grommet in lever, then cut away old grommet.Use pliers to snap new grommet into lever and rodinto grommet.

(1) S e t p a r k in g br a k e .

(2) Place gearshift lever in P (PARK) position.(3) Loosen clamp bolt on gearshift cable bracket.

(4) Colu m n sh ift : I n su r e t h a t p r eloa d a d ju st m en t

spring engages fork on transaxle bracket.

(5) P u ll t h e sh if t le ver by h a n d t o t h e f r o n t d e t e n t

posit ion (P ARK) a nd t ighten lock. Tighten screw to

11 Nm (100 in. lbs.). Gearshift linkage should now

be properly adjusted.

(6) Check adjustment as follows:

(a ) D e t e n t p o sit io n f o r n e u t r a l a n d d r ive sh o u ld

be w it h in l im it s o f h a n d le ve r g a t e st o p s.

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

in park or neutral posit ions.

THROTTLE PRESSURE LI NKAGE ADJUSTMENTThe thrott le pressure cable adjustment is very im-

p or t a n t t o p r op er t r a n sa x le op er a t io n . Th is a d ju st -

m e n t p osit ion s a va lve w h ich con t r o ls sh ift sp ee d ,

sh if t q u a l i t y , a n d p a r t t h r o t t le d o w n sh if t se n sit ivi t y .

If the sett ing is too long, early shifts and slippage be-

t w e e n s h i f t s m a y o c c u r . I f t h e s e t t i n g i s t o o s h o r t ,

s h if t s m a y b e d e la y e d a n d p a r t t h r ot t l e d ow n s h i ft s

m a y be ve r y se n sit ive .

CABLE ADJUSTMENT PROCEDURE (4-CYL.)

(1) P e r for m t r a n sa x le t h r o t t le p r essu r e ca ble a d -

ju s t m en t w h i le en g in e i s a t n or m a l op er a t i n g t e m -

perature.

(2) Loosen cable mounting bracket lock screw.

(3) Bracket should be posit ioned with both bracket

a l ig n m en t t a bs t o uch in g t h e t r a n sa x le ca st su r f a ce .

Tighten lock screw to 12 Nm (105 in. lbs.) see Fig-

ure 8.

(4) Release cross-lock on the cable a ssembly (pullcross-lock upward) see Figure 7.

(5) To insure proper adjustment, the cable must be

f r e e t o s l i d e a l l t h e w a y t o w a r d t h e e n g i n e , a g a i n s t

its stop, after the cross-lock is released.

(6) M ov e t r a n s a x le t h r ot t l e con t r ol l ev er f u ll y

clo ck w ise , a g a in st i t s in t e r n a l s t o p , a n d p r e ss cr o ss-

lock downward into locked position (Fig. 7).

(7) Th e a d ju st m en t i s com pl et e a n d t r a n s a xl e

t h r ot t le ca ble ba ck la sh w a s a u t o m a t ica l ly r e m oved .

(8) Test cable freedom of operation by moving the

tra nsaxle thrott le lever forwa rd (counterclockwise).

Then slowly release it to confirm it will return fullyrearward (clockwise).

(9) No lubrication is required for any component of

t h e t h r o t t le ca ble sy st e m .

ROD ADJUSTMENT PROCEDURE (6-CYL.)

(1) P e r for m t r a n sa x le t h r ot t le p r essu r e ca ble a d -

ju s t m en t w h i le e ng in e i s a t n or m a l op er a t i n g t e m -

perature.

(2) Loosen adjustment swivel lock screw.

(3) To in su r e p r op er a d ju st m e n t , sw ivel m u st be

free to slide along flat end of thrott le rod so that pre-

loa d sp r in g a ct ion is n o t r e st r ict ed . D isa sse m ble a n d

cle a n o r r e p a ir p a r t s t o a ssu r e f r e e a ct io n , i f n e ce s-s a r y .

(4) H old t r a n sa x le t h r o t t le le ver f ir m ly t o w a r d e n -

gine, against its internal stop and t ighten swivel lock

scr e w t o 11 Nm (100 in. lbs.)

(5) Th e a d ju st m en t is f in ish e d a n d l in k a g e ba ck

l a s h w a s a u t om a t i ca l ly r em ov ed b y t h e pr el oa d

spring.

(6) I f l ub ri ca t i on i s r eq u ir ed s ee L u br ica t i on ,

Group 0.

Fig. 8 Throttle Pressure CableTypical

21 - 46 TRANSAXLE


47/188

BAND ADJUSTMENT

KICKDOWN BAND (FRONT)

Th e k ick d ow n ba n d a d ju st in g scr e w is loca t e d o n

left side (top front) of the transaxle case.

(1) Loosen locknut and back off nut approximately

f ive t u r n s. Te st a d ju st in g scr e w f or f r ee t u r n in g in

t h e t r a n sa x le ca se .(2) U sing w rench, Tool C-3880-A wit h a da pter Tool

C-3705, t ighten band adjusting screw to 5 Nm (47 to

50 in. lbs.). I f adapter C-3705 is not used, t ighten ad-

justing screw to 8 Nm (72 in. lbs.) which is the true

torque.

(3) B a ck of f a d ju st in g scr ew t h e n u m ber of t u r n s

listed in Specifications. Hold adjusting screw in this

posit ion and t ighten locknut to 47 Nm (35 ft . lbs.)

LOW/REVERSE BAND-REAR

To adjust low-reverse band, proceed as follows:

(1) L oosen a n d ba ck of f lockn u t a p p r ox im a t e ly 5

t u r n s.(2) U sin g a n in ch -p ou n d t o r q u e w r e n ch , t ig h t en

a d ju st in g scr e w t o 5 Nm (41 in. lbs.) true torque.

(3) B a ck of f a d ju st in g scr ew t h e n u m ber of t u r n s

listed under Specifications in t h e r e a r o f t h e T r a n -sa x le Se ct ion in t h is se rvice m a n u a l .

(4) Tighten locknut to 14 Nm (10 ft. lbs.).

HYDRAULIC CONTROL PRESSURE ADJUSTMENTS

LINE PRESSURE

An incorrect thrott le pressure sett ing will cause in-

correct line pressure readings even though line pres-

s ur e a d ju st m en t i s cor r ect . Al w a y s i ns pect a n dcorrect thrott le pressure adjustment before adjusting

the line pressure.

Th e a p p r ox im a t e a d ju st m e n t f or l in e p r essu r e is

1-5/16 in ch e s, m e a su r ed f r om va lve bod y t o in n er

e d g e o f a d ju st in g n u t . Ho w e ve r , d u e t o m a n u f a ct u r -

in g t o ler a n ces, t h e a d ju st m e n t ca n be va r ie d t o ob-

tain specified line pressure.

T h e a d ju st in g scr e w m a y be t u r n e d w it h a n Alle n

w r en ch . O ne com pl et e t u rn of a d ju st i ng s cr ew

changes closed thrott le line pressure a pproximately

1-2/3 psi. Turning a djusting screw count erclockwise

increases pressure, an d clockwise decreases pressure.

THROTTLE PRESSURE

Th r ot t l e p re ss u re s ca n n ot b e t e st e d a c cu r a t e ly ;

t h er ef or e, t h e a d ju s t m en t s h ou ld b e m ea s u r ed i f a

malfunction is evident.

(1) I n se rt g a u g e p in of Tool C-3763 bet w e e n t h e

thrott le lever cam and kickdown valve.

(2) B y p us h in g i n on t ool , com pr es s k ick d ow n

v a lv e a g a i ns t i ts s pr in g s o t h r ot t l e v a l v e i s com -

pletely bottomed inside the valve body.

(3) While compressing spring, turn thrott le lever

st o p scre w w it h a d a p t er C-4553. Tu r n u n t i l h e a d of

screw touches thrott le lever tang, with thrott le lever

cam t ouching tool and t hrott le valve bottomed. B e sure

adjustment is made with spring fully compressed and

valve bottomed in the valve body.

VEHICLE SPEED SENSOR PINION GEARWhen the speed sensor is removed for any reason, a

NEW O-ring must be installed on its outside diameter.

REMOVAL AND INSTALLATION

(1) Remove speedometer cable (if so equ ipped).

(2) Remove ha rness connector from sensor. Ma ke

sure weatherseal stays on harness connector.

(3) Remove bolt securing t he dista nce sensor in the

extension housing.

(4) Carefully pull sensor and pinion gear assembly

out of extension housing.

(5) Remove pinion gear from sensor.

(6) To inst all , reverse the above procedure. Make

su r e e x t en sion h ou sin g a n d se n sor f la n g e a r e clea n

prior to installation. Always use a NEW sensor O-ring.

(7) Tig h t en se cu r in g bolt t o 7 Nm (60 in . lbs.).

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

PARK/NEUTRAL POSITION AND BACK-UP LAMPSWITCH

REPLACEMENT AND TEST

The P a rk/Neutra l swit ch is the cent er termina l of the

3 t e r m in a l sw it ch . I t p r o vid e s g r o u n d f o r t h e st a r t e r

solenoid circuit through the selector lever in only Park

and Neutral posit ions.

(1) To test switch, remove wiring connector fromsw it ch a n d t e st f o r co n t in u it y be t w e e n ce n t e r p in o f

swit ch and t ran saxle case. Continuity should exist only

w h e n t r a n sa x le is in P a r k o r N eu t r a l .

(2) Check gearshift cable adjustment before replac-

in g a sw it ch w h ich t e st s ba d .

(3) U n s cr ew s w i t ch f r om t r a n s a x le ca s e a l l ow i n g

fluid to drain into a container. Move selector lever to

P ark a nd then to Neutral posit ions. Inspect to see that

t h e s w i t ch op er a t i n g l ev er f in g er s a r e ce nt e re d i n

swit ch opening in the case.

(4) S cr e w t h e sw it ch w it h a n e w se a l in t o t r a n sa x le

ca se a n d t ig h t en t o 33 Nm (24 ft. lbs.). Retest switch

w it h t h e t e st la m p .

(5) Add fluid to tra nsa xle to bring up t o proper level.

(6) The back-up lamp switch circuit is through the

two outside terminals of the 3 terminal switch.

(7) To test switch, remove wiring connector from

swit ch and test for continuity between the tw o outside

pins.

(8) Co n t in u it y sh o u ld e x ist o n ly w it h t r a n sa x le in

Reverse position.

(9) No continuity should exist from either pin to the

case.

TRANSAXLE 21 - 47


48/188

GOVERNORTo service the governor assembly in the vehicle, it

is n o t n e ce ssa r y t o r e m ove t h e t r a n sf e r g ea r cove r,

t r a n sf e r g ea r , a n d g over n or su pp or t . Th e g over n or

m a y be se r vice d by r e m o vin g t h e t r a n sa x le o i l p a n

a n d va lve bod y a ssem bly . Wit h t h e o il p a n a n d va lve

bod y r e m ove d, t h e g ove rn or m a y be u n bolt e d f r om

the governor support and removed.Wh e n cle a n in g or a sse m blin g t h e g over n or , m a k e

sure the governor valves move freely in the bores of

the governor body.

ALUMINUM THREAD REPAIRD a m a g e d o r w o r n t h r e a d s i n t h e a l u m i n u m t r a n -

sa x le ca se a n d va lve bod y ca n be r e pa ir e d by t h e u se

of H eli-Coils, or equiva lent. This repair consists of

drilling out the worn-out damaged threads. Then tap-

ping the hole with a Heli-Coil tap, or equivalent, and

in st a l l in g a He li-Co il in ser t , or e q u iva le n t , in t o t h e

hole. This brings the hole back to its original thread

size.

H e li -C oi l, or eq u iv a len t , t ool s a n d i ns er t s a r e

readily available from most automotive parts suppli-

ers.

OIL COOLERS AND TUBES REVERSE FLUSHINGWh en a t r a n sa x le f a il ur e h a s con t a m in a t ed t h e

f luid , t h e oi l cooler (s) m u st be f lush e d. Th e t o r q u e

con ver t e r m u st be r e pla ced w it h a n e xch a n g e u n it .

Th is w ill in su r e t h a t m e t a l p a r t icles or s lu d ge d o i l

a r e n ot t r a n sf e r r ed ba ck in t o t h e r e con d it ion e d (or

replaced) tra nsa xle.

CAUTION: If vehicle is equipped with two oil cool-

ers (one in the radiator tank, one in front of the ra-

diator) they must be flushed separately. Do not

attempt to flush both coolers at one time.

(1) Disconnect the cooler lines at the transmission.

(2) U s in g a h a n d s u ct i on g u n f il le d w i t h m i n er a l

spirits, reverse flush the cooler. Force mineral spirits

in t o t h e From Cooler l ine of the cooler (Fig. 9) and

ca t c h t h e ex it i n g s pi ri t s f r om t h e To Cooler line.

O bs er v e f or t h e p re se nce of d eb r is i n t h e e xi t in g

f luid . Co n t in u e u n t i l f lu id e xit in g is cle a r a n d f r ee

from debris.

(3) U sin g com p r essed a ir in in t e rm it t e n t sp ur t s ,

blow a n y r e m a in in g m in er a l sp ir i t s f r om t h e cooler ,

again in the reverse direction.

(4) To remove any remaining mineral spirits from

t h e cooler , on e (1) q u a r t of a u t o m a t ic t r a n sm ission

fluid should be pumped through the cooler before re-

connecting.

(5) I f a t a n y s t a g e o f t h e cl ea n i ng pr oces s, t h e

cooler does not freely pa ss fluid, the cooler m ust be

replaced.

OIL COOLER FLOW CHECKAf t e r t h e n e w or r e pa ir e d t r a n sm ission h a s bee n

i n st a l l ed a n d f il le d t o t h e p rop er l ev el w i t h a u t o-

ma tic t ran smission fluid. The flow should be checked

using the following procedure:

(1) Disconnect the From cooler l i n e a t t h e t r a n s -m ission a n d p la ce a col le ct in g con t a in e r u n d er t h e

disconnected line.

(2) Ru n t h e e n g in e at curb idle speed, w i t h t h eshift selector in neutral.

(3) If the fluid flow is intermittent or it takes more

t h a n 20 s econ d s t o col le ct on e q u a r t of a u t om a t i c

transmission fluid, the cooler should be replaced.

CAUTION: With the fluid set at the proper level,

fluid collection should not exceed (1) quart or inter-nal damage to the transmission may occur.

(4) I f f lo w is f o u n d t o be w it h in a cce p t a ble l im it s ,

reconnect the cooler line. Then fill tra nsmission to

t h e p r op er leve l, u sin g t h e a p p r oved t y p e o f a u t o -

m a t ic t r a n sm ission f luid .

TRANSAXLE AND TORQUE CONVERTER REMOVALTransaxle removal does NOT require engine

removal.(1) The transaxle and torque converter must be re-

m ov ed a s a n a s s em b ly ; ot h er w i s e, t h e t or q u e c on -

ve r t e r d r ive p la t e , p u m p bu sh in g , o r o i l se a l m a y be

d a m a g e d. Th e d r iv e p l a t e w i l l n o t s u pp or t a l oa d ;

therefore, none of the weight of the transaxle should

be a l low e d t o r e st o n t h e p la t e d u r in g r e m ova l .

(2) Disconnect battery negative cable.(3) D iscon n e ct t h r o t t le l in k a g e a n d sh ift l in k a g e

f r om t r a n sa x le .

Fig. 9 Cooler Line Identification

21 - 48 TRANSAXLE


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If equipped, unplug torque converter clutchplug, located near the dipstick.

CAUTION: Raise vehicle. Remove front wheels. Refer

to Suspension, Group 2 to remove or install wheel

hub nut and both drive shafts.

Remove torque converter dust cover. Marktorque converter and drive plate with chalk, for

reassembly. Remove torque converter mountingbolts.

Fig. 1 Remove Upper and Lower Oil Cooler Hoses

Fig. 2 Engine Support Fixture

Fig. 3 Remove Bell Housing Upper Bolts

Fig. 4 Remove or Install Left Splash Shield

Fig. 5 Remove or Install Access Plug in RightSplash Shield to Rotate Engine Crankshaft

Fig. 6 Remove or Install Wire to Neutral/Park SafetySwitch

TRANSAXLE 21 - 49


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Re m ove o r in st a l l s t a r t e r . Re m ove o r in st a l l low e r

bell housing bolts.

Ca r e f u lly w o r k t r a n sa x le a n d t o r q u e co n ve r t e r a s-

se m bly r e a r w a r d o f f e n g in e blo ck d o w e ls a n d d ise n -

gage converter hub from end of crankshaft . Attach a

small Cclamp to edge of bell housing. This will

hold torque converter in place during transaxle

removal. Lower transaxle and remove assembly from

under the vehicle.

When inst alling tra nsa xle, reverse the above proce-

dure.

I f t o r q u e con ver t e r w a s r e m oved f r om t r a n sa x le be

su r e t o a l ig n p u m p in n e r g e a r p i lo t f la t s w it h t o r q u e

converter impeller hub flats.Adjust gearshift and thrott le cables.

Re fi ll t r a n sa x le w it h MO PAR ATF P LU S (Auto-

ma tic Tra nsmiss ion F luid) Type 7176.

DISASSEMBLY SUBASSEMBLY REMOVALP r i or t o r em ov in g a n y t r a n s a x le s u ba s s em b li es ,

p lu g a l l op en in g s a n d t h o r ou g h ly cle a n e xt e r ior of

t h e u n it , p re fer a b l y b y s t ea m . C l ea n l in es s t h r ou g h

e n t ir e d isa ssem bly a n d a sse m bly ca n n ot be o ver e m -

p h a siz ed . Wh e n d isa ssem blin g , e a ch p a r t sh ou ld be

Fig. 7 Remove or Install Engine Mount Bracket from

Front Crossmember

Fig. 8 Remove or Install Front Mount InsulatorThrough-Bolt and Bell Housing Bolts

Fig. 9 Positioning Transmission Jack

Fig. 10 Remove or Install Left Engine Mount

Fig. 11 Remove or Install Left Engine Mount fromEngine

21 - 50 TRANSAXLE


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w a s h ed i n a s ui t a bl e s ol ven t , t h en d r ied b y com -

p r e sse d a ir . D o n o t w ip e p a r t s w it h sh o p t o w e ls. All

m a t in g su r f a ce s in t h e t r a n sa x le s a r e a ccu r a t e ly m a -

ch in e d ; t h e r e f o r e , ca r e f u l h a n d lin g o f a l l p a r t s m u st

be exercised to avoid nicks or burrs.

Re m ove a l l o ld se a la n t bef or e a p ply in g n e w MO -

P AR Adhesive Sealant .Use only MOPAR Ad h e sive Se a la n t w h e n in st a l l-

in g o i l p a n .

P u t M OP AR Ad h es iv e S ea l a n t on t h e oi l pa n

flange (Fig. 2) and on all oil pan bolts (underside ofbolt head).

Fig. 12 Raise or Lower Transaxle

Fig. 13 Pry Engine for Clearance

Fig. 1 Transaxle Oil Pan Bolts

Fig. 2 Transaxle Oil Pan

Fig. 3 Oil Filter Screws

TRANSAXLE 21 - 51


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R em ov e or i n st a l l n eu t r a l s t a r t i n g a n d b a ck -u p

la m p sw it ch .

Measuring input shaft end play before disassembly

w il l u su a lly in d ica t e w h e n a t h r u st w a sh e r ch a n g e is

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

t h r u st w a s h e r i s l oca t e d b et w e en i n pu t a n d ou t pu t

sh a f t s .

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

w i t h i t s p l un g er s ea t e d a g a i n s t en d of i n pu t s h a f t

(Fig. 9).

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MANUAL DE TRANSMISIONES CHRYSLER AÑOS 90 PRINCIPALMENTE

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