Sunteți pe pagina 1din 116

TRANSAXLE

CONTENTS
page page
42LE FOUR SPEED AUTOMATIC TRANSAXLE . . 1
42LE HYDRAULIC SCHEMATICS . . . . . . . . . . 101
42LE ON-BOARD DIAGNOSTICS . . . . . . . . . . . 84
42LE SPECIFICATIONS . . . . . . . . . . . . . . . . . . 114
42LE FOUR SPEED AUTOMATIC TRANSAXLE
INDEX
page page
42LE General Diagnosis . . . . . . . . . . . . . . . . . . . . 3
Air Pressure Test of Transaxle Sump . . . . . . . . . . 20
Aluminum Thread Repair . . . . . . . . . . . . . . . . . . . 23
Back Up Lamp Diagnosis . . . . . . . . . . . . . . . . . . . 25
Bearing Adjustment Procedures . . . . . . . . . . . . . . 82
Clutch Air Pressure Tests . . . . . . . . . . . . . . . . . . . 17
Coolers and Tubes Reverse Flushing . . . . . . . . . . 23
Determining No. 4 Thrust Plate Thickness
(Input Shaft End Play) . . . . . . . . . . . . . . . . . . . . 63
Differential Carrier-Recondition . . . . . . . . . . . . . . . 82
Differential Recondition . . . . . . . . . . . . . . . . . . . . 66
Drive Sprocket Height Adjustment Procedure . . . . 65
Floor Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fluid and Filter Change-Transmission Sump . . . . . . 9
Fluid Drain and Refill-Differential Sump . . . . . . . . . 10
Fluid Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fluid Level and Condition . . . . . . . . . . . . . . . . . . . . 9
Gearshift LinkageColumn Shift . . . . . . . . . . . . . 10
Gearshift LinkageFloor Shift . . . . . . . . . . . . . . . 13
General Information . . . . . . . . . . . . . . . . . . . . . . . . 1
Hydraulic Pressure Tests . . . . . . . . . . . . . . . . . . . 16
Input Clutches-Recondition . . . . . . . . . . . . . . . . . . 51
Long Stub Shaft Seal Replacement . . . . . . . . . . . 21
Low/Reverse Clutch Clearance . . . . . . . . . . . . . . . 51
Manual Valve Lever Position Sensor . . . . . . . . . . . 23
Oil Cooler Flow Check . . . . . . . . . . . . . . . . . . . . . 23
Oil Pump Seal Replacement . . . . . . . . . . . . . . . . . 33
Output Shaft Bearing Preload Shim Selection . . . . 49
Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Selection of Lubricants . . . . . . . . . . . . . . . . . . . . . . 9
Short Stub Shaft Seal Replacement . . . . . . . . . . . 22
Snubber Gap Measurement . . . . . . . . . . . . . . . . . 65
Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . 24
Special Additives . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Speed Sensor-Input . . . . . . . . . . . . . . . . . . . . . . . 27
Speed Sensor-Output . . . . . . . . . . . . . . . . . . . . . . 27
Torque Converter Clutch Break-In Procedure . . . . 34
Transaxle Disassemble/Reassemble . . . . . . . . . . . 35
Transaxle Quick Learn Procedure . . . . . . . . . . . . . 35
Transaxle Removal and Installation . . . . . . . . . . . . 32
Transfer Chain Length Measurement . . . . . . . . . . 63
Transfer Shaft Seal Replacement . . . . . . . . . . . . . 30
Transmission Control Module . . . . . . . . . . . . . . . . 25
Transmission Control Relay . . . . . . . . . . . . . . . . . 24
Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
GENERAL INFORMATION
The 42LE Four Speed Transaxl e uses ful l y-adapti ve
control s. Adapti ve control s are those whi ch perform
thei r functi ons based on real -ti me feedback sensor
i nformati on. The transaxl e i s conventi onal i n the use
of hydraul i cal l y appl i ed cl utches to shi ft a pl anetary
gear trai n. I t uses el ectroni cs to control vi rtual l y al l
other functi ons.
42LE TRANSAXLE IDENTIFICATION
The 42LE transaxl e i denti fi cati on code i s pri nted on
a bar code l abel . The l abel i s l ocated on the transaxl e
case (Fi g. 1).
IN-VEHICLE SERVICE
The fol l owi ng i s a l i st of transaxl e components that
are servi ceabl e i n the vehi cl e:
Fig. 1 Identification Tag Location
TRANSAXLE 21 - 1
Val ve Body Assembl y
Sol enoi d Pack
Manual Val ve Lever Posi ti on Sensor (MVLPS)
I nput Speed Sensor
Output Speed Sensor
Transfer Chai n
Chai n Sprockets
Short (Ri ght) Stub Shaft Seal
Long (l eft) Stub Shaft and Bal l Beari ng
OPERATION
The 42LE transaxl e provi des forward rati os of
2.84, 1.57, 1.00, and 0.69. The torque converter
cl utch i s avai l abl e i n 2nd, di rect, or overdri ve gear.
The Reverse rati o i s 2.21. The shi ft l ever i s conven-
ti onal wi th si x posi ti ons (P, R, N, OD, 3, and L).
When OD i s sel ected the transaxl e shi fts normal l y
through al l four speeds wi th the torque converter
cl utch operati onal i n thi rd and overdri ve; thi s posi -
ti on i s recommended for most dri vi ng. The 3 posi ti on
i s tai l ored for use i n hi l l y or mountai nous dri vi ng.
When 3 i s sel ected, the transmi ssi on uses onl y 1st,
2nd, and di rect gears wi th 2nd-di rect shi ft del ayed to
40 mph or greater. When operati ng i n 3 or L posi -
ti ons torque converter cl utch appl i cati on occurs i n
di rect gear. Thi s i mproves transmi ssi on cool i ng
when towi ng trai l ers and/or dri vi ng on steep grades.
I f hi gh engi ne cool ant temperature occurs, the
torque converter cl utch wi l l al so engage i n 2nd gear.
The L posi ti on provi des maxi mum engi ne braki ng
for descendi ng steep grades. Unl i ke most current
transaxl es, upshi fts are provi ded to 2nd or di rect
gear at peak engi ne speeds i f the accel erator i s de-
pressed. Thi s provi des engi ne over-speed protecti on
and maxi mum performance.
CLUTCH AND GEAR
The 42LE transaxl e consi sts of:
Three mul ti pl e-di sc i nput cl utches
Two mul ti pl e-di sc grounded cl utches
Four hydraul i c accumul ators
Two pl anetary gear sets
Thi s provi des four forward rati os and a reverse
rati o. The cl utch appl y pi stons have a centri fugal l y
bal anced oi l cavi ti es so that qui ck response and good
control can be achi eved. A push/pul l pi ston i s i ncorpo-
rated for two of the three i nput cl utches.
CAUTION: Some clutch packs appear similar, but
they are not the same. Do not interchange clutch
components as they might fail.
HYDRAULICS
The hydraul i cs of the transaxl e provi de:
Manual shi ft l ever sel ect functi on
Mai n l i ne pressure regul ati on
Torque converter fl ow control
Transaxl e oi l cool er fl ow control
Oi l fl ow to the fri cti on el ements i s control l ed di -
rectl y by four sol enoi d val ves. The hydraul i cs al so
i ncl ude a l ogi c-control l ed sol enoi d swi tch val ve. I t
l ocks out the 1st gear reacti on el ement wi th the appl i -
cati on of 2nd, di rect, or overdri ve gear el ements. I t
al so redi rects the 1st gear sol enoi d output so that i t
can control torque converter cl utch operati on. To re-
gai n access to 1st gear, a speci al sequence of sol enoi d
commands must be used to unl ock and move the
sol enoi d swi tch val ve. Thi s precl udes any appl i cati on
of the 1st gear reacti on el ement wi th other el ements
appl i ed. I t al so al l ows one sol enoi d to control two
fri cti on el ements.
Smal l , hi gh-rate accumul ators are provi ded i n each
control l ed fri cti on el ement ci rcui t. These serve to ab-
sorb the pressure responses, and al l ow the control s to
read and respond to changes that are occurri ng.
SOLENOIDS
Si nce the sol enoi d val ves perform al l control func-
ti ons, these val ves must be durabl e and tol erant of
Fig. 2 Left Side View of Transaxle
Fig. 3 Right Side View of Transaxle
21 - 2 TRANSAXLE
di rt parti cl es. For that reason hardened-steel poppet
and bal l val ves are used. These are free from any
cl ose operati ng cl earances, and the sol enoi ds operate
the val ves di rectl y. Di rect operati on means that these
uni ts must have very hi gh output. They must cl ose
agai nst the si zeabl e fl ow areas and hi gh l i ne pres-
sures. Fast response i s al so requi red to meet the
control requi rements.
Two of the sol enoi ds are normal l y-venti ng and two
are normal l y-appl yi ng; thi s was done to provi de a
defaul t mode of operati on. Wi th no el ectri cal power,
the transmi ssi on provi des 2nd gear i n OD, 3, or L
shi ft l ever posi ti ons. Al l other shi ft l ever posi ti ons
wi l l functi on normal l y. The choi ce of 2nd gear was
made to provi de adequate performance whi l e sti l l ac-
commodati ng hi ghway speeds.
SENSORS
There are three pressure swi tches whi ch i denti fy
sol enoi d appl i cati on. The pressure swi tches are i ncor-
porated i n an assembl y wi th the sol enoi ds. Two speed
sensors read i nput (torque converter turbi ne) and
output (parki ng sprag) speeds. There i s al so a manual
val ve l ever posi ti on sensor (MVLPS) whi ch senses
manual val ve posi ti on.
Engi ne speed, throttl e posi ti on, temperature, etc.,
are al so observed. Some of these si gnal s are read
di rectl y from the engi ne control sensors; others are
read from a mul ti pl ex ci rcui t wi th the engi ne control -
l er.
ADAPTIVE CONTROLS
These control s functi on by readi ng the i nput and
output speeds over 140 ti mes a second and respond-
i ng to each new readi ng. Thi s provi des the fri cti on
el ement control needed to make smooth cl utch-to-
cl utch shi fts for al l gear changes wi thout the use of
overrunni ng cl utches. As wi th most automati c tran-
saxl es, al l shi fts i nvol ve rel easi ng one el ement and
appl yi ng a di fferent el ement. I n si mpl i fi ed terms, the
upshi ft l ogi c al l ows the rel easi ng el ement to sl i p
backwards sl i ghtl y to ensure that i t does not have
excess capaci ty; the appl y el ement i s fi l l ed unti l i t
begi ns to make the speed change to the hi gher gear;
i ts appl y pressure i s then control l ed to mai ntai n the
desi red rate of speed change unti l the shi ft i s com-
pl ete. The key to provi di ng excel l ent shi ft qual i ty i s
preci si on; for exampl e, as menti oned, the rel ease el e-
ment for upshi fts i s al l owed to sl i p backwards
sl i ghtl y; the amount of that sl i p i s typi cal l y l ess than
a total of 20 degrees. To achi eve that preci si on, the
transmi ssi on control modul e l earns the characteri s-
ti cs of the parti cul ar transaxl e that i t i s control l i ng. I t
l earns:
The rel ease rate of the rel easi ng el ement.
The appl y ti me of the appl yi ng el ement.
The rate the appl y el ement bui l ds pressure.
Thi s method achi eves more preci si on than woul d be
possi bl e wi th exacti ng tol erances. I t can al so adapt to
any changes that occur wi th age or envi ronment.
For ki ckdown shi fts, the control l ogi c al l ows the
rel easi ng el ement to sl i p. Then control s the rate at
whi ch the i nput (and engi ne) accel erate. When the
l ower gear speed i s achi eved, the rel easi ng el ement
reappl i es to mai ntai n that speed unti l the appl y el e-
ment i s fi l l ed. Thi s provi des qui ck response and a
smooth torque exchange si nce the rel ease el ement can
control the rate of torque i ncrease. Thi s control can
make any powertrai n feel more responsi ve wi thout
i ncreasi ng harshness.
Adapti ve control s respond to i nput speed changes.
They compensate for changes i n engi ne or fri cti on
el ement torque. Thi s provi de consi stent shi ft qual i ty
for the l i fe of the transaxl e.
DIAGNOSTICS
These control s al so provi de comprehensi ve, on-
board transaxl e di agnosti cs. The i nformati on avai l -
abl e can ai d i n transaxl e di agnosi s. For exampl e,
appl y el ement bui l dup rate i ndi cates sol enoi d perfor-
mance. Al so i ncl uded are sel f-di agnosti c functi ons
whi ch al l ow the techni ci an to test the el ectroni c con-
trol s. The transmi ssi on control modul e moni tors i ts
cri ti cal functi ons, records any mal functi ons, and the
number of engi ne starts si nce the l ast mal functi on.
The techni ci an can use thi s i nformati on i n the event
of a customer compl ai nt. Refer to the 42LE Transaxl e
Di agnosti c Procedure Manual for speci fi cs.
42LE GENERAL DIAGNOSIS
CAUTION: Before attempting any repair on the 42LE
Four Speed Automatic Transaxle, always check for
proper shift linkage adjustment. Also check for diag-
nostic trouble codes with the DRB scan tool and the
42LE Transaxle Diagnostic Procedure Manual.
42LE automati c transaxl e mal functi ons may be
caused by these general condi ti ons:
Poor engi ne performance
I mproper adjustments
Hydraul i c mal functi ons
Mechani cal mal functi ons
El ectroni c mal functi ons
When di agnosi ng a probl em al ways begi n wi th re-
cordi ng the compl ai nt. The compl ai nt shoul d be de-
fi ned as speci fi c as possi bl e. I ncl ude the fol l owi ng
checks:
Temperature at occurrence (col d, hot, both)
Dynami c condi ti ons (accel erati on, decel erati on, up-
shi ft, corneri ng)
El ements i n use when condi ti on occurs (what gear
i s transaxl e i n duri ng condi ti on)
Road and weather condi ti ons
Any other useful di agnosti c i nformati on.
TRANSAXLE 21 - 3
After noti ng al l condi ti ons, check the easi l y acces-
si bl e vari abl es:
Fl ui d l evel and condi ti on
Shi ft l i nkage adjustment
Di agnosti c troubl e code i nspecti on
Then perform a road test to determi ne i f the prob-
l em has been corrected or that more di agnosi s i s
necessary. I f the probl em exi sts after the prel i mi nary
tests and correcti ons are compl eted, hydraul i c pres-
sure checks shoul d be performed.
DIAGNOSIS GUIDE-ABNORMAL NOISE
21 - 4 TRANSAXLE
DIAGNOSIS GUIDE-VEHICLE WILL NOT MOVE
TRANSAXLE 21 - 5
DIAGNOSIS GUIDE-FLUID LEAKS
21 - 6 TRANSAXLE
DIAGNOSTIC TROUBLE CODE CHART A
TRANSAXLE 21 - 7
DIAGNOSIS CHART B
21 - 8 TRANSAXLE
FLUID LEVEL AND CONDITION
The transmission and differential have separate
oil sumps. The transmission sump requires auto-
matic transmission fluid. The differential sump re-
quires petroleumbased hypoid gear lube.
TRANSMISSION SUMP
The transmi ssi on sump has a di psti ck to check oi l
si mi l ar to most automati c transmi ssi ons. I t i s l ocated
on the l eft si de of the engi ne. Be sure to wi pe al l di rt
from di psti ck handl e before removi ng.
The torque converter fi l l s i n both the P Park and N
Neutral posi ti ons. Pl ace the sel ector l ever i n P Park
to be sure that the fl ui d l evel check i s accurate. The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground. The fl ui d shoul d be at normal operati ng
temperature (approxi matel y 82 C. or 180 F.). The
fl ui d l evel i s correct i f i t i s i n the HOT regi on (cross-
hatched area) on the oi l l evel i ndi cator (Fi g. 1).
Low fl ui d l evel can cause a vari ety of condi ti ons
because i t al l ows the pump to take i n ai r al ong wi th
the fl ui d. As i n any hydraul i c system, ai r bubbl es
make the fl ui d spongy, therefore, pressures wi l l be
l ow and bui l d up sl owl y.
I mproper fi l l i ng can al so rai se the fl ui d l evel too
hi gh. When the transaxl e has too much fl ui d, the
gears churn up foam and cause the same condi ti ons
whi ch occur wi th a l ow fl ui d l evel .
I n ei ther case, ai r bubbl es can cause overheati ng
and/or fl ui d oxi dati on, and varni shi ng. Thi s can i nter-
fere wi th normal val ve, cl utch, and accumul ator op-
erati on. Foami ng can al so resul t i n fl ui d escapi ng
from the transaxl e vent where i t may be mi staken for
a l eak.
Al ong wi th fl ui d l evel , i t i s i mportant to check the
condi ti on of the fl ui d. When the fl ui d smel l s burned,
and i s contami nated wi th metal or fri cti on materi al
parti cl es, a compl ete transaxl e recondi ti on i s needed.
Be sure to exami ne the fl ui d on the di psti ck cl osel y. I f
there i s any doubt about i ts condi ti on, drai n out a
sampl e for a doubl e check.
After the fl ui d has been checked, seat the di psti ck
ful l y to seal out water and di rt.
The transmi ssi on fl ui d l evel shoul d be i nspected at
l east every si x months.
DIFFERENTIAL SUMP
The di fferenti al sump i s checked separatel y from
the transmi ssi on. A fi l l pl ug l ocated on the si de of the
transaxl e must be removed to check fl ui d l evel (Fi g.
2). The fl ui d shoul d be l evel wi th the bottom of the fi l l
hol e. The di fferenti al capaci ty i s .946 l i ters (32
ounces).
I nspect the di fferenti al area duri ng engi ne oi l
changes for any l eaks. I f l eakage i s present, deter-
mi ne the source of the l eak and repai r as requi red.
Remove the fi l l pl ug and veri fy the proper l evel . Ad-
just i f needed.
SELECTION OF LUBRICANTS
I t i s i mportant that the proper l ubri cants be used i n
the 42LE transaxl e. Mopar ATF Pl us (Automati c
Transmi ssi on Fl ui d-Type 7176) shoul d be used i n the
transmi ssi on si de of the transaxl e. Substi tute fl ui ds
can i nduce torque converter cl utch shudder.
The di fferenti al si de of the transaxl e shoul d be
fi l l ed wi th Mopar petrol eum based hypoi d gear l ubri -
cant 80W-90. Syntheti c gear l ubri cants shoul d not be
used.
SPECIAL ADDITIVES
Chrysl er Corporati on does not recommend the addi -
ti on of any fl ui ds to the transmi ssi on, other than the
fl ui d l i sted above. An excepti on to thi s pol i cy i s the
use of speci al dyes to ai d i n detecti ng fl ui d l eaks. The
use of transmi ssi on seal ers shoul d be avoi ded, si nce
they may adversel y affect seal s.
FLUID AND FILTER CHANGE-TRANSMISSION
SUMP
Only fluids of the type labeled Mopar ATF
Plus (Automatic Transmission fluid) Type 7176
should be used. A filter change should be made
Fig. 2 Differential Oil Fill Plug Location
Fig. 1 Dipstick Markings
TRANSAXLE 21 - 9
at 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 rea-
son, the fluid and filter should be changed.
(1) Rai se vehi cl e on a hoi st (See Lubri cati on, Group
0). Pl ace a drai n contai ner wi th a l arge openi ng,
under transaxl e oi l pan.
(2) Loosen pan bol ts and tap the pan at one corner
to break i t l oose al l owi ng fl ui d to drai n, then remove
the oi l pan.
(3) I nstal l a new fi l ter and o-ri ng on bottom of the
val ve body and ti ghten retai ni ng screws to 5 Nm (40
i n. l bs.).
(4) Cl ean the oi l pan and magnet. Rei nstal l pan
usi ng new Mopar Si l i cone Adhesi ve seal ant. Ti ghten
oi l pan bol ts to 19 Nm (165 i n. l bs.).
(5) Pour four quarts of Mopar ATF Pl us (Automati c
Transmi ssi on Fl ui d) Type 7176 through the di psti ck
openi ng.
(6) Start engi ne and al l ow to i dl e for at l east one
mi nute. Then, wi th parki ng and servi ce brakes ap-
pl i ed, move sel ector l ever momentari l y to each posi -
ti on, endi ng i n the park or neutral posi ti on.
(7) Add suffi ci ent fl ui d to bri ng the l evel 1/4 i nch
above the bottom hol e of the di psti ck. Room temperature
oi l (70F.) set at thi s l evel wi l l expand (when heated to
180F.) to a l evel wi thi n the hot range (Fi g. 3).
Recheck the fl ui d l evel after the transaxl e has
reached normal operati ng temperature (180F.).
To prevent di rt from enteri ng transaxl e, make certai n
that di psti ck i s ful l seated i nto the di psti ck openi ng.
FLUID DRAIN AND REFILL-DIFFERENTIAL SUMP
The di fferenti al fl ui d can be drai ned and fi l l ed wi th-
out havi ng to remove the transaxl e from the vehi cl e.
Use onl y Mopar 80W-90 petrol eum based hypoi d gear
l ubri cant when repl aci ng fl ui d.
REMOVAL
(1) Rai se vehi cl e on hoi st.
(2) Remove di fferenti al drai n pl ug l ocated on the
bottom of the di fferenti al housi ng. Al l ow the fl ui d to
drai n i nto oi l drai n pan.
(3) Remove di fferenti al fi l l pl ug l ocated on the di f-
ferenti al si de cover. Thi s wi l l assi st the fl ow of fl ui d
from the drai n pl ug hol e.
INSTALLATION
(1) I nstal l drai n pl ug i nto di fferenti al housi ng.
Ti ghten drai n pl ug to 7 Nm (60 i n. l bs.)
(2) Fi l l di fferenti al wi th Mopar 80W-90 or equi va-
l ent petrol eum based hypoi d gear l ubri cant. The fl ui d
shoul d be l evel wi th the bottom of the fi l l hol e. The
di fferenti al capaci ty i s .946 l i ters (32 ounces).
CAUTION: Overfilling the differential can result in oil
foaming and/or oil loss from the differential vent.
(3) I nstal l di fferenti al fi l l pl ug. Ti ghten fi l l pl ug to
47 Nm (35 ft. l bs.).
GEARSHIFT LINKAGE COLUMN SHIFT
The gear shi ft l i nkage shoul d be adjusted i f any of
the fol l owi ng repai rs or si tuati ons are encountered:
Transaxl e repl acement.
Val ve body repai r.
Shi ft cabl e repl acement.
Col umn shi fter repl acement.
I nterl ock cabl e repl acement.
When there i s no cranki ng i n Park or Neutral .
I f the fol l owi ng condi ti ons are encountered, the i n-
terl ock cabl e i s out of adjustment. Refer to I nterl ock
Cabl e Adjustment procedure.
When the transaxl e can be shi fted wi thout the key
i n the i gni ti on.
I f the key can be removed wi th the shi fter i n
reverse.
When the key can not be removed wi th the shi fter
i n the park posi ti on.
REMOVAL
(1) Remove under panel si l encer/duct assembl y
(Fi g. 1).
Fig. 3 Dipstick Markings
Fig. 1 Panel Removal
21 - 10 TRANSAXLE
(2) Remove col umn cover screws (Fi g. 2).
(3) Ti l t col umn down and remove upper hal f of
col umn cover (Fi g. 3).
(4) Rai se col umn up and remove ti l t l ever (Fi g. 4).
(5) Wi th key removed, remove l ower col umn cover
(Fi g. 5).
(6) Remove cabl e from shi ft pi n (Fi g. 6).
(7) Remove cabl e retai ner cl i p from shi ft cabl e con-
dui t bracket (Fi g. 7).
CAUTION: Column must be tilted fully upward to
remove cable retainer clip.
Fig. 2 Lower Column Cover Screw Removal
Fig. 3 Upper Column Removal
Fig. 4 Tilt Lever Screw Removal
Fig. 5 Lower Column Cover Removal
Fig. 6 Cable Removal From Shift Pin
Fig. 7 Shift Cable Retainer Clip Removal
TRANSAXLE 21 - 11
(8) From underhood si de of dash panel , unseat
grommet and pul l cabl e from i nteri or of vehi cl e.
(9) Rai se vehi cl e on hoi st and unbol t fi l l tube
bracket. Rotate fi l l tube to gai n access to shi ft cabl e
cl amp (Fi g. 8).
(10) Loosen shi ft cabl e cl amp on transaxl e.
(11) Di sconnect shi fter cabl e from shi ft l ever as-
sembl y at transaxl e (Fi g. 9).
(12) Remove cabl e from underneath vehi cl e.
INSTALLATION
(1) Route new cabl e from undersi de of vehi cl e. The
cabl e must be routed between the engi ne bl ock and
the heater return tube (Fi g. 10).
(2) Snap new transaxl e cabl e on to transaxl e shi ft
l ever assembl y.
(3) Set shi ft l ever assembl y i n park posi ti on at
transaxl e. Thi s i s the most rearward posi ti on.
CAUTION: Park sprag must be engaged when ad-
justing linkage. Rock vehicle back and forth to en-
sure that park sprag is fully engaged.
(4) Pl ace condui t end fi tti ng i n cl amp and ti ghten
mounti ng bol t.
(5) Rotate fi l l tube to ori gi nal l ocati on. I nstal l and
ti ghten fi l l tube bracket bol t.
(6) Route transaxl e shi ft cabl e through hol e i n dash
panel .
(7) I nstal l cabl e grommet i n dash panel .
(8) Route transaxl e shi ft cabl e al ong steeri ng col -
umn (Fi g. 11).
(9) Connect transaxl e shi ft cabl e to shi ft cabl e con-
dui t bracket and secure wi th new cl i p.
(10) Attach shi ft cabl e (wi th shi ft l ever i n park
posi ti on) to attachi ng stud (pi n) by snappi ng i nto
pl ace.
(11) Engage the park sprag. Shi ft the transaxl e
l ever to park. Move the steeri ng col umn to ful l ti l t
downward. Put the col umn shi fter i n park wi th key
removed.
Fig. 8 Fill Tube Bracket Bolt Removal
Fig. 9 Cable Removal
Fig. 10 Shift Cable Routing
Fig. 11 Shift Cable Routing
21 - 12 TRANSAXLE
(12) Adjust cabl e by rotati ng the adjuster i nto l ock
posi ti on (Fi g. 12). The adjuster wi l l cl i ck when l ock i s
ful l y adjusted.
(13) Rei nstal l upper and l ower steeri ng col umn
shrouds. Then i nstal l underpanel si l encer/duct.
(14) Check shi fter for proper operati on. I t shoul d
operate smoothl y wi thout bi ndi ng. The engi ne starter
shoul d crank i n Park or Neutral posi ti ons onl y.
ADJ USTMENT
(1) Remove upper steeri ng col umn shroud.
(2) Rotate cabl e adjuster i nto unl ock posi ti on. Use a
strai ght bl ade screwdri ver to unl ock adjuster (Fi g.
13).
(3) Make sure that the transaxl e shi ft l ever (at
transaxl e) i s i n the park posi ti on and the park sprag
i s ful l y engaged.
CAUTION: Park sprag must be engaged when ad-
justing linkage. Rock vehicle back and forth to en-
sure that park sprag is fully engaged.
(4) Ti l t the steeri ng col umn to the ful l down posi -
ti on.
(5) Pl ace shi fter i n the park posi ti on wi th the key
removed.
(6) Adjust by rotati ng adjuster i nto l ock posi ti on
(Fi g. 12).
(7) Rei nstal l upper steeri ng col umn shroud.
(8) Check shi fter for proper operati on. I t shoul d
operate smoothl y wi thout bi ndi ng. The vehi cl e shoul d
crank i n Park or Neutral onl y.
GEARSHIFT LINKAGE FLOOR SHIFT
The gear shi ft l i nkage shoul d be adjusted i f any of
the fol l owi ng repai rs or si tuati ons are encountered:
Transaxl e repl acement.
Val ve body repai r.
Shi ft cabl e repl acement.
Fl oor Shi fter Repl acement
I nterl ock cabl e repl acement.
When there i s no cranki ng i n park or neutral .
I f the fol l owi ng condi ti ons are encountered, the i n-
terl ock cabl e i s out of adjustment. Refer to I nterl ock
Cabl e Adjustment procedure.
When the transaxl e can be shi fted wi thout the key
i n the i gni ti on.
I f the key can be removed wi th the shi fter i n
reverse.
When the key can not be removed wi th the shi fter
i n the park posi ti on.
REMOVAL
(1) Remove shi ft handl e (Fi g. 1).
(2) Remove consol e bezel from vehi cl e (Fi g. 2).
(2) Loosen nut on shi ft cabl e adjust l ever (Fi g. 3).
(3) Remove retai ni ng cl i p from shi ft cabl e condui t
bracket.
(4) Di sconnect shi fter cabl e from cabl e attach stud
(pi n).
(5) Remove cabl e from center consol e routi ng.
Leave fl at on fl oor for ease of removal .
Fig. 12 Shift Cable Adjuster Lock
Fig. 13 Cable Lock Mechanism
Fig. 1 Shift Handle Retaining Screw
TRANSAXLE 21 - 13
(6 From underhood si de of dash panel unseat grom-
met and remove cabl e from i nteri or of vehi cl e.
(7) Rai se vehi cl e on hoi st and di sconnect fi l l tube
bracket from transaxl e. Rotate fi l l tube to gai n access
to shi ft cabl e cl amp.
(8) Loosen bol t that cl amps shi ft cabl e to transaxl e.
(9) Di sconnect shi fter cabl e from shi ft l ever assem-
bl y at transaxl e.
(10) Remove cabl e from underneath vehi cl e.
INSTALLATION
(1) Reroute new cabl e from undersi de of vehi cl e.
The cabl e must be routed between the engi ne bl ock
and the heater return tube (Fi g. 5).
(2) Snap new transaxl e cabl e on to shi ft l ever as-
sembl y.
(3) Set shi ft l ever assembl y i n park posi ti on at
transaxl e. Thi s i s the most rearward posi ti on.
CAUTION: Park sprag must be engaged when ad-
justing linkage. Rock vehicle back and forth to en-
sure that park sprag is fully engaged.
(4) Pl ace condui t end fi tti ng i n cl amp and ti ghten
mounti ng bol t.
(5) Rotate fi l l tube to ori gi nal l ocati on. I nstal l and
ti ghten fi l l tube bracket bol t.
(6) Route transaxl e shi ft cabl e through hol e i n dash
panel .
(7) I nstal l cabl e grommet i n dash panel .
(8) Route transaxl e shi ft cabl e under A/C duct, over
central di stri buti on duct, through support strut and
ai r bag mounti ng bracket. Then route over carpeti ng
and down to the shi fter bracket. (Fi g. 6).
(9) Pl ace shi fter i n the Park posi ti on.
(10) Route cabl e through hol e i n shi fter bracket
and attach to cabl e attachi ng stud (pi n) by snappi ng
i nto pl ace.
(11) I nstal l a new cl i p onto the cabl e at the shi fter
bracket.
(12) Ti ghten the adjuster nut.
(13) Rei nstal l consol e bezel and shi fter handl e.
Fig. 2 Console Bezel Removal
Fig. 3 Shift Cable Adjust Lever Nut
Fig. 4 Fill Tube Bracket Bolt Removal
Fig. 5 Shift Cable Routing
21 - 14 TRANSAXLE
(14) Check shi fter for proper operati on. I t shoul d
operate smoothl y wi thout bi ndi ng. The vehi cl e shoul d
crank i n Park or Neutral onl y.
ADJ USTMENT
(1) Remove shi fter handl e and consol e bezel .
(2) Loosen nut on shi fter cabl e adjuster (Fi g. 7).
(3) Set shi ft l ever assembl y i n park posi ti on at
transaxl e. Thi s i s the most rearward posi ti on.
CAUTION: Park sprag must be engaged when ad-
justing linkage. Rock vehicle back and forth to en-
sure that park sprag is fully engaged.
(4) Pl ace shi fter i n park posi ti on.
(5) Pl ace i gni ti on i n l ock wi th key removed.
(6) Ti ghten adjuster nut at shi fter (Fi g. 7).
(7) Rei nstal l consol e bezel and shi fter handl e.
(8) Check shi fter for proper operati on. I t shoul d
operate smoothl y wi thout bi ndi ng. The vehi cl e shoul d
crank i n Park or Neutral onl y.
FLOOR SHIFTER
REMOVAL
(1) Remove shi fter handl e and consol e bezel .
(2) Loosen adjuster nuts on i nterl ock adjuster and
shi fter adjuster.
(3) Di sconnect shi fter cabl e from cabl e attachi ng
stud (pi n).
(4) Di sconnect i nterl ock cabl e from shi fter base
sl ot. Be careful not to break tab on i nterl ock cabl e
condui t end fi tti ng (Fi g. 8).
(5) Remove the three fl oor pan attachi ng nuts from
the i nteri or of the shi fter base.
(6) Remove shi fter assembl y from vehi cl e.
INSTALLATION
(1) I nstal l new shi fter. Make sure eyel et of shi fter
cabl e i s i nsi de of shi fter housi ng.
(2) I nstal l three fl oor pan attachi ng nuts to hol d
shi fter base.
(3) Pl ace shi ft l ever and transaxl e i n park.
CAUTION: Park sprag must be engaged when ad-
justing linkage. Rock vehicle back and forth to en-
sure that park sprag is fully engaged.
(4) Wi th the i gni ti on i n the l ock posi ti on, attach
shi ft cabl e eyel et to cabl e attachi ng stud (pi n).
(5) Sl i p i nterl ock cabl e core wi re i nto i nterl ock ad-
justment l ever groove. Make sure the i nterl ock cabl e
sl ug i s seated i n the groove.
(6) Sl i p i nterl ock cabl e condui t end fi tti ng i nto base
and snap i nto pl ace.
CAUTION: Both the shift cable and the interlock
cable must be adjusted. Refer to the cable adjust-
ment procedures in this manual.
Fig. 6 Interior Cable Routing
Fig. 7 Shift Cable Adjust Lever Nut
Fig. 8 Interlock Cable Removal
TRANSAXLE 21 - 15
ROAD TEST
Pri or to performi ng a road test, veri fy that the fl ui d
l evel , fl ui d condi ti on, and l i nkage adjustment have
been approved.
Duri ng the road test, the transaxl e shoul d be oper-
ated i n each posi ti on to check for sl i ppi ng and any
vari ati on i n shi fti ng.
I f the vehi cl e operates properl y at hi ghway speeds,
but has poor accel erati on, the converter stator over-
runni ng cl utch may be sl i ppi ng. I f accel erati on i s
normal , but hi gh throttl e openi ng i s needed to mai n-
tai n hi ghway speeds, the converter stator cl utch may
have sei zed. Both of these stator defects requi re re-
pl acement of the torque converter and thorough tran-
saxl e cl eani ng.
An engi ne mi ss coul d be attri buted to a cracked
dri ve pl ate. A cracked dri ve pl ate coul d cause the
camshaft posi ti on sensor and crankshaft posi ti on sen-
sor si gnal s to be out of synchroni zati on. Thi s coul d
cause a no-start condi ti on.
A sl i ppi ng cl utch can be determi ned by operati ng
the transaxl e i n al l sel ector posi ti ons. Then compar-
i ng whi ch i nternal uni ts are appl i ed i n those posi -
ti ons. The El ements i n Use Chart provi des a basi s for
road test anal ysi s.
The process of el i mi nati on can be used to detect any
uni t whi ch sl i ps and to confi rm proper operati on of
good uni ts. Road test anal ysi s can di agnose sl i ppi ng
uni ts, but the cause of the mal functi on can not be
determi ned. Practi cal l y any condi ti on can be caused
by l eaki ng hydraul i c ci rcui ts or sti cki ng val ves.
HYDRAULIC PRESSURE TESTS
Pressure testi ng i s a very i mportant step i n the
di agnosti c procedure. These tests usual l y reveal the
cause of most transaxl e probl ems.
Before performi ng pressure tests, be certai n that
fl ui d l evel and condi ti on, and shi ft cabl e adjustments
have been checked and approved. Fl ui d must be at
operati ng temperature (150 to 200 degrees F.).
I nstal l an engi ne tachometer, rai se vehi cl e on hoi st
whi ch al l ows front wheel s to turn, and posi ti on ta-
chometer so i t can be read.
Usi ng speci al adapters (L-4559), attach 300 psi
gauges to ports requi red for test bei ng conducted.
Test port l ocati ons are shown i n (Fi gure 1).
ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER
Fig. 1 Pressure Taps
21 - 16 TRANSAXLE
TEST ONE-SELECTOR IN L
This test checks pump output, pressure regu-
lation and condition of the low/reverse clutch
hydraulic circuit and shift schedule.
(1) Attach pressure gauge to the l ow/reverse cl utch
tap.
(2) Move sel ector l ever to the L posi ti on.
(3) Al l ow vehi cl e wheel s to turn and i ncrease
throttl e openi ng to achi eve an i ndi cated vehi cl e speed
to 20 mph.
(4) Low/reverse cl utch pressure shoul d read 115 to
145 psi .
TEST TWO-SELECTOR IN 3
This test checks the underdrive clutch hy-
draulic circuit as well as the shift schedule.
(1) Attach gauge to the underdri ve cl utch tap.
(2) Move sel ector l ever to the 3 posi ti on.
(3) Al l ow vehi cl e wheel s to turn and i ncrease
throttl e openi ng to achi eve an i ndi cated vehi cl e speed
of 30 mph.
(4) Underdri ve cl utch pressure shoul d read 110 to
145 psi .
TEST THREE-SELECTOR IN OD
This test checks the overdrive clutch hydrau-
lic circuit as well as the shift schedule.
(1) Attach gauge to the overdri ve cl utch tap.
(2) Move sel ector l ever to the OD posi ti on.
(3) Al l ow vehi cl e wheel s to turn and i ncrease
throttl e openi ng to achi eve an i ndi cated vehi cl e speed
of 20 mph.
(4) Overdri ve cl utch pressure shoul d read 74 to 95
psi .
(5) Move sel ector l ever to the 3 posi ti on and i n-
crease i ndi cated vehi cl e speed to 30 mph.
(6) The vehi cl e shoul d be i n second gear and over-
dri ve cl utch pressure shoul d be l ess than 5 psi .
TEST FOUR-SELECTOR IN OD
This test checks the 2/4 clutch hydraulic cir-
cuit.
(1) Attach gauge to the 2/4 cl utch tap.
(2) Move sel ector l ever to the OD posi ti on.
(3) Al l ow vehi cl e front wheel s to turn and i ncrease
throttl e openi ng to achi eve an i ndi cated vehi cl e speed
of 30 mph.
(4) The 2/4 cl utch pressure shoul d read 75 to 95
psi .
TEST FIVE-SELECTOR IN OD
Thesetests checks thetorqueconverter clutch
hydraulic circuit.
(1) Attach gauge to the torque converter cl utch off
pressure tap.
(2) Move sel ector l ever to the OD posi ti on.
(3) Al l ow vehi cl e wheel s to turn and i ncrease
throttl e openi ng to achi eve an i ndi cated vehi cl e speed
of 50 mph.
CAUTION: Both wheels must turn at the same
speed.
(4) Torque converter cl utch off pressure shoul d be
l ess than 5 psi .
(5) Now attach the gauge to the torque converter
cl utch on pressure tap.
(6) Move sel ector to the OD posi ti on.
(7) Al l ow vehi cl e wheel s to turn and i ncrease
throttl e openi ng to achi eve an i ndi cated vehi cl e speed
of 50 mph.
(8) Veri fy the torque converter cl utch i s appl i ed
mode usi ng the RPM di spl ay of the DRB scan tool .
(9) torque converter cl utch on pressure shoul d be
60-90 psi .
TEST SIX-SELECTOR IN R
This test checks the reverse clutch hydraulic
circuit.
(1) Attach gauge to the reverse cl utch tap.
(2) Move sel ector l ever to the R posi ti on.
(3) Read reverse cl utch pressure wi th output sta-
ti onary (foot on brake) and throttl e opened to achi eve
1500 rpm.
(4) Reverse cl utch pressure shoul d read 165 to 235
psi .
TEST RESULT INDICATIONS
(1) I f proper l i ne pressure i s found i n any one test,
the pump and pressure regul ator are worki ng prop-
erl y.
(2) Low pressure i n al l posi ti ons i ndi cates a defec-
ti ve pump, a cl ogged fi l ter, or a stuck pressure regul a-
tor val ve.
(3) Cl utch ci rcui t l eaks are i ndi cated i f pressures
do not fal l wi thi n the speci fi ed pressure range.
(4) I f the overdri ve cl utch pressure i s greater than
5 psi i n step (6) of Test Three, a worn reacti on shaft
seal ri ng i s i ndi cated.
CLUTCH AIR PRESSURE TESTS
I noperati ve cl utches can be l ocated by substi tuti ng
ai r pressure for fl ui d pressure. The cl utches may be
tested by appl yi ng ai r pressure to thei r respecti ve
passages after the val ve body has been removed. Use
Speci al Tool 6599-1 and 6599-2 to perform test (Fi g.
2).
To make ai r pressure tests, proceed as fol l ows:
The compressed air supply must be free of all
dirt and moisture. Use a pressure of 30 psi.
Remove oi l pan and val ve body. See Val ve body
recondi ti on.
Appl y ai r pressure to the hol es i n the speci al tool ,
one at a ti me.
TRANSAXLE 21 - 17
Li sten for the cl utch to appl y. I t wi l l gi ve a sl i ght
thud sound. I f a l arge amount of ai r i s heard escap-
i ng, the transaxl e must be removed from vehi cl e,
di sassembl ed and al l seal s i nspected.
OVERDRIVE CLUTCH
Appl y ai r pressure to the overdri ve cl utch appl y
passage and watch for the push/pul l pi ston to move
forward. The pi ston shoul d return to i ts starti ng posi -
ti on when the ai r pressure i s removed.
UNDERDRIVE CLUTCH
Because thi s cl utch pi ston cannot be seen, i ts opera-
ti on i s checked by functi on. Ai r pressure i s appl i ed to
the l ow/reverse or the 2/4 cl utches. Thi s l ocks the
output shaft. Use a pi ece of rubber hose wrapped
around the i nput shaft and a pai r of cl amp-on pl i ers
to turn the i nput shaft. Next appl y ai r pressure to the
underdri ve cl utch (Fi g. 3). The i nput shaft shoul d not
rotate wi th hand torque. Rel ease the ai r pressure and
confi rm that the i nput shaft wi l l rotate.
REVERSE CLUTCH
Appl y ai r pressure to the reverse cl utch appl y pas-
sage and watch for the push/pul l pi ston to move rear-
ward. The pi ston shoul d return to i ts starti ng posi ti on
when the ai r pressure i s removed.
2/4 CLUTCH
Appl y ai r pressure to the feed hol e l ocated on the
2/4 cl utch retai ner. Look i n the area where the 2/4
pi ston contacts the fi rst separator pl ate and watch
42LE PRESSURE CHECK SPECIFICATIONS
Fig. 2 Air Pressure Test Plate
21 - 18 TRANSAXLE
careful l y for the 2/4 pi ston to move rearward. The
pi ston shoul d return to i ts ori gi nal posi ti on after the
ai r pressure i s removed.
LOW/REVERSE CLUTCH
Appl y ai r pressure to the l ow/reverse cl utch feed
hol e passage. Look i n the area where the l ow/reverse
pi ston contacts the fi rst separator pl ate. Watch care-
ful l y for the pi ston to move forward. The pi ston
shoul d return to i ts ori gi nal posi ti on after the ai r
pressure i s removed.
FLUID LEAKAGE
The 42LE i s a dual sump transaxl e. The transaxl e
uses both automati c transaxl e fl ui d (ATF) for the
mai n sump and hypoi d gear l ube for the di fferenti al
sump. When di agnosi ng a l eak, i t i s i mportant to
di sti ngui sh whi ch type of fl ui d i s l eaki ng. Factory fi l l
ATF i s dyed red, whi l e di fferenti al hypoi d oi l i s brown
i n col or and has a di sti ncti ve odor.
There are two seal s at the boundary of the two
sumps. There i s a weep hol e i n the ri ght si de of the
transaxl e case (Fi g. 4) whi ch vents the area between
the two seal s. I f oi l i s l eaki ng from the weep hol e,
there i s at l east one seal l eaki ng. Never pl ug the
weep hol e to correct a l eaki ng condi ti on. Pl uggi ng the
weep hol e coul d resul t i n contami nati ng one or both
transaxl e sumps, l ow oi l l evel , poor transaxl e perfor-
mance or transaxl e fai l ure. I n order to correctl y re-
pai r thi s type of l eak the transaxl e must be removed
from the vehi cl e and both transfer shaft seal s re-
pl aced. Refer to Transfer Shaft Seal Repl acement pro-
cedure i n thi s secti on.
FLUID LEAKAGE-TORQUE CONVERTER
HOUSING AREA
(1) Check for source of l eakage. Fl ui d l eakage from
the torque converter area may ori gi nate from an en-
gi ne oi l l eak, a di fferenti al oi l l eak or an ATF oi l l eak.
The area shoul d be exami ned cl osel y.
(2) Pri or to removi ng the transaxl e, perform the
fol l owi ng checks:
When l eakage i s determi ned to be automati c trans-
mi ssi on fl ui d, check fl ui d l evel pri or to removal of the
transaxl e and torque converter.
Hi gh oi l l evel can resul t i n oi l l eakage out the vent.
I f the fl ui d l evel i s hi gh, adjust to proper l evel .
After performi ng thi s operati on, i nspect for l eak-
age. I f a l eak persi sts, perform the fol l owi ng operati on
on the vehi cl e. Thi s wi l l determi ne i f i t i s the torque
converter or transaxl e that i s l eaki ng.
LEAKAGE TEST PROBE
(1) Remove torque converter housi ng dust shi el d.
(2) Cl ean the i nsi de of torque converter housi ng
(l ower area) as dry as possi bl e. A sol vent spray fol -
l owed by compressed ai r dryi ng i s preferabl e.
(3) Fabri cate and fasten test probe (Fi g. 5) securel y
to conveni ent dust shi el d bol t hol e. Make certai n
torque converter i s cl eared by test probe. Tool must be
cl ean and dry.
Fig. 3 Testing Underdrive Clutch
Fig. 4 Weep Hole Location
Fig. 5 Leak Locating Test Probe Tool
TRANSAXLE 21 - 19
(4) Run engi ne at approxi matel y 2,500 rpm wi th
transaxl e i n neutral , for about 2 mi nutes. Transaxl e
must be at operati ng temperature.
(5) Stop engi ne and careful l y remove tool .
(6) I f upper surface of test probe i s dry, there i s no
torque converter l eak. A path of fl ui d across probe
i ndi cates a torque converter l eak. Oi l l eaki ng under
the probe i s comi ng from the transaxl e.
(7) Remove transaxl e and torque converter assembl y
from vehi cl e for further i nvesti gati on. The fl ui d shoul d
be drai ned from the transaxl e. Rei nstal l oi l pan (wi th
Mopar Adhesi ve Seal ant) at speci fi ed torque.
Possi bl e sources of transaxl e torque converter area
ATF fl ui d l eakage are:
Torque converter hub seal .
Seal l i p cut, check torque converter hub fi ni sh.
Bushi ng moved and/or worn.
Oi l return hol e i n pump housi ng pl ugged or omi t-
ted.
Seal worn out (hi gh-mi l eage vehi cl es).
Fl ui d l eakage at the outsi de di ameter from pump
housi ng O-ri ng.
Fl ui d l eakage at the front pump to case bol ts.
Check condi ti on of washers on bol ts and use new
bol ts, i f necessary.
Fl ui d l eakage due to case or front pump housi ng
porosi ty.
One ounce of oi l dye can be added to the automati c
transmi ssi on fl ui d to hel p l ocate l eaks. Add the dye
through the transaxl e di psti ck tube. Then reproduce
the l eak and check for traces of dye. Repai r l eak as
requi red.
TORQUE CONVERTER LEAKAGE
Possi bl e sources of torque converter l eakage are:
Torque converter wel d l eaks at the outsi de (peri ph-
eral ) wel d.
Torque converter hub wel d.
Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter.
FLUID LEAKAGEDIFFERENTIAL HOUSING
AREA
The di fferenti al uses 80w-90 petrol eum based hy-
poi d gear l ube. I t can be di sti ngui shed from ATF by
i ts brown col or (ATF i s dyed red). Al so gear l ube has a
di sti ncti ve odor (hypoi d smel l ).
(1) I f i t i s suspected that the l eakage i s gear l ube,
check the di fferenti al for proper fl ui d l evel . Hi gh oi l
l evel can resul t i n l eakage from the di fferenti al vent.
CAUTION: A crushed vent baffle will cause oil to
leak from vent hose.
(2) I f fl ui d l evel i s correct, add 1/4 to 1/2 ounce of
l eak detecti ng fl orescent dye to the di fferenti al .
(3) Cl ean the suspect area of the transaxl e wi th
sol vent.
(4) Road test the vehi cl e unti l the l eak reoccurs.
(5) Usi ng a bl ack l i ght determi ne the source of the
l eak and repai r as requi red.
Do not add oi l dye to both the ATF sump and the
di fferenti al sump at the same ti me. Thi s can cause
confusi on when tryi ng to pi npoi nt a l eak source.
AIR PRESSURE TEST OF TRANSAXLE SUMP
I t may be necessary to ai r pressure test the tran-
saxl e to pi npoi nt the l eak. The fol l owi ng two secti ons
descri be the recommended procedure for pressure
testi ng the ATF si de and the di fferenti al si de of the
transaxl e.
Transaxl e temperature may be a factor i n oi l l eaks,
therefore some l eaks may not show-up duri ng ai r
pressure testi ng.
AUTOMATIC TRANSMISSION FLUID SIDE
Fabri cate equi pment needed for test as shown i n
Fi gures 6 and 7.
The transaxl e shoul d be prepared for pressure test
as fol l ows after removal of the torque converter:
Fig. 6 Torque Converter Hub Seal Cup
Fig. 7 Hub Seal Cup Retaining Strap
21 - 20 TRANSAXLE
(1) Pl ug di psti ck tube and pl ug oi l cool er l i ne fi t-
ti ngs.
CAUTION: Prevent manual shaft rotation during in-
stallation and removal.
(2) Wi th rotary moti on, i nstal l converter hub seal
cup over i nput shaft, and through the converter hub
seal . The cup must bottom agai nst the pump gear
l ugs. Secure wi th cup retai ner strap usi ng starter
upper hol e and opposi te bracket hol e.
(3) Pl ug cool er l i nes.
(4) Remove the remote vent hose from the mai n
sump vent fi tti ng. Then attach and cl amp hose from
nozzl e of tool C-4080 or 7700 to the vent fi tti ng.
CAUTION: Do not, under any circumstances, pres-
surize a transaxle to more than 10 psi.
(5) Pressuri ze the transaxl e usi ng Tool C-4080 or
7700 unti l the pressure gauge reads 8 psi . Posi ti on
transaxl e so that pump housi ng and case front may
be covered wi th soapy sol uti on of water. Leaks are
someti mes caused by porosi ty i n the case or pump
housi ng.
I f a l eak source i s l ocated, that part and al l associ -
ated seal s, O-ri ngs, and gaskets shoul d be repl aced
wi th new parts.
TRANSAXLE DIFFERENTIAL SUMP SIDE
(1) Leave stub shafts secured i n the di fferenti al .
(2) Remove the remote vent hose from the di fferen-
ti al vent fi tti ng. Then attach and cl amp hose from
nozzl e of tool C-4080 or 7700 to the vent fi tti ng.
CAUTION: Do not, under any circumstances, pres-
surize a transaxle to more than 10 psi.
(3) Pressuri ze the di fferenti al to 8 psi .
(4) Posi ti on transaxl e so that the di fferenti al area
of the transaxl e can be covered wi th a soapy sol uti on
of water. Be sure to cover the case wi th sol uti on to
check for case porosi ty.
(5) Look for bubbl es to appear i n the soapy sol uti on
that was appl i ed to the transaxl e. Thi s wi l l i ndi cate
the l eak poi nt.
I f a l eak source i s l ocated, that part and al l associ -
ated seal s, O-ri ngs, and gaskets shoul d be repl aced
wi th new parts.
LONG STUB SHAFT SEAL REPLACEMENT
I f i t has been di agnosed that the l ong stub shaft
seal i s l eaki ng, the fol l owi ng procedure can be used to
repl ace fai l ed seal . Thi s procedure wi l l al l ow the re-
pl acement of the seal s wi thout havi ng to set backl ash
and measure di fferenti al beari ng turni ng torque.
CAUTION: The differential bearings and the differen-
tial adjusters must be reused in order to use this
procedure. If any of the items listed above require
replacement, this procedure cannot be used. Refer
to Differential Recondition section of this manual.
(1) Remove transaxl e from vehi cl e. Refer to Tran-
saxl e Removal and I nstal l ati on procedure i n thi s sec-
ti on.
(2) Remove l ong stub shaft from transaxl e (Fi g. 1).
(3) I ndex the i nner di fferenti al adjuster wi th a
cross hai r as shown i n fi gure 2.
CAUTION: If short stub shaft has corrosion, use
caution when removing differential cover. Inspect
seal and shaft for damage after removal of cover.
Replace shaft and/or seal as required.
(4) I ndex outer adjuster (Fi g. 3). Remove l ock
bracket and back out adjuster exactl y one revol uti on.
Then remove di fferenti al cover.
(5) Remove the i nner adjuster l ock bracket. Then
remove the i nner adjuster.
Fig. 1 Long Stub Shaft Removal
Fig. 2 Indexing Inner Adjuster
TRANSAXLE 21 - 21
CAUTION: Keep the inner adjuster for reinstallation.
(6) Lube i nner adjuster threads wi th gear oi l and
rei nstal l to the cross hai red i ndex marks.
(7) I nstal l the di fferenti al carri er. Then i nstal l stub
shaft seal protector.
(8) I nstal l the di fferenti al cover/outer adjuster as-
sembl y wi th seal ant appl i ed. I nstal l and ti ghten di f-
ferenti al cover bol ts.
(9) Ti ghten the outer adjuster 3/4 of a turn. Seat
beari ngs by turni ng di fferenti al carri er three or four
turns i n both di recti ons. Fi ni sh ti ghteni ng the ad-
juster 1/4 turn to i ts i ndex mark (ori gi nal l ocati on).
(10) Rei nstal l l ong stub shaft, fi l l di fferenti al wi th
fl ui d and rei nstal l transaxl e.
(11) After i nstal l i ng transaxl e check transmi ssi on
si de fl ui d l evel .
SHORT STUB SHAFT SEAL REPLACEMENT
The fol l owi ng procedure can be used to repl ace the
short stub shaft seal wi thout havi ng to remove the
transaxl e from the vehi cl e. I f the adjuster or beari ng
l ocated behi nd the adjuster requi re repl acement, do
not use thi s procedure. Refer to Di fferenti al Recondi -
ti on secti on of thi s manual .
(1) Pl ace vehi cl e i n neutral and l i ft vehi cl e on hoi st.
(2) Remove short dri ve shaft.
(3) I ndex the outer adjuster (Fi g. 4).
(4) Remove Outer adjuster l ock (Fi g. 5)
(5) Usi ng speci al tool 6503 l oosen outer adjuster,
then reti ghten to the i ndex mark usi ng a torque
wrench. Record the amount of torque requi red to
return the i ndex marks to thei r ori gi nal l ocati on.
Remove the adjuster.
(6) Use speci al tool 6558 to remove ol d seal and
i nstal l new seal (Fi g. 6).
(7) I nspect stub shaft for corrosi on (Fi g. 7). I f corro-
si on exi sts, wrap stub shaft wi th wax paper and
i nstal l seal protector over wax paper.
(8) Lube o-ri ng, threads on adjuster, seal protector
and seal l i ps wi th gear oi l before i nstal l i ng.
Fig. 4 Indexing Outer Adjuster
Fig. 5 Outer Adjuster Lock Removal
Fig. 6 Seal Removal and Installation
Fig. 3 Indexing Outer Adjuster
21 - 22 TRANSAXLE
(9) I nstal l outer adjuster i nto transaxl e case and
ti ghten adjuster wi thi n 10 ft. l bs. of the torque read-
i ng recorded i n step fi ve.
(10) Rotate ri ng gear three or four revol uti ons i n
both di recti ons to seat di fferenti al beari ngs.
(11) Conti nue ti ghteni ng outer adjuster unti l i ndex
marks l i ne up (ori gi nal l ocati on).
(12) I nstal l adjuster l ock.
(13) I nstal l new dri veshaft retai ni ng ci rcl i p and
o-ri ng on stub shaft. Then rei nstal l dri veshaft.
(14) Check fl ui d l evel i n di fferenti al and adjust as
requi red.
(15) Road test and recheck for l eaks as requi red.
ALUMINUM THREAD REPAIR
Damaged or worn threads i n the al umi num tran-
saxl e case and val ve body can be repai red by the use
of Hel i -Coi l s, or equi val ent. Thi s repai r consi sts of
dri l l i ng out the damaged threads, tappi ng the hol e
wi th a speci al Hel i -Coi l tap, or equi val ent. Then i n-
stal l i ng a Hel i -Coi l i nsert, or equi val ent, i nto the
tapped hol e. Thi s bri ngs the hol e back to i ts ori gi nal
thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are
readi l y avai l abl e from most automoti ve parts suppl i -
ers.
COOLERS AND TUBES REVERSE FLUSHING
When a transaxl e fai l ure has contami nated the
fl ui d, the oi l cool er(s) must be fl ushed. The cool er
bypass val ve i n the transaxl e must be repl aced. The
torque converter must al so be repl aced wi th an ex-
change uni t. Thi s wi l l i nsure that metal parti cl es or
sl udged oi l are not transferred back i nto the recondi -
ti oned (or repl aced) transaxl e.
CAUTION: If vehicle is equipped with two oil coolers
they must be flushed separately. Do not attempt to
flush both coolers at one time.
Use the fol l owi ng procedure to fl ush cool er:
(1) Di sconnect the cool er l i nes at the transaxl e.
(2) Usi ng a hand sucti on gun fi l l ed wi th mi neral
spi ri ts, reverse fl ush the cool er. Thi s i s done by forc-
i ng mi neral spi ri ts i nto the FromCooler l i ne of the
cool er (Fi g. 8). Catch the exi ti ng spi ri ts from the To
Cooler l i ne. Observe for the presence of debri s i n the
exi ti ng fl ui d. Conti nue unti l fl ui d exi ti ng i s cl ear and
free from debri s.
(3) Usi ng compressed ai r i n i ntermi ttent spurts,
bl ow any remai ni ng mi neral spi ri ts from the cool er,
agai n i n the reverse di recti on.
(4) To remove remai ni ng mi neral spi ri ts from the
cool er, pump one (1) quart of transmi ssi on fl ui d
through the cool er. Thi s shoul d be done pri or to recon-
necti ng the hoses to the transaxl e.
(5) I f at any stage of the cl eani ng process, the
cool er does not freel y pass fl ui d, the cool er must be
repl aced.
OIL COOLER FLOW CHECK
After the new or repai red transmi ssi on has been
i nstal l ed, oi l cool er fl ow shoul d be checked usi ng the
fol l owi ng procedure:
(1) Di sconnect the From cooler l i ne at the trans-
mi ssi on and pl ace a col l ecti ng contai ner under the
di sconnected l i ne.
(2) Run the engi ne at curb idle speed, wi th the
shi ft sel ector i n neutral .
(3) I f fl ui d fl ow i s i ntermi ttent or takes more than
20 seconds to col l ect one quart of fl ui d, the cool er
shoul d be repl aced.
CAUTION: With the fluid set at the proper level, fluid
collection should not exceed (1) quart or internal
damage to the transmission may occur.
(4) I f fl ow i s found to be wi thi n acceptabl e l i mi ts,
reconnect the cool er l i ne. Then fi l l transmi ssi on to the
proper l evel , usi ng the approved type of transmi ssi on
fl ui d.
MANUAL VALVE LEVER POSITION SENSOR
The Manual Val ve Lever Posi ti on Sensor (MVLPS)
i nterprets the posi ti on of the manual val ve. Thi s i n-
Fig. 7 Stub Shaft Corrosion
Fig. 8 Cooler Line Identification
TRANSAXLE 21 - 23
formati on i s sent to the transmi ssi on control modul e.
Al so the MVLPS provi des for Park/Neutral onl y
starter operati on and back-up l amp operati on.
The MVLPS connector extends outsi de the tran-
saxl e on the l eft si de, next to the fi l l tube. The MV-
LPS i s mounted to the top of the val ve body. The
MVLPS and val ve body must be removed from the
transaxl e as an assembl y.
TEST
Refer to the 1993 42LE Transaxl e Di agnosti c Proce-
dures Manual for MVLPS di agnosti c test procedures.
REMOVAL AND INSTALLATION
(1) Di sconnect the MVLPS connector.
(2) Remove val ve body assembl y from vehi cl e. Refer
to Val ve Body i n thi s secti on for procedure.
(3) Remove manual shaft retai ni ng screw (Fi g. 1).
(4) Sl i de MVLPS off of manual val ve shaft.
To i nstal l , reverse removal procedure.
SOLENOID ASSEMBLY
The transaxl e sol enoi d pack i s l ocated on the top
si de of the val ve body. The val ve body must be re-
moved from the transaxl e i n order to servi ce the
sol enoi d pack.
The sol enoi d pack contai ns four sol enoi ds. I f any
one of the sol enoi ds fai l , al l of the sol enoi ds must be
repl aced. There are no servi ceabl e parts for the sol e-
noi d pack.
TEST
Refer to the 1993 42LE Transaxl e Di agnosti c Proce-
dures Manual for di agnosti c test procedures.
REMOVAL AND INSTALLATION
(1) Rai se vehi cl e on hoi st.
(2) Remove val ve body assembl y from transaxl e. Refer
to Val ve Body i n thi s secti on for removal procedure.
(3) Remove sol enoi d retai ni ng screws from sol enoi d
(Fi g. 2).
(4) Remove sol enoi d and screen from val ve body
(Fi g. 3).
To i nstal l , reverse removal procedure.
TRANSMISSION CONTROL RELAY
The transmi ssi on control modul e control s power to
the sol enoi d pack through the transmi ssi on control
rel ay. The rel ay i s l ocated i n the power di stri buti on
center on the l eft strut tower.
TEST
Refer to the 1993 42LE Transaxl e Di agnosti c Proce-
dures Manual for test procedures.
REMOVAL AND INSTALLATION
(1) Open hood and l ocate power di stri buti on center
i n the engi ne compartment.
Fig. 2 Solenoid Retaining Screws
Fig. 3 Solenoid and Screen removal
Fig. 1 Manual Shaft Retaining Screw
21 - 24 TRANSAXLE
(2) Remove power di stri buti on center pl asti c cover.
(3) Pul l rel ay out of power di stri buti on center (Fi g.
4).
To i nstal l , reverse removal procedure.
TRANSMISSION CONTROL MODULE
The transmi ssi on control modul e i s l ocated i n the
engi ne compartment between the l eft front fender
and the battery. I t i s hel d i n pl ace by four mounti ng
screws. The battery must be moved to gai n access to
the transmi ssi on control modul e.
If the transmission control module has been
replaced, refer to Quick Learn Procedure. This
program will allow the transmission control
module to learn the characteristics of the ve-
hicle.
REMOVAL
(1) Loosen battery hol d-down cl amp and sl i de the
battery to the ri ght.
(2) Loosen 60 way retai ni ng screw, l ocated i n the
center of the 60 way connector. Then di sconnect the
60 way connector on transmi ssi on control modul e.
(3) Remove transmi ssi on control modul e mounti ng
screws and l i ft modul e from vehi cl e.
INSTALLATION
(1) I nstal l transmi ssi on control modul e and ti ghten
mounti ng screws.
(2) I nstal l 60 way connector. Then ti ghten 60 way
retai ni ng screw to 4 Nm (35 i n. l bs.).
(3) Pl ace battery back i n i ts ori gi nal l ocati on and
ti ghten battery hol d-down cl amp.
BACK UP LAMP DIAGNOSIS
The back-up l amps are control l ed by the Manual
Val ve Lever Posi ti on Sensor (MVLPS). The fol l owi ng
fl ow chart wi l l assi st i n di agnosi ng the back-up l amp
system. Refer to Manual Val ve Lever Posi ti on Sensor
i n thi s secti on for removal procedure.
Fig. 4 Transmission Control Relay Location
TRANSAXLE 21 - 25
B
A
C
K
-
U
P
L
A
M
P
D
I
A
G
N
O
S
T
I
C
C
H
A
R
T
21 - 26 TRANSAXLE
SPEED SENSOR-INPUT
The i nput speed sensor can be servi ced wi thout
havi ng to remove the transaxl e from the vehi cl e.
CAUTION: When disconnecting speed sensor con-
nector, be sure that the weather seal does not fall
off or remain in the old sensor.
The input speed sensor is not interchangeable
with the output speed sensor.
The i nput speed sensor i s l ocated on the l eft si de of
the transaxl e case (Fi g. 5). The sensor threads i nto
the transaxl e case. Ti ghten i nput speed sensor to
20-34 Nm (180-300 i n. l bs.).
SPEED SENSOR-OUTPUT
The output speed sensor can be servi ced wi thout
havi ng to remove the transaxl e from the vehi cl e.
CAUTION: When disconnecting speed sensor con-
nector, be sure that the weather seal does not fall
off or remain in old sensor.
The output speed sensor is not interchange-
able with the input speed sensor.
The output speed sensor i s l ocated on the l eft si de
of the transaxl e case (Fi g. 5). The sensor threads i nto
the transaxl e case. Ti ghten output speed sensor to
20-34 Nm (180-300 i n. l bs.).
VALVE BODY
The val ve body can be removed wi th the transaxl e
remai ni ng i n the vehi cl e, or wi th the transaxl e re-
moved. The i l l ustrati ons i n thi s procedure shows the
transaxl e removed from the vehi cl e for cl ari ty.
The sol enoi d pack and Manual Val ve Lever Posi ti on
Sensor (MVLPS) are mounted on top si de of the val ve
body. They wi l l remai n attached to the val ve body
when the val ve body i s removed from the transaxl e.
The sol enoi d pack and MVLPS can onl y be removed
from the val ve body after the val ve body i s removed
from the transaxl e.
REMOVAL AND INSTALLATION
(1) Di sconnect the MVLPS wi ri ng connector. The
sol enoi d wi ri ng connector can remai n attached to the
case.
(2) Di sconnect the shi ft cabl e from the shi ft l ever
(at the transaxl e).
(3) Move the shi ft l ever cl ockwi se as far as i t wi l l
go. Thi s shoul d be one posi ti on past the L posi ti on.
Then remove the shi ft l ever.
(4) Remove transaxl e pan bol ts (Fi g. 1).
(5) Remove transaxl e oi l pan. When rei nstal l i ng oi l
pan be sure that pan fl ange i s cl ean and oi l free.
Appl y a 1/8 i nch bead of Mopar Si l i cone Seal er onto
oi l pan fl ange before i nstal l i ng.
Fig. 5 Speed Sensor Location
Fig. 1 Remove Transaxle Oil Pan Bolts
Fig. 2 Remove Transaxle Oil Pan
TRANSAXLE 21 - 27
(6) Remove oi l fi l ter from val ve body (Fi g. 3). I t i s
hel d i n pl ace by two cl i ps.
CAUTION: The 42LE transaxle oil filter is not inter-
changeable with the 41TE transaxle filter. Installa-
tion of a 41TE oil filter in a 42LE may cause
transaxle damage.
(7) Remove val ve body bol ts (Fi g. 4).
(8) Careful l y remove val ve body assembl y from
transaxl e (Fi g. 5).
CAUTION: The overdrive and underdrive accumula-
tors and springs may fall out when removing the
valve body.
To rei nstal l val ve body, reverse removal procedure.
Fig. 5 Remove Valve Body From Transaxle
Fig. 6 Underdrive Accumulator and Spring
Fig. 7 Overdrive Accumulator and Springs
Fig. 3 Remove Transaxle Oil Filter
Fig. 4 Remove Valve Body Bolts
21 - 28 TRANSAXLE
RECONDITION
(1) Remove manual shaft screw (Fi g. 9)
(2) Remove Manual Val ve Lever Posi ti on Sensor
(MVLPS) and manual shi ft l ever.
(3) Remove sol enoi d pack from val ve body (Fi g. 10).
(4) Remove val ve body sti ffener pl ate (Fi g. 11).
(5) Remove 2/4 accumul ator retai ni ng pl ate screws.
(6) Remove thermal val ve (Fi g. 12).
(7) Remove val ve body check bal l s. Note the l oca-
ti on of val ve body check bal l s (Fi g. 13).
Fig. 8 Accumulator Locations
Fig. 9 Manual Shaft Screw
Fig. 10 Solenoid Pack Location
Fig. 11 Stiffener Plate Location
Fig. 12 Thermal Valve Location
Fig. 13 Ball Check Location
TRANSAXLE 21 - 29
(8) Remove dual retai ner pl ate from val ve body.
Use speci al tool 6301 to remove pl ate (Fi g. 14).
(9) Remove retai ner pl ate from val ve body usi ng
speci al tool 6302 (Fi g. 15).
(10) Tag al l spri ngs, as they are removed, for reas-
sembl y i denti fi cati on (Fi g. 16).
Cl eanl i ness through enti re di sassembl y and assem-
bl y of the val ve body cannot be overemphasi zed.
When di sassembl i ng, each part shoul d be washed i n a
sui tabl e sol vent, then dri ed by compressed ai r. Do
not wipe parts with shop towels. Al l mati ng sur-
faces i n the val ve body are accuratel y machi ned;
therefore, careful handl i ng of al l parts must be exer-
ci sed to avoi d ni cks or burrs.
To reassembl e, reverse recondi ti on procedure.
TRANSFER SHAFT SEAL REPLACEMENT
I f i t has been di agnosed that one or both of the
transfer shaft seal s are l eaki ng, the fol l owi ng proce-
dure can be used to repl ace fai l ed seal s. Thi s proce-
dure wi l l al l ow the techni ci an to repl ace the seal s
wi thout havi ng to set backl ash and measure di fferen-
ti al beari ng turni ng torque.
CAUTION: The transfer shaft rear shim, bearing
cups and cones, differential bearings and the differ-
ential adjusters must be reused to use this proce-
dure. If any of the items listed above require re-
placement, refer to Differential Recondition section
of this manual.
(1) Remove transaxl e from vehi cl e. Refer to Tran-
saxl e Removal and I nstal l ati on procedure i n thi s sec-
ti on.
(2) Remove val ve body from transaxl e.
(3) Remove sol enoi d connector from transaxl e case.
(4) Remove l ong stub shaft from transaxl e (Fi g. 17).
(5) I ndex the i nner di fferenti al adjuster wi th a
cross hai r as shown i n fi gure 18.
CAUTION: If short stub shaft has corrosion, use
caution when removing differential cover. Inspect
seal and shaft for damage after removal of cover.
Replace shaft and/or seal as required.
(6) I ndex outer adjuster (Fi g. 19). Remove l ock
bracket and back out adjuster exactl y one revol uti on.
Then remove di fferenti al cover.
(7) Remove the i nner adjuster l ock bracket. Then
remove the i nner adjuster.
CAUTION: Keep the inner adjuster for reinstallation.
(8) Remove the transfer shaft nut, rear cone, rear
cup, oi l baffl e, rear shi m, transfer shaft and transfer
shaft seal s. Refer to appropri ate procedures wi thi n
thi s secti on for detai l ed removal and i nstal l ati on pro-
cedures i f requi red.
CAUTION: Keep rear shim and rear bearing cup
cone for reinstallation.
(9) I nstal l transfer shaft, transfer shaft seal s, oi l
baffl e, rear cup, rear shi m, rear cone and a new nut.
Refer to appropri ate procedures wi thi n thi s secti on
for detai l ed removal and i nstal l ati on procedures i f
requi red.
(10) I nstal l a new o-ri ng onto the i nner adjuster.
(11) Lube i nner adjuster threads and o-ri ng wi th
gear oi l and rei nstal l to the cross hai red i ndex marks.
(12) Rei nstal l the i nner adjuster l ocki ng bracket.
(13) I nstal l the di fferenti al carri er. Then i nstal l
stub shaft seal protector.
(14) I nstal l the di fferenti al cover/outer adjuster as-
sembl y wi th Mopar Si l i cone Seal ant appl i ed. I nstal l
and ti ghten di fferenti al cover bol ts.
(15) Ti ghten the outer adjuster 3/4 of a turn. Seat
beari ngs by turni ng di fferenti al carri er three or four
Fig. 14 Remove or Install Dual Retainer Plate
Fig. 15 Remove or Install Retainer Plate
21 - 30 TRANSAXLE
turns i n both di recti ons. Fi ni sh ti ghteni ng the ad-
juster 1/4 turn to i ts i ndex mark (ori gi nal l ocati on).
(16) Rei nstal l the outer adjuster l ocki ng bracket.
Fig. 16 Valve Body Components
Fig. 17 Long Stub Shaft Removal
Fig. 18 Indexing Inner Adjuster
TRANSAXLE 21 - 31
TRANSAXLE REMOVAL AND INSTALLATION
The transaxl e can be removed without havi ng to
remove the engi ne.
(1) Di sconnect battery.
(2) Remove engi ne ai r i nl et tube.
(3) Di sconnect crankshaft posi ti on sensor connector
and remove sensor (Fi g. 1). The sensor i s l ocated on
the upper ri ght si de of the transaxl e bel l housi ng.
(4) Di sconnect transaxl e wi ri ng connector l ocated
on the ri ght shock tower (Fi g. 2).
(5) Li ft vehi cl e on hoi st.
(6) Remove front wheel s.
(7) Remove strut to steeri ng knuckl e bol ts on both
si des of the vehi cl e (Fi g. 3).
(8) Remove Anti -l ock Brake System (ABS) wheel
speed sensor (i f equi pped).
CAUTION: Do not allow drive shaft or CV joint to
hang freely. Internal joint damage may occur if al-
lowed to hang freely.
CAUTION: Drive shaft retainer clips and seals lo-
cated on the stub shafts must be replaced before
reinstalling drive shafts.
(9) Usi ng a pry bar, di sconnect the i nner CV joi nt
from the transaxl e (Fi g. 4).
(10) Pul l top of knuckl e and dri ve shaft outward to
al l ow cl earance duri ng transaxl e removal . The dri ve
shafts do not have to be compl etel y removed from the
vehi cl e. Do not allow the inner CV joint to hang
unsupported or joint damage may occur.
(11) Remove engi ne to transaxl e brackets.
(12) Remove transaxl e bel l -housi ng cover.
(13) Remove torque converter bol ts. The torque
converter i s i ndexed to the fl ex pl ate. Mark the torque
converter l ocati on to ensure that the torque converter
i s rei nstal l ed correctl y.
CAUTION: The drive plate to torque converter bolts
and the drive plate to crankshaft bolts must not be
reused. Install new bolts whenever these bolts are
removed.
Fig. 19 Indexing Outer Adjuster
Fig. 1 Crankshaft Position Sensor Location
Fig. 2 Wiring Connector Location
Fig. 3 Strut to Steering Knuckle Bolts
21 - 32 TRANSAXLE
(14) Unbol t starter assembl y. Do not di sconnect
wi ri ng or compl etel y remove the starter from the
vehi cl e. Al l ow the starter to si t between the engi ne
and the frame.
(15) Di sconnect transaxl e cool er l i nes at the tran-
saxl e.
(16) Di sconnect the gear sel ector cabl e from the
transaxl e.
(17) Di sconnect the exhaust system at the exhaust
mani fol ds and remove the exhaust system from the
vehi cl e.
(18) Pl ace a transmi ssi on jack under the transaxl e.
Secure the transaxl e to the jack.
(19) Rai se transaxl e sl i ghtl y to rel i eve the wei ght
on the rear transaxl e mount.
(20) Remove the transaxl e mount through-bol t.
(21) Remove rear crossmember mounti ng bol ts.
(22) Pry the transaxl e mount rearward to separate
the mount from the transaxl e.
(23) Remove the rear crossmember.
(24) Lower the rear of the transaxl e to gai n access
to the bel l housi ng bol ts.
(25) Remove bel l housi ng bol ts.
(26) Remove di psti ck tube from transaxl e. Be pre-
pared to pl ug the di psti ck hol e when removi ng di p-
sti ck to prevent fl ui d from spi l l i ng out of the tran-
saxl e.
(27) Remove engi ne to transaxl e bol ts.
(28) The transaxl e can now be l owered from the
vehi cl e.
When i nstal l i ng transaxl e, reverse the above proce-
dure.
The factory torque converters for 3.3 and 3.5 l i ter
engi nes are not interchangeable. There wi l l be onl y
one torque converter rel eased for servi ce use. The
servi ce torque converter can be used i n ei ther engi ne
appl i cati on.
I f the torque converter i s bei ng repl aced, appl y a
l i ght coati ng of grease to the crankshaft pi l ot hol e.
I nspect the dri vepl ate for cracks before rei nstal l i ng
transaxl e. I f any cracks are found repl ace the dri ve-
pl ate. Do not attempt to repai r a cracked dri vepl ate.
Al ways use new torque converter to dri vepl ate
bol ts.
If the torque converter has been replaced, re-
fer to Torque Converter Clutch Break-in Proce-
dure in this section. This procedure will reset
the transmission control module break-in sta-
tus. Failure to perform this procedure may
cause torque converter shutter.
If the transaxle assembly, TCM, solenoid pack
or clutch plates have been replaced, refer to
Quick Learn Procedure. This program will al-
low the transmission control module to compen-
sate for any parts replaced in the electronic
transaxle system.
Check and/or adjust gear shi ft cabl e. Refer to Shi ft
Li nkage i n thi s secti on for procedure.
When i nstal l i ng the transaxl e, ensure the fuel tubes
at the rear of the engi ne do not contact the fol l owi ng:
Ti e rod attachment pl ate at the power steeri ng
rack
Exhaust Gas Reci rcul ati on (EGR) Tube
Transaxl e wi ri ng harness
Refi l l transaxl e wi th Mopar ATF Pl us (Automati c
Transmi ssi on Fl ui d) Type 7176.
OIL PUMP SEAL REPLACEMENT
The transaxl e must be removed from the vehi cl e to
repl ace thi s oi l seal .
REMOVAL
(1) Remove the transaxl e from the vehi cl e.
(2) Remove the torque converter from the transaxl e
bel l housi ng.
(3) Use speci al tool C-3981B to remove oi l pump
seal (Fi g. 5).
Fig. 4 Drive Shaft Removal
Fig. 5 Oil Seal Removal
TRANSAXLE 21 - 33
INSTALLATION
(1) Cl ean and i nspect oi l pump seal seat. Then
i nstal l seal usi ng speci al tool C-4193A (Fi g. 6).
(2) Cl ean and i nspect torque converter hub. I f
ni cks, scratches or hub wear are found, torque con-
verter repl acement wi l l be requi red.
CAUTION: The factory torque converters for 3.3 and
3.5 liter engines are not interchangeable. There will
be only one torque converter released for service
use. The service torque converter can be used in
either engine application.
CAUTION: If the torque converter is being replaced,
apply a light coating of grease to the crankshaft pilot
hole. Also inspect the engine drive plate for cracks. If
any cracks are found replace the drive plate. Do not
attempt to repair a cracked drive plate. Always use new
torque converter to drive plate bolts.
(3) Appl y a l i ght fi l m of transmi ssi on oi l to the
torque converter hub and oi l seal l i ps. Then i nstal l
torque converter i nto transaxl e. Be sure that the hub
l ugs mesh wi th the front pump l ugs when i nstal l i ng.
(4) Rei nstal l the transaxl e i nto the vehi cl e.
TORQUE CONVERTER CLUTCH BREAK-IN
PROCEDURE
El ectroni c Modul ated Converter Cl utch (EMCC) modu-
l ates the appl i cati on of the torque converter cl utch.
A torque converter cl utch break-i n program i s bei ng
used to properl y condi ti on the torque converter
cl utch. Thi s wi l l el i mi nate shudder duri ng torque con-
verter cl utch operati on on a new torque converter.
I f the torque converter i s repl aced, the new cl utch
wi thi n the torque converter wi l l requi re break-i n. The
current break-i n status stored i n the transmi ssi on
control modul e wi l l have to be reset to the start of
break-i n wi th the DRB scan tool .
I f a new transmi ssi on control modul e i s put on the
vehi cl e, the status wi l l be at the start of break-i n.
Thi s status i s acceptabl e regardl ess of the mi l eage on
the torque converter. No modi fi cati on of the break-i n
status i s requi red.
To properl y servi ce these vehi cl es, i t i s necessary to
use a DRB scan tool to read or reset the break-i n
status. Perform the fol l owi ng steps wi th the DRB
scan tool to reset the break-i n status:
(1) Pl ug the DRB scan tool i nto the bl ue CCD Bus
connector. The connector i s l ocated under the i nstru-
ment panel on the dri vers si de of the vehi cl e.
(2) I nsert the 1993 DRB scan tool cartri dge i nto the
DRB scan tool .
(3) The red and green l i ghts on the DRB scan tool wi l l
l i ght up and then begi n fl ashi ng. Wai t unti l the l i ghts
stop fl ashi ng before conti nui ng wi th thi s procedure.
(4) Press the number 4 key on the DRB scan tool
key pad. I tem number 4 wi l l not appear on the DRB
screen unl ess you scrol l down. I t i s not necessary to
scrol l down to be abl e to choose i tem 4.
(5) Press the number 2 on the DRB scan tool key
pad (Transmi ssi on).
(6) Press the number 1 on the DRB scan tool key
pad. Wai t for the DRB scan tool to perform the fol l ow-
i ng three tests before conti nui ng.
Bus Test
I ni ti al i ze
Control l er Part Number
(7) Press the number 5 on the DRB scan tool key
pad (Adjustments).
(8) Press the number 1 on the DRB scan tool key
pad (Reset EMCC). The DRB scan tool wi l l di spl ay
one of three screens.
(a) EMCC Break-i n Status: Start
(b) EMCC Break-i n Status: In-progress Press
ENTER to Reset Break-i n status
(c) EMCC Break-i n Status: Complete Press EN-
TER to Reset Break-i n status
I f screen (a) appears, the control l er i s at the begi n-
ni ng of i ts break-i n program. No further acti on i s
requi red.
I f screen (b) appears, the control l er i s i n the mi ddl e
of a i ts break-i n program. Press the enter key on the
DRB scan tool key pad to return the status to the
start of break-i n.
I f screen (c) appears, the control l er has compl eted
i ts break-i n status program. Press the enter key on
the DRB scan tool key pad to return the status to the
start of break-i n.
(9) After pressi ng the enter key a second ti me i n
step 8 a screen wi l l appear that says RESET EMCC
ARE YOU SURE ?. Press the enter key on the DRB
scan tool key pad. The DRB scan tool wi l l then carry
out the reset command.
(10) After the DRB scan tool compl etes the reset
command, a screen wi l l appear sayi ng EMCC
Fig. 6 Oil Seal Installation
21 - 34 TRANSAXLE
Break-i n Status has been RESET to Start. Thi s
screen wi l l i ndi cate that the reset procedure has been
successful l y compl eted.
(11) Di sconnect the DRB scan tool from the bl ue
CCD Bus connector.
TRANSAXLE QUICK LEARN PROCEDURE
The qui ck l earn procedure requi res the use of the
DRB scan tool and the 1993 DRB scan tool cartri dge.
Thi s program al l ows the el ectroni c transaxl e system
to recal i brate i tsel f. Thi s provi des the best possi bl e
transaxl e operati on. The qui ck l earn procedure
shoul d be performed i f any of the fol l owi ng proce-
dures are performed:
Transaxl e Assembl y Repl acement
Transmi ssi on Control Modul e Repl acement
Sol enoi d Pack Repl acement
Cl utch Pl ate and/or Seal Repl acement
Val ve Body Repl acement or Recondi ti on
To perform the Qui ck Learn Procedure, the fol l ow-
i ng condi ti ons must be met:
The brakes must be appl i ed
The engi ne speed must be above 500 rpm
The throttl e angl e (TPS) must be l ess than 3 de-
grees
The shi ft l ever posi ti on must stay unti l prompted
to shi ft to overdri ve
The shi ft l ever posi ti on must stay i n overdri ve
after the Shi ft to Overdri ve prompt unti l the DRB
i ndi cates the procedure i s compl ete
The cal cul ated oi l temperature must be i n the
range of 65-130F. I ncorrect val ues may be l earned at
temperatures out of thi s range.
The precedi ng condi ti ons must be met to keep the
procedure from bei ng aborted.
(1) Pl ug the DRB scan tool i nto the bl ue CCD Bus
connector. The connector i s l ocated under the i nstru-
ment panel on the dri vers si de of the vehi cl e.
(2) I nsert the 1993 DRB scan tool cartri dge i nto the
DRB scan tool .
(3) The red and green l i ghts on the DRB scan tool
wi l l l i ght up and then begi n fl ashi ng. Wai t unti l the
l i ghts stop fl ashi ng before conti nui ng wi th thi s proce-
dure.
(4) Press the number 4 key on the DRB scan tool
key pad. I tem number 4 wi l l not appear on the DRB
screen unl ess you scrol l down. I t i s not necessary to
scrol l down to be abl e to choose i tem 4.
(5) Press the number 2 on the DRB scan tool key
pad (Transmi ssi on).
(6) Press the number 1 on the DRB scan tool key
pad. Wai t for the DRB scan tool to perform the fol l ow-
i ng three tests before conti nui ng.
Bus Test
I ni ti al i ze
Control l er Part Number
(7) Press the number 5 on the DRB scan tool key
pad (Adjustments).
(8) Press the number 1 on the DRB scan tool key
pad (Qui ck Learn). Then fol l ow the i nstructi ons on
the DRB scan tool screen.
TRANSAXLE DISASSEMBLE/REASSEMBLE
Before di sassembl i ng transaxl e, move the shi ft l ever
cl ockwi se as far as i t wi l l go. Thi s shoul d be one posi ti on
past the L posi ti on. Then remove the shi ft l ever.
Tag all clutch pack assemblies, as they are
removed, for reassembly identification.
CAUTION: Do not intermix clutch discs or plates as
the unit might then fail.
Measuri ng i nput shaft end pl ay before di sassembl y
wi l l usual l y i ndi cate when a #4 thrust pl ate change i s
requi red. The number 4 thrust pl ate i s l ocated behi nd
the overdri ve cl utch hub. Attach a di al i ndi cator to
transaxl e bel l housi ng wi th i ts pl unger seated agai nst
end of i nput shaft (Fi g. 1). Move i nput shaft i n and
out to obtai n end pl ay readi ng. End pl ay speci fi ca-
ti ons are .13 to .64 mm (.005 to .025 i nch). Record
i ndi cator readi ng for reference when reassembl i ng the
transaxl e.
Remove both speed sensors from transaxl e case (Fi g. 2).
Fig. 2 Remove Input and Output Speed Sensor
Fig. 1 Measure Input Shaft End Play
TRANSAXLE 21 - 35
For valvebody recondition procedure, refer to
Valve Body in this section.
Fig. 3 Remove Transaxle Oil Pan
Fig. 4 Remove Transaxle Oil Filter
Fig. 5 Remove Valve Body Bolts
Fig. 6 Remove Valve Body From Transaxle
Fig. 7 Remove Underdrive Accumulator and Spring
Fig. 8 Remove Overdrive Accumulator and Springs
21 - 36 TRANSAXLE
CAUTION: Tag the springs for the Overdrive Accu-
mulator so that they are not confused with the
springs in the Low/Reverse Accumulator.
Fig. 11 Low/Reverse Accumulator Plug (Cover)
Fig. 9 Accumulator Locations
Fig. 10 Remove Low/Reverse Accumulator
Fig. 12 Low/Reverse Accumulator Piston
Fig. 13 Low/Reverse Accumulator
Fig. 14 Remove Long Stub Shaft Snap Ring
TRANSAXLE 21 - 37
CAUTION: Drive shaft retainer clips and seals lo-
cated on the stub shafts must be replaced before
reinstalling drive shafts.
CAUTION: By-pass valve must be replaced trans-
mission failure occurs.
Fig. 15 Remove Long Stub Shaft From Bell-housing
Fig. 16 Remove Oil Pump Attaching Bolts
Fig. 17 Oil Pump Pullers
Fig. 18 Remove Oil Pump
Fig. 19 Remove Oil Pump Gasket
Fig. 20 Remove By-Pass Valve
21 - 38 TRANSAXLE
Fig. 21 Remove No. 1 Caged Needle Bearing
Fig. 22 Remove Input Clutch Assembly
Fig. 23 Remove Front Sun Gear Assembly
Fig. 24 Remove Front Carrier and Rear Annulus
Assembly
Fig. 25 Remove Rear Sun Gear
TRANSAXLE 21 - 39
The number 7 needl e beari ng has anti reversal tabs
and i s common wi th the number 5 and number 2
posi ti on. The ori entati on shoul d al l ow the beari ng to
seat fl at agai nst the rear sun gear (Fi g. 26). A smal l
amount of petrol atum can be used to hol d the beari ng
to the rear sun gear.
Fig. 26 Number 7 Bearing
Fig. 27 Remove 2/4 Clutch Retainer Snap Ring
Fig. 28 Remove 2/4 Clutch Retainer
Fig. 29 Remove 2/4 Clutch Retainer
Fig. 30 Remove 2/4 Clutch Return Spring
21 - 40 TRANSAXLE
Fig. 31 2/4 Retainer and Spring Indexed
Fig. 32 Remove 2/4 Clutch Pack
Fig. 33 Remove Tapered Snap Ring
Fig. 34 Tapered Snap Ring Instructions
Fig. 35 Snap Ring Installed
TRANSAXLE 21 - 41
Stand Trans Upri ght on Bel l -housi ng
Chai n cover must be free of ol d seal ant, di rt and oi l
before appl yi ng new seal ant. Appl y a 1/8 i nch bead of
seal ant to fl ange of cover.
Fig. 36 Low/Reverse Reaction Plate
Fig. 37 Remove One Disc
Fig. 38 Remove Low/Reverse Reaction Plate Snap
Ring
Fig. 39 Remove Low/Reverse Clutch Pack
Fig. 40 Remove Chain Cover
Fig. 41 Remove Chain Oiler
21 - 42 TRANSAXLE
CAUTION: Be sure to reinstall the chain snubber
and chain oiler when reassembling.
CAUTION: The chain sprockets have a slip fit onto
there shafts. Apply only a slight amount of pressure
to the chain spreader to release the chain pressure.
If chain sprockets are not spread slightly removal or
installation will be difficult. Overspreading of the
chain sprocket will also make sprocket removal dif-
ficult.
Fig. 42 Remove Chain Snubber
Fig. 43 Remove Output Shaft Sprocket Snap Ring
and Wave Washer
Fig. 44 Remove Transfer Shaft Sprocket Snap Ring
and Wave Washer
Fig. 45 Install Chain Spreader
Fig. 46 Remove Chain and Both Sprockets as an
Assembly
TRANSAXLE 21 - 43
CAUTION: When reinstalling drive chain, the blue
link must face outward.
When rei nstal l i ng transaxl e dri ve chai n and sprock-
ets, sprocket hei ght must be checked. Refer to Dri ve
Sprocket Hei ght Adjustment Procedure i n thi s group.
Remove mai n sump baffl e from transaxl e case (Fi g.
48).
When rei nstal l i ng mai n sump baffl e appl y Mopar
Si l i cone Seal ant as shown i n fi gure 49.
CAUTION: Failure to grind and open stakes of the
output shaft nut and transfer shaft nut will result in
thread damage to the shafts during nut removal.
WARNING: WEAR SAFETY GOGGLES WHILE
GRINDING STAKE NUTS.
Usi ng a di e gri nder or equi val ent, gri nd the stakes
i n the shoul der of the shaft nuts as shown i n fi gure
50 and 51. Do not gri nd al l the way through the nut
and i nto the shaft. There are two stakes on each nut.
Fig. 47 Output Sprocket Spacer
Fig. 48 Main Sump Vent Baffle Location
Fig. 49 Correctly Applied Sealant
Fig. 50 Grinding Stakes
Fig. 51 Stake Grinding Pattern
21 - 44 TRANSAXLE
Usi ng a smal l chi sel , careful l y open stakes on nut
(Fi g. 52).
Use speci al tool 6497 and 6498 to remove the trans-
fer shaft nut or the output shaft nut (Fi g. 53). Note
that your breaker bar wi l l turn cl ockwi se to remove
the nut and counter cl ockwi se to i nstal l the nut.
CAUTION: Do not reuse old transfer shaft nut or
output shaft nut because the removed stake weak-
ens the nut flange.
When i nstal l i ng new nuts use speci al tool 6639 to
stake output shaft nut and speci al tool 6589 to stake
transfer shaft nut (Fi g. 54).
Use speci al tool 6596 to remove front output shaft
beari ng cup (Fi g. 55).
Fig. 54 Use Arbor Press to Remove Output Shaft
from Case
Fig. 55 Remove Front Bearing Cup
Fig. 52 Opening Nut Stakes
Fig. 53 Remove Output Shaft Nut
TRANSAXLE 21 - 45
Use speci al tool 6597 and handl e C-4171 and
C-4171-2 to press rear output shaft beari ng cup rear-
ward (Fi g. 56).
Use speci al tool 5050A to i nstal l both front and rear
beari ng cups (Fi g. 57).
Fig. 56 Remove Rear Bearing Cup
Fig. 57 Bearing Cup Installation Special Tool 5050A
Fig. 58 Remove Rear Carrier Front Bearing Cone
Fig. 59 Low/Reverse Spring Compressor Tool
21 - 46 TRANSAXLE
CAUTION: When installing, be sure guide bracket
and split sleeve touch the rear of the transaxle case.
Fig. 61 Remove Snap Ring
Fig. 62 Low/Reverse Piston Return Spring
Fig. 60 Compressor Tool in Use
Fig. 63 Remove Parking Sprag Pivot Retaining
Screw
Fig. 64 Anchor Shaft Removal
Fig. 65 Guide Bracket Pivot Shaft
TRANSAXLE 21 - 47
AT THIS POINT the Centerl i ne of the transaxl e
has been removed. I f the condi ti on for di sassembl y
di d not pertai n to the di fferenti al , i ts di sassembl y
may not be requi red. I nspect the rear transfer shaft
area and the transfer shaft seal area for contami na-
ti on. I f evi dence of contami nati on i s present, repl ace
the rear transfer shaft beari ng and/or the transfer
shaft seal . Refer to the Transfer Shaft Seal Removal Sec-
ti on and the Di fferenti al Di sassembl y/Assembl y secti on.
To assembl e transaxl e, reverse the above procedure.
Be sure to check both grounded cl utch cl earances.
Before i nstal l i ng the i nput cl utches retai ner, fol l ow
the i nstructi ons i n Determining No. 4 Thrust
Plate Thickness.
Fig. 68 Low/Reverse Clutch Piston
Fig. 69 Piston Retainer Attaching Screws
Fig. 70 Piston Retainer
Fig. 71 Piston Retainer Gasket
Fig. 66 Guide Bracket Assembled
Fig. 67 Guide Bracket Disassembled
21 - 48 TRANSAXLE
OUTPUT SHAFT BEARING PRELOAD SHIM
SELECTION
When assembl i ng, the output beari ng prel oad must
be checked and/or adjusted i f any of the fol l owi ng
i tems have been repl aced:
Output shaft (rear carri er assembl y)
Output shaft beari ngs
Transaxl e case
SHIM SELECTION
(1) I nstal l rear output shaft beari ng cone and spe-
ci al tool 6618A (Fi g. 2).
(2) I nstal l speci al tool 6618A (Fi g. 3). Li ghtl y
ti ghten retai ni ng screws. Screws shoul d be bel ow the
pl ate surface, but do not snug screws.
(3) Turn case over on arbor press so that the pl ate
i s resti ng on the press base
CAUTION: The output shaft will extend through the
hole of tool 6618A. Ensure your press table has
clearance for the output shaft.
(4) I nstal l shi m on output shaft (Fi g. 4). Appl y
smal l amount of petrol atum onto the shi m to hol d i t
i n pl ace. Use the ori gi nal shi m as a starti ng poi nt. I f
ori gi nal shi m i s not avai l abl e, use the thi ckest shi m
avai l abl e. Refer to Output Shaft Rear Shi m Chart for
avai l abl e si zes.
Fig. 1 Install Rear Carrier Front Bearing Cone
Fig. 2 Bearing Installation
Fig. 3 Special Tool Installed
Fig. 4 Shim Installation
TRANSAXLE 21 - 49
(5) I nstal l output shaft/rear carri er i nto rear beari ng.
The shaft must be pressed i nto posi ti on. Use speci al tool
MD-998911 (Di sc) and C-4171 and C4171-2 (Handl e) to
press shaft i nto rear beari ng (Fi g. 5).
(6) Usi ng speci al tool s 6497 and 6498, i nstal l new
output shaft nut. Do not reuse ol d output shaft nut.
Ti ghten new output shaft nut to 271 Nm (200 ft. l bs.).
(7) Check the turni ng torque of the output shaft
(Fi g. 6). The shaft shoul d have 1 to 8 i n. l bs. of
turni ng torque. I f the turni ng torque i s higher than
8 i n. l bs., i nstal l a thi cker shi m. I f the turni ng torque
i s less than 1 i n. l b., i nstal l a thi nner shi m. Make
sure there i s no end pl ay.
CAUTION: Failure to stake shaft nuts could allow
the nuts to back-off during use.
(8) The new nut must be staked after the correct
turni ng torque i s obtai ned (Fi g. 7). Use speci al tool
6639 to stake output shaft nut and speci al tool 6589
to stake transfer shaft.
OUTPUT SHAFT REAR SHIM CHART
Fig. 5 Press Shaft Into Case
Fig. 6 Checking Turning Torque
Fig. 7 Staking Output Shaft Nut
21 - 50 TRANSAXLE
LOW/REVERSE CLUTCH CLEARANCE
Press down cl utch pack wi th fi nger and zero di al
i ndi cator. Low/Reverse clutch pack clearance is
1.04 to 1.65 mm(.042 to .065 inch).
Sel ect the proper l ow/reverse reacti on pl ate to
achi eve speci fi cati ons:
Press down cl utch pack wi th fi nger and zero di al
i ndi cator. The 2/4 clutch pack clearance is 0.76 to
2.64 mm (.030 to .104 inch). I f not wi thi n speci fi ca-
ti ons, the cl utch i s not assembl ed properl y. There is
no adjustment for the 2/4 clutch clearance.
INPUT CLUTCHES-RECONDITION
DISASSEMBLY
Fig. 1 Tapping Reaction Plate
Fig. 8 Correctly Staked Nut
Fig. 9 Check Low/Reverse Clutch Clearance
LOW/REVERSE REACTION PLATE CHART
Fig. 10 Check 2/4 Clutch Clearance
TRANSAXLE 21 - 51
i
Tag reverse clutch pack for reassembly identi-
fication.
Fig. 2 Reverse Clutch Snap Ring
Fig. 3 Pry Reverse Clutch Reaction Plate
Fig. 4 Reverse Clutch Reaction Plate
Fig. 5 Reverse Clutch Pack
Fig. 6 OD/Reverse Pressure Plate Snap Ring
Fig. 7 OD/Reverse Pressure Plate
21 - 52 TRANSAXLE
Tag overdrive clutch pack for reassembly
identification.
Fig. 8 Waved Snap Ring
Fig. 9 Remove OD Clutch Pack
Fig. 10 Overdrive Clutch Pack
Fig. 11 Overdrive Shaft Assembly
Fig. 12 Underdrive Shaft Assembly
Fig. 13 No. 2 Needle Bearing
TRANSAXLE 21 - 53
Tag underdrive clutch pack for reassembly
identification.
CAUTION: Compress return spring just enough to
remove or install snap ring.
Fig. 14 OD/UD Reaction Plate Tapered Snap Ring
Fig. 15 OD/UD Reaction Plate
Fig. 16 Remove One UD Clutch Disc
Fig. 17 UD Clutch Flat Snap Ring
Fig. 18 Underdrive Clutch Pack
Fig. 19 UD Spring Retainer Snap Ring
21 - 54 TRANSAXLE
Fig. 23 Tap on Input Hub Fig. 20 UD Return Spring and Retainer
Fig. 21 Underdrive Clutch Piston
Fig. 22 Input Hub Tapered Snap Ring
Fig. 24 Input Hub Removed
Fig. 25 Pull Retainer from Piston
TRANSAXLE 21 - 55
ASSEMBLY
Use petrol atum on al l seal s to ease assembl y of
components.
Fig. 29 Remove Input Shaft Fig. 26 Install Snap Ring
Fig. 27 Snap Ring and Return Spring
Fig. 28 Remove Input Shaft Snap Ring
Fig. 1 Install Input Shaft
Fig. 2 Install Input Shaft Snap Ring
21 - 56 TRANSAXLE
Fig. 3 Return Spring and Snap Ring
Fig. 4 Install Snap Ring
Fig. 5 Install OD/Reverse Piston
Fig. 6 Install Input Shaft Hub Assembly
Fig. 7 Input Hub Tapered Snap Ring
Fig. 8 Underdrive Clutch Piston
TRANSAXLE 21 - 57
CAUTION: Compress return spring just enough to
remove or install snap ring.
Fig. 9 Seal Compressor Special Tool 5067
Fig. 10 UD Return Spring and Retainer
Fig. 11 Install UD Spring Retainer and Snap Ring
Fig. 12 Underdrive Clutch Pack
Fig. 13 UD Clutch Flat Snap Ring
Fig. 14 Install Last UD Clutch Disc
21 - 58 TRANSAXLE
Snap ring ends must be located within one
finger of theinput clutch hub. Besurethat snap
ring is fully seated, by pushing with screw-
driver, into snap ring groove all the way
around.
Underdrive clutch pack clearance must be
0.91 to 1.47 mm (.036 to .058 inch). Sel ect the
proper reacti on pl ate to achi eve speci fi cati ons:
Fig. 17 Seating Tapered Snap Ring
Fig. 18 Set Up Dial Indicator for Clutch Clearance
Fig. 19 Use Hook Tool to Raise One Clutch Disc
Fig. 15 OD/UD Reaction Plate
Fig. 16 Tapered Snap Ring
UNDERDRIVE REACTION PLATE CHART
TRANSAXLE 21 - 59
Fig. 20 Install OD Clutch Pack
Fig. 21 Install Waved Snap Ring
Fig. 22 OD/Reverse Pressure Plate
Fig. 23 Pressure Plate Installed
Fig. 24 Install Flat Snap Ring
Fig. 25 Check OD Clutch Pack Clearance
21 - 60 TRANSAXLE
The overdrive (OD) clutch pack clearance is
.965 to 2.26 mm (.038 to .089 inch). I f not wi thi n
speci fi cati ons, the cl utch i s not assembl ed properl y.
There i s no adjustment for the OD cl utch cl earance.
The reverse clutch pack clearance is 0.76 to
1.24 mm (.030 to .049 inch). Sel ect the proper re-
verse cl utch snap ri ng to achi eve speci fi cati ons:
Al l cl utch cl earances i n the i nput cl utch retai ner
have now been checked and approved.
To compl ete the assembl y of the i nput cl utch re-
tai ner, the reverse cl utch and the overdri ve cl utch
must be removed from the retai ner.
Fig. 26 Install Reverse Clutch Pack
Fig. 27 Install Reaction Plate
Fig. 28 Install Reverse Clutch Snap Ring
Fig. 29 Seating Snap Ring to Determine Reverse
Clutch Clearance
Fig. 30 Check Reverse Clutch Pack Clearance
REVERSE CLUTCH SNAP RING CHART
TRANSAXLE 21 - 61
CAUTION: Do not intermix clutch parts. Keep in
exact same order.
Now proceed wi th the next phase of the assembl y:
Rei nstal l overdri ve cl utch and reverse cl utch as
shown i n Fi gures 20 through 28. Rechecking these
clutch clearances is not necessary, as they were
set and approved previously.
Fig. 31 Install No. 2 Needle Bearing
Fig. 32 Install Underdrive Shaft Assembly
Fig. 33 Install No. 3 Thrust Washer
Fig. 34 Install No. 3 Thrust Plate
Fig. 35 Install Overdrive Shaft Assembly
Fig. 36 Input Clutch Assembly
21 - 62 TRANSAXLE
DETERMINING No. 4 THRUST PLATE THICKNESS
(Input Shaft End Play)
The i nput cl utch assembl y must be compl eted pri or
to performi ng thi s step.
To determi ne the proper thi ckness of the No. 4
thrust pl ate, sel ect the thi nnest No. 4 thrust pl ate
(Fi g. 1). Usi ng petrol atum to hol d thrust pl ate i n
posi ti on, i nstal l i nput cl utch assembl y.
Be sure the i nput cl utch assembl y i s compl etel y
seated. Thi s can be veri fi ed by l ooki ng i nto the tur-
bi ne speed sensor hol e (Fi g. 2).
CAUTION: If view through input speed sensor hole
is not as shown in figure 2, the input clutch assem-
bly is not seated properly.
Remove the oi l pump O-ri ng. You wi l l be abl e to
i nstal l and remove the oi l pump and gasket very
easi l y to sel ect the proper No. 4 thrust pl ate.
CAUTION: Be sure to reinstall O-ring on oil pump
after selecting the proper No. 4 thrust plate.
Input shaft end play must be .005 to .025 inch.
For exampl e, i f end pl ay readi ng i s .055 i nch, sel ect
No. 4 Thrust Pl ate whi ch i s .071 to .074 thi ck. Thi s
shoul d provi de an i nput shaft end pl ay readi ng of
.020 i nch whi ch i s wi thi n speci fi cati ons.
See chart bel ow to sel ect the proper No. 4 thrust
pl ate.
TRANSFER CHAIN LENGTH MEASUREMENT
The need to repl ace the transfer chai n because of
excessi ve wear i s unl i kel y. I f the chai n l ength i s sus-
pected to be l ong, perform the fol l owi ng procedure to
measure the chai n l ength:
(1) I nsert a screwdri ver i nto the 18 mm hol e wi th
the screwdri ver ABOVE the chai n (Fi g. 1).
(2) Pry the chai n down at the center of the chai n.
(3) Butt a scal e agai nst the snubber and mark the
scal e at the bottom of the chai n (Fi g. 2).
(4) I nsert a screwdri ver i nto the 18 mm hol e wi th
the screwdri ver BELOW the chai n (Fi g. 3). A assi s-
tant may be needed to perform thi s step.
(5) Pry the chai n up at the center of the chai n.
Fig. 1 Select Thinnest No. 4 Thrust Plate
Fig. 2 View Through Turbine Speed Sensor Hole
Fig. 3 Remove Oil Pump O-Ring
Fig. 4 Measure Input Shaft End Play
TRANSAXLE 21 - 63
(6) Butt a scal e agai nst the snubber and pl ace a
second mark on the scal e at the bottom of the chai n
(Fi g. 4).
(7) Measure the di stance between the two marks
pl aced on the scal e (Fi g. 5). I f the two marks on the
scal e are more than one i nch apart, repl ace the dri ve
chai n.
NO. 4 THRUST PLATE CHART
Fig. 1 Screwdriver Placement
Fig. 2 Chain Measurement
Fig. 3 Screwdriver Placement
Fig. 4 Chain Measurement
Fig. 5 Measuring Marks on Scale
21 - 64 TRANSAXLE
I f the transfer chai n was repl aced, refer to Snubber
Gap Measurement i n thi s secti on to veri fy correct
snubber cl earance.
SNUBBER GAP MEASUREMENT
The gap between the snubber face and the top of
the chai n shoul d be 0.0 to 0.030 i nch wi th chai n
sl ack removed. The gap can be adjusted by i nstal l i ng
snubbers wi th di fferent off-set mounti ng hol es. The
amount of off-set the mounti ng hol es has wi l l deter-
mi ne the posi ti on of the chai n snubber.
The snubbers can be i denti fi ed by thei r col or. There
are three di fferent snubber col ors avai l abl e (bl ack,
green and tan). The bl ack snubber wi l l gi ve the most
cl earance between the chai n and the snubber face.
The green snubber wi l l gi ve the l east cl earance be-
tween the chai n and the snubber face. The tan snub-
ber i s the nomi nal snubber.
(1) I nsert screwdri ver i nto the 18 mm hol e bel ow
the chai n and pry up on chai n to remove sl ack i n
chai n.
(2) Usi ng a feel er gauge, measure the gap between
the snubber face and the top of the chai n (Fi g. 6).
(3) I f the measurement i s not wi thi n speci fi cati ons,
i nstal l the correct snubber as requi red.
DRIVE SPROCKET HEIGHT ADJUSTMENT
PROCEDURE
A spacer beneath the output sprocket i s used to
posi ti on the output sprocket i n l i ne wi th the transfer
sprocket. The sprocket must be wi thi n 0.015 of each
other. I n order to do thi s operati on, i nstal l ori gi nal
spacer over the output shaft. I f ori gi nal spacer i s not
avai l abl e, use the thi ckest avai l abl e shi m as a start-
i ng poi nt. Refer to Output Sprocket Spacer Chart for
avai l abl e si zes. Then i nstal l the two sprockets wi th-
out the chai n.
The chai n sprockets are not reversi bl e. The output
sprocket has 32 teeth and the transfer sprocket has
33 teeth. Check the hei ght di fference usi ng a strai ght
edge (speci al tool 6311 or equi val ent) and a set of
feel er gauges.
I f the output sprocket i s l ower than transfer
sprocket, add the amount measured to the shi m that
was i nstal l ed (Fi g. 7).
I f the output sprocket i s hi gher than transfer sprocket,
subtract the amount measured to the shi m that was
i nstal l ed (Fi g. 8).
Fig. 6 Chain to Snubber Gap
Fig. 7 Checking Sprocket Height
Fig. 8 Checking Sprocket Height
OUTPUT SPROCKET SPACER CHART
TRANSAXLE 21 - 65
DIFFERENTIAL RECONDITION
The val ve body and sol enoi d wi ri ng connector must
be removed from the transaxl e i n order to recondi ti on
the transaxl e di fferenti al . The transfer shaft cannot
be removed wi th the val ve body i n pl ace. Refer to
Val ve Body Recondi ti on for removal procedure.
I f any beari ngs i n the di fferenti al requi re repl ace-
ment, al l the beari ngs on the di fferenti al carri er and
transfer shaft must al so be repl aced. The di fferenti al
adjusters must al so be repl aced when di fferenti al
beari ngs are repl aced.
DISASSEMBLY
Fig. 3 Remove Chain Snubber
Fig. 4 Remove Output Shaft Sprocket Snap Ring
and Wave Washer
Fig. 5 Remove Transfer Shaft Sprocket Snap Ring
and Wave Washer
Fig. 1 Remove Chain Cover
Fig. 2 Remove Chain Oiler
21 - 66 TRANSAXLE
CAUTION: The chain sprockets have a slip fit onto
there shafts. Apply only a slight amount of pressure
to the chain spreader to release the chain pressure.
If chain sprockets are not spread slightly removal or
installation will be difficult. Overspreading of the
chain sprocket will also make sprocket removal dif-
ficult.
CAUTION: When reinstalling drive chain, the blue
link must face outward.
CAUTION: Drive shaft retainer clips and seals lo-
cated on the stub shafts must be replaced before
reinstalling drive shafts.
Fig. 6 Install Chain Spreader
Fig. 7 Remove Chain and Sprockets as an
Assembly
Fig. 8 Remove Long Stub Shaft Snap Ring
Fig. 9 Remove Long Stub Shaft
Fig. 10 Remove Inner Differential Adjuster Lock
TRANSAXLE 21 - 67
I f the carri er requi res recondi ti oni ng, refer to Di f-
ferenti al Carri er Recondi ti on.
CAUTION: Failure to grind and open stakes on the
transfer shaft nut will result in thread damage to
transfer shaft during nut removal.
WARNING: WEAR SAFETY GOGGLES WHILE
GRINDING STAKE NUTS.
Fig. 11 Remove Outer Adjuster
Fig. 12 Loosen Outer Adjuster
Fig. 13 Remove Differential Side Cover, Carrier and
Ring Gear Assembly
Fig. 14 Remove Inner Adjuster By Turning
Clockwise
21 - 68 TRANSAXLE
Usi ng a di e gri nder or equi val ent, gri nd the stakes
i n the shoul der of the shaft nut as shown i n fi gure 16
and 17. Do not gri nd through the transfer shaft nut
i nto the shaft. There are two stakes on the nut.
Usi ng a smal l chi sel , careful l y open stakes on nut
(Fi g. 18).
Remove the transfer shaft nut.
CAUTION: Do not reuse old transfer shaft nut be-
cause the removed stake weakens the nut flange.
CAUTION: The transfer shaft cannot be removed
from the case at this time.
Fig. 15 Remove Differential Vent Baffle
Fig. 16 Grinding Stakes
Fig. 17 Stake Grinding Pattern
Fig. 18 Opening Nut Stakes
Fig. 19 Press Transfer Shaft Downward to Remove
Rear Cone
TRANSAXLE 21 - 69
I nstal l speci al tool 6577 to remove rear transfer
beari ng cup (Fi g. 20).
Remove transfer shaft prel oad shi m (Fi g. 21). I f
transfer shaft beari ngs are to be reused, the ori gi nal
shi m must al so be reused.
CAUTION: If the transfer shaft is removed from the
transaxle case for any reason, both seals must be
replaced.
Remove transfer shaft seal s (Fi g. 23) usi ng speci al
tool 6310 and foot 6310-9 (Tar 960). Do not reuse ol d
seal s. The seal s wi l l be pul l ed out the rear of the case.
Remove the front transfer shaft beari ng cup usi ng
speci al tool 6495 and handl e C-4171 (Fi g. 24). Use a
press wi th speci al tool s to remove cup.
Fig. 20 Transfer Bearing Cup Removal
Fig. 21 Preload Shim Removal
Fig. 22 Remove Transfer Shaft Assembly From Case
Fig. 23 Transfer Shaft Seal Remover
Fig. 24 Front Transfer Shaft Cup Removal
21 - 70 TRANSAXLE
Support speci al tool P-334 on press tabl e so that
pi ni on head of transfer shaft can be pressed through
tabl e (Fi g. 25).
ASSEMBLE AND BEARING ADJ USTMENT
PROCEDURE
The fol l owi ng steps wi l l determi ne the correct shi m
thi ckness requi red to obtai n proper pi ni on depth. Al l
speci al tool s descri bed i n thi s procedure must be used
to obtai n correct resul ts.
CAUTION: Failure to adjust pinion depth correctly
could cause gear noise or transaxle failure.
(1) I nstal l front transfer shaft beari ng cup (Fi g. 1).
The transfer shaft beari ng cup must be i nstal l ed be-
fore maki ng pi ni on depth measurement. Use speci al
tool 6494 to i nstal l beari ng cup. There are no shi ms
l ocated behi nd thi s beari ng cup.
CAUTION: The bearing cup is seated in the case
correctly if there is no clearance between the bot-
tom of the bearing cup and case. If a 0.001 or 0.002
feeler gauge does not fit, the bearing cup is com-
pletely seated into transaxle case.
(2) I nstal l centeri ng bl ock (speci al tool 6549-2) i nto
the transaxl e case (Fi g. 2). Screw centeri ng bl ock i nto
i nner adjuster hol e of case unti l i t bottoms. The pegs
on the speci al tool are onl y used for i nstal l ati on.
Ori entati on wi th i n the case i s not requi red.
(3) I nstal l new front beari ng (actual beari ng to be
used duri ng reassembl y) onto gauge di sc (speci al tool
6549-3) (Fi g. 3).
(4) I nstal l gauge di sc and beari ng i nto case usi ng
gauge di sc rod (Fi g. 4).
(5) I nstal l centeri ng di sc (speci al tool 6494-2) onto
gauge di sc rod (Fi g. 5).
(6) I nstal l centeri ng nut as shown i n fi gure 6.
(7) Hand ti ghten centeri ng nut unti l al l pl ay i n the
tool has been removed.
(8) I nstal l di al i ndi cator i nto l ocati ng bl ock. Then
screw extensi on rod onto di al i ndi cator.
Fig. 25 Remove Front Transfer Shaft Bearing And
Pinion Depth Shim
Fig. 1 Install Front Transfer Shaft Cup
Fig. 2 Installing Centering Block
TRANSAXLE 21 - 71
The dial indicator used to make this measure-
ment must have a face that shows 0-50-0 (0.001
inch increments) readings (Fig. 8). All steps
fromthis point forward will reflect this assump-
tion. If the dial indicator being used is a 0-100
reading face, take the reading obtained and
subtract it from 100. This will give you proper
shimthickness.
(9) Before maki ng a pi ni on depth measurement the
di al i ndi cator must be zeroed. Thi s i s done by pl aci ng
the di al i ndi cator i n the zeroi ng fi xture (speci al tool
6549-6). Then pl ace the zeroi ng fi xture on a fl at sur-
face. Adjust the di al face so that the poi nter on the
di al i ndi cator l i nes up wi th the zero (Fi g. 9).
(10) Compress the di al i ndi cator sl i ghtl y and i nsert
di al i ndi cator pi n i nto centeri ng bl ock (Fi g. 10).
Fig. 3 Gauge Disc and Bearing
Fig. 4 Installing Gauge Disc with Front Transfer
Shaft Bearing
Fig. 5 Disc Installation
Fig. 6 Installing Centering Nut
Fig. 7 Dial indicator, Locating Block and Extension
Rod
Fig. 8 0-50-0 Dial Indicator
21 - 72 TRANSAXLE
(11) Pi vot di al i ndi cator back and forth (Fi g. 11) on
centeri ng pi n to obtai n the shortest di stance measure-
ment. This will be the highest number reading
on dial indicator. Record the number obtai ned. Now
rotate the gauge di sc cl ockwi se 1/3 of a turn and
recheck readi ngs. Record number obtai ned. Rotate
the gauge di sc another 1/3 of a turn cl ockwi se and
take another readi ng. Average of the three readi ngs.
Record thi s pi ni on depth measurement. I f the read-
i ngs di ffer by more than two thousandths recheck
guage di sc i nstal l ati on, i t may have been i nstal l ed
sl i ghtl y cocked.
(12) To determi ne the requi red shi m thi ckness the
pi ni on depth measurement must be adjusted. The
pi ni on shi m adjustment number i s the fi rst of seven
di gi ts i nk stamped on the shank of the transfer shaft
(Fi g. 12). Usi ng the adjustment factor chart, convert
the adjustment number to the correspondi ng adjust-
ment factor. Uti l i zi ng the pi ni on depth measurement
obtai ned i n step 11, add or subtract the adjustment
factor to cal cul ate the requi red shi m thi ckness. Refer
to pi ni on head shi m chart for shi m sel ecti ons. Thi s i s
the shi m that wi l l be i nstal l ed between the transfer
shaft pi ni on head and the front transfer shaft bear-
i ng. Refer to the fol l owi ng exampl es for further expl a-
nati on:
Exampl e 1 i n (MM):
Measured pi ni on shi m depth: 0.789mm
Adjustment number on transfer shaft: +2
Adjustment factor (mm): -0.051mm
Shi m si ze needed: 0.789-0.051=0.738mm
Exampl e 2 i n (I N):
Measured pi ni on shi m depth: 0.032i n
Adjustment number on transfer shaft: -1
Adjustment factor (i n): +0.001
Shi m si ze needed: 0.032+0.001=0.033in
(13) Remove Di al i ndi cator, gauge di sc and center-
i ng bl ock from transaxl e.
(14) I nstal l shi m sel ected i n step 12 of thi s proce-
dure onto the transfer shaft (Fi g. 12).
(15) Press front transfer shaft beari ng onto transfer
shaft (speci al tool 6052). The shi m must be i n pl ace
before pressi ng on beari ng (Fi g. 13).
Fig. 9 Zero Dial Indicator
Fig. 10 Mounting Dial Indicator to Centering Block
Fig. 11 Pivot Dial Indicator
ADJ USTMENT FACTOR CHART
TRANSAXLE 21 - 73
At thi s poi nt the pi ni on depth has been determi ned
and the shi m has been i nstal l ed onto the transfer
shaft. Before the pi ni on i s i nstal l ed i nto the transaxl e
case, beari ng prel oad must be determi ned for the
di fferenti al beari ngs. The fol l owi ng steps must be
performed before the pi ni on i s i nstal l ed.
The fol l owi ng steps wi l l determi ne how many foot
pounds are requi red on the outer di fferenti al adjuster
to obtai n the correct turni ng torque.
CAUTION: Failure to set differential bearing preload
correctly may cause bearing failure, gear noise
and/or axle shaft seal failure.
(16) Remove outer adjuster wi th speci al tool 6503
(Fi g. 14).
PINION HEAD SHIM CHART
Fig. 12 Shim Installation
Fig. 13 Bearing Installation
Fig. 14 Outer Adjuster Removal
21 - 74 TRANSAXLE
(17) Remove ol d stub shaft seal s. Press i nner ad-
juster seal out wi th speci al tool 6502B. Press outer
adjuster seal out wi th speci al tool 6558.
(18) I nstal l new stub shaft seal s i n both adjusters
usi ng speci al tool 6558 (Fi g. 15).
(19) Lube adjuster threads and o-ri ng wi th gear oi l
before i nstal l i ng. Fai l ure to l ube threads wi l l resul t i n
thread damage to the adjuster and transaxl e case.
(20) Screw i n the i nner adjuster usi ng speci al tool
6502B (Fi g. 16). The i nner adjuster shoul d be screwed
i n unti l under-fl ush wi th i nsi de of the case (vi ewed
from di fferenti al si de).
(21) I nstal l di fferenti al assembl y i nto the transaxl e
case (Fi g. 17).
(22) I nstal l di fferenti al cover (Fi g. 18). Do not appl y
si l i cone seal ant at thi s ti me. Al l bol ts shoul d be i n-
stal l ed and ti ghtened.
(23) I nstal l seal protector (speci al tool 6591) as
shown i n fi gure 19). Appl y a thi n fi l m of gear oi l on
the protector.
Fig. 15 Axle Shaft Seal Installation
Fig. 16 Inner Adjuster Installation
Fig. 17 Differential Assembly Installation
Fig. 18 Differential Cover Installation
Fig. 19 Seal Protector
TRANSAXLE 21 - 75
CAUTION: Lube threads and o-ring on adjuster be-
fore installing. Failure to due so will result in thread
damage to the adjuster and transaxle case.
(24) Screw on outer adjuster and ti ghten adjuster
down fi nger ti ght (Fi g. 20).
(25) I nsert speci al tool 6548 (Fi g. 21). Thi s tool wi l l be
used to check turni ng torque of the di fferenti al assembl y.
CAUTION: Differential bearings must be seated be-
fore taking turning torque readings. This is done by
rotating the differential three or four turns in both
directions.
CAUTION: Turning torque of 19 to 23 in. lbs. can
only be obtain when using new bearings. Do not
attempt to obtain this turning torque with used bear-
ings.
(26) Ti ghten outer adjuster wi th tool 6503 unti l 19 to
23 i n. l bs. of turni ng torque i s obtai ned on tool 6548.
Record how many foot pounds were required on
the outer adjuster to obtain the correct turning
torque (Fi g. 22). Record the foot pound readi ng. The
readi ng that you are recordi ng wi l l be used i n step 48 of
thi s procedure.
Fig. 20 Outer Adjuster Installation
Fig. 21 Special Tool 6548
Fig. 22 Determining Turning Torque
21 - 76 TRANSAXLE
(27) Remove the di fferenti al cover, di fferenti al car-
ri er assembl y and i nner adjuster.
At thi s poi nt the amount of torque requi red on the
outer di fferenti al adjuster has been determi ned. The
transfer shaft can now be i nstal l ed i nto the transaxl e
case. Perform the fol l owi ng steps to i nstal l transfer
shaft i nto transaxl e case.
(28) I nstal l transfer shaft i nto transaxl e case (Fi g.
23).
CAUTION: Bottom of support fixture must be flush
with face of bell housing. If the support fixture is not
flush, the seals and rear transfer shaft bearing cup
will be pressed in cocked.
(29) I nstal l transfer shaft support fi xture (speci al
tool 6595) (Fi g. 24).
(30) I nstal l transfer shaft seal protector (speci al
tool 6592) (Fi g. 25). Appl y thi n fi l m of gear oi l to
protector.
(31) Appl y a smal l amount of l ube to seal l i ps and
i nstal l front transfer shaft seal . The serrated edges
must face toward the rear of the transaxl e (Fi g. 26).
(32) I nstal l seal wi th speci al tool 6567A (Fi g. 27).
Use a press to i nstal l seal . The i nstal l ati on tool wi l l
set the seal depth. Do not use a hammer to i nstal l
seal . The seal may be damaged i f i nstal l ed wi th a
hammer.
(33) I nstal l rear transfer shaft seal . The seal must
be i nstal l ed so that the spri ng si de of the seal faces
the i nstal l ati on tool (Fi g. 28). Use the same speci al
tool (6567A) to i nstal l the seal . The i nstal l ati on tool
wi l l set the seal depth. Use a press to i nstal l thi s seal .
Do not use a hammer.
(34) I nstal l rear transfer shaft cup i nto case (Fi g.
29).
Fig. 23 Transfer Shaft Installation
Fig. 24 Transfer Shaft Support Fixture
Fig. 25 Seal Protector Installation
Fig. 26 Correct Seal Orientation
TRANSAXLE 21 - 77
CAUTION: Properly seated cups are essential in cor-
rectly setting bearing preload.
(35) Use speci al tool 6560 to press cup i nto case
(Fi g. 30).
(36) I nstal l Transfer shaft prel oad shi m (Fi g. 31).
Use the ori gi nal shi m that was taken out of transaxl e
i f possi bl e. I f ori gi nal shi m i s not avai l abl e, use the
thi ckest shi m as a starti ng poi nt. Refer to Transfer
Shaft Rear Shi m Chart for avai l abl e si zes.
FIg. 27 Seal Installation
Fig. 28 Correct Seal Orientation
Fig. 29 Rear Transfer Bearing Cup
Fig. 30 Rear Transfer Shaft Cup Installation
Fig. 31 Transfer Preload Shim Installation
21 - 78 TRANSAXLE
(37) I nstal l rear transfer shaft cone (Fi g. 32). Press
cone on transfer shaft usi ng speci al tool 6560.
(38) Remove transfer shaft support fi xture (speci al
tool 6595).
CAUTION: Always use a new transfer shaft nut. Do
not reuse old transfer shaft nut.
(39) I nstal l a new transfer shaft nut (Fi g. 33).
Ti ghten nut to 271 Nm (200 ft. l bs.). Use speci al
tool s 6497 hol der and 6498 shaft socket to ti ghten
nut.
CAUTION: Failure to set the transfer shaft turning
torque correctly may cause transfer shaft bearings
or seals to fail. Be sure transfer shaft does not have
end play. If end play exists, install a thinner preload
shim.
(40) Check the turni ng torque of the transfer shaft
usi ng a torque wrench (Fi g. 34). The turni ng torque
shoul d be 0.5 to 1.3 Nm (5 to 12 i n. l bs.). I f the
turni ng torque i s too hi gh, i nstal l a thi cker transfer
shaft prel oad shi m. I f the turni ng torque i s too l ow,
i nstal l a thi nner transfer shaft prel oad shi m.
CAUTION: A press and special tool 6589 must be
used when staking the transfer shaft nut. Do not use
a hammer and the special tool to stake nut. If a
hammer is used seal, bearing and/or tool damage
may result. Also the stake will not be seated against
the shaft correctly. This will allow the nut to loosen.
(41) After the correct turni ng torque i s obtai ned,
use speci al tool 6589 to stake the new transfer shaft
nut (Fi g. 35). Be sure that the tool arms l i ne up wi th
sl ots i n the transfer shaft. Use a press wi th the
speci al tool to make the stakes i n the nut.
TRANSFER SHAFT REAR SHIM CHART
Fig. 32 Transfer Shaft Cone Installation
Fig. 33 Transfer Shaft Nut Installation
Fig. 34 Checking Turning Torque
TRANSAXLE 21 - 79
CAUTION: Failure to stake the transfer shaft nut
correctly may allow the nut to loosen during tran-
saxle operation. This will cause transaxle failure.
At thi s poi nt the transfer shaft, new oi l seal s, pi n-
i on depth and transfer shaft pre-l oad have been set.
The fol l owi ng steps wi l l set the backl ash between the
transfer shaft and the ri ng gear.
I f the carri er requi res recondi ti oni ng, refer to Di f-
ferenti al Carri er Recondi ti on.
(42) I nstal l vent baffl e. Appl y seal er as shown i n
fi gure 37.
(43) I nstal l new i nner adjuster o-ri ng. Lube i nner
adjuster threads and o-ri ng. Then i nstal l i nner ad-
juster fl ush wi th di fferenti al si de of case.
(44) I nstal l di fferenti al assembl y (wi th ri ng gear
attached) i nto transaxl e case (Fi g. 38).
(45) Transfer shaft to ri ng gear backl ash shoul d be
0.006 to 0.009 thousands of an i nch. To get the
backl ash cl ose enough to measure, perform the fol l ow-
i ng steps. Hol d the transfer shaft wi th one hand and
rock the ri ng gear back and forth (Fi g. 39). You shoul d
feel some backl ash between the gears. I f no backl ash
i s fel t use speci al tool 6502B to turn the i nner ad-
juster so that i t rai ses the di fferenti al assembl y. Thi s
wi l l i ncrease backl ash. I f there i s to much backl ash,
use speci al tool 6502B to turn the i nner adjuster so
that i t l owers the di fferenti al assembl y. Thi s wi l l
decrease backl ash. Recheck the backl ash after each
adjustment.
Fig. 37 Baffle Installation
Fig. 38 Differential Assembly Installation
Fig. 35 Staking New Nuts
Fig. 36 Correctly Staked Nut
21 - 80 TRANSAXLE
(46) Appl y a 1/8 i nch bead of seal ant to di fferenti al
cover fl ange. Then i nstal l di fferenti al cover wi th seal -
ant (Fi g. 40) and ti ghten cover bol ts.
(47) I nstal l seal protector (speci al tool 6591) on
shaft (Fi g. 41).
CAUTION: Lube threads and o-ring on adjuster be-
fore installing. Failure to due so will result in thread
damage to the adjuster and differential cover.
(48) I nstal l outer adjuster wi th new o-ri ng (Fi g.
42). Torque the outer adjuster (speci al tool 6503) to
the torque readi ng recorded i n step 25. Then seat
beari ngs by turni ng di fferenti al three or four revol u-
ti ons i n both di recti ons. Ti ghten adjuster a second
ti me to same torque recorded i n step 25. Agai n reseat
beari ngs. Repeat thi s sequence unti l correct adjuster
torque i s mai ntai ned.
(49) To check and/or adjust backl ash remove the
i nspecti on pl ug from the top of the di fferenti al . I nstal l
di al i ndi cator as shown i n fi gure 43. The ti p of the
di al i ndi cator must be perpendi cul ar agai nst one
of the ri ng gear teeth. Hol d transfer shaft wi th l ock-
i ng pl i ers. Move ri ng gear back and forth wi th speci al
tool 6548. Read the amount of backl ash wi th di al
i ndi cator. Backl ash shoul d be 0.006 to 0.009 thou-
sands of an i nch.
Fig. 41 Seal Protector Fig. 39 Rocking Ring Gear Back and Forth
Fig. 40 Differential Cover Installation
Fig. 42 Outer Adjuster Installation
Fig. 43 Dial Indicator Installation
TRANSAXLE 21 - 81
I f there i s too much backl ash, l oosen the outer
adjuster wi th speci al tool 6503. Then turn the i nner
adjuster so that i t moves away fromthe ring gear.
After adjusti ng the i nner adjuster, reti ghten the outer
adjuster to the torque recorded i n step 26. The i nner
adjuster shoul d be turned i n smal l i ncrements.
I f there i s not enough backl ash, l oosen the outer
adjuster wi th speci al tool 6503. Then turn the i nner
adjuster so that i t moves towards the ring gear.
After adjusti ng the i nner adjuster, reti ghten the outer
adjuster to the torque recorded i n step 25. The i nner
adjuster shoul d be turned i n smal l i ncrements.
(50) Once backl ash i s wi th i n speci fi cati ons, re-
check the back l ash i n four spots on the ri ng gear 90
degrees apart. Al l four readi ngs shoul d be wi thi n
speci fi cati ons.
(51) I nstal l i nner and outer adjuster l ocki ng brack-
ets.
(52) I nstal l new i nspecti on pl ug. Use a wooden
bl ock to tap i nspecti on pl ug i nto pl ace.
I t i s easi er to fi l l the di fferenti al pri or to i nstal l i ng
the transaxl e back i nto the vehi cl e. The di fferenti al
hol ds 32 ounces of fl ui d.
DIFFERENTIAL CARRIER-RECONDITION
CAUTION: Ring gear bolts are not reusable. When
reassembling use new bolts.
CAUTION: When reassembling use a new roll pin
BEARING ADJUSTMENT PROCEDURES
GENERAL RULES ON SERVICING BEARINGS
Take extreme care when removi ng and i nstal l i ng
beari ng cups and cones. Use only an arbor press
for installation, as a hammer may not properl y
al i gn the beari ng cup or cone. Burrs or ni cks on the
beari ng seat wi l l gi ve a fal se end pl ay readi ng, whi l e
gaugi ng for proper shi ms. I mproperl y seated beari ng
cup and cones are subject to l ow-mi l eage fai l ure.
Beari ng cups and cones shoul d be repl aced i f they
show si gns of pi tti ng or heat di stress.
Fig. 1 Remove Ring Gear Bolts
Fig. 2 Tap Off Ring Gear
Fig. 3 Pry Differential Carrier Apart
Fig. 4 Remove C-Clip
21 - 82 TRANSAXLE
I f di stress i s seen on ei ther the cup or beari ng
rol l ers, both cup and cone must be repl aced.
Bearing end play and drag torque specifica-
tions must be maintained to avoid premature
bearing failures.
Used (ori gi nal ) beari ng may l ose up to 50 percent of
the ori gi nal drag torque after break-i n.
All bearingadjustments must be made with no
other component interference or gear inter-
mesh, except the transfer gear bearing.
Oi l al l beari ngs before checki ng turni ng torque.
Fig. 5 Remove Pinion Shaft Roll Pin
Fig. 6 Slide Out Differential Pinion Shaft and
Remove Pinion Gears and Side Gears
Fig. 7 Carrier Bearing Removal
Fig. 8 Carrier Bearing Installation
TRANSAXLE 21 - 83
42LE ON-BOARD DIAGNOSTICS
INDEX
page page
CCD Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Diagnostic Trouble Code Charts . . . . . . . . . . . . . . 85
Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . 84
DRB Scan Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 85
General Information . . . . . . . . . . . . . . . . . . . . . . . 84
Limp-In Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
On-Board Diagnostics Information . . . . . . . . . . . . . 84
GENERAL INFORMATION
The i nformati on i n thi s manual i s desi gned to hel p
the techni ci an repai r the transaxl e wi th the ai d of
on-board di agnosti cs.
Chrysler Corporation has developed a com-
plete set of diagnostic manuals which cover the
diagnosis of the 42LE transaxle. They have been
designed to make transaxle diagnosis accurate
and simple. Use these manuals with the DRB
scan tool and the latest cartridge, when diag-
nosing transaxle problems.
ON-BOARD DIAGNOSTICS INFORMATION
The 42LE transaxl e i s control l ed and moni tored by
the transmi ssi on control modul e. The transmi ssi on
control modul e moni tors cri ti cal i nput and output
ci rcui ts wi thi n the transaxl e.
Some ci rcui ts are tested conti nuousl y; others are
checked onl y under certai n condi ti ons. Each ci rcui t
moni tored by the transmi ssi on control modul e has a
correspondi ng faul t message assi gned to i t. The mes-
sage can be read wi th the DRB scan tool .
I f the on-board di agnosti c system senses that one of
the ci rcui ts i s mal functi oni ng, the correspondi ng code
i s stored i n memory. I f the mal functi on goes away
after the code i s stored, the transmi ssi on control mod-
ul e wi l l erase the code after 75 key cycl es.
CCD BUS
I n order to di agnose the 42LE transaxl e, di agnosti c
troubl e codes i n the TCMs memory shoul d be read
usi ng the DRB scan tool . I f more than one di agnosti c
troubl e code exi sts, di agnosti c pri ori ty shoul d be
gi ven to the most recent code. Wi th CCD bus bi as and
communi cati on probl ems, however, the DRB scan tool
di spl ays an appropri ate message. Di agnosti c troubl e
codes mi ght not be accessi bl e unti l the bus probl em i s
fi xed. The fol l owi ng i s a l i st of probabl e causes for a
bus probl em:
Open or short to ground/battery i n ei ther or both
CCD bus wi res (pi ns 4 and 43).
Open or short to ground/battery i n ei ther or both
42LE transaxl es bi as wi res (pi n 5 and 44).
Open or short to ground/battery i n the di agnosti c
connector bus wi re.
I nternal fai l ure of any modul e connected to the
bus.
The CCD bus shoul d have 2.5 vol ts (+2.5 vol ts on
CCD+ and -2.5 vol ts on CCD-).
The bus error message di spl ayed by the DRB scan
tool shoul d be hel pful i n di agnosi ng the CCD bus.
For i nformati on on di agnosi ng CCD bus, refer to
the 1993 Di agnosti c Procedures Manual for non-
communi cati on wi th the CCD bus. Al l other probl ems
refer to the 1993 Body Vehi cl e Communi cati ons Di ag-
nosti c Procedures Manual .
DIAGNOSTIC TROUBLE CODES
Di agnosti c Troubl e Codes are two-di gi t numbers
that i denti fy whi ch ci rcui t i s mal functi oni ng. A code
can be set for hydraul i c and mechani cal reasons as
wel l as for el ectri cal probl ems. I n most cases, codes do
not pi npoi nt whi ch speci fi c component i s defecti ve.
Diagnostic trouble codes can only be read
with the use of the DRB scan tool or equivalent.
HARD FAULTS
Any Di agnosti c troubl e code that comes back wi thi n
3 engi ne starts (reset count 3 or l ess) i s a Hard Faul t.
Thi s means that the defect i s there every ti me the
transmi ssi on control modul e checks that ci rcui t.
SOFT FAULTS
A Soft Faul t i s one that occurs i ntermi ttentl y. I t i s
not there every ti me the transmi ssi on control modul e
checks the ci rcui t. Most soft faul ts are caused by
wi ri ng or connector probl ems. I ntermi ttent defects
must be l ooked for under the speci fi c condi ti ons that
caused them.
LIMP-IN MODE
The transmi ssi on control modul e conti nuousl y
checks for el ectri cal and i nternal transaxl e probl ems.
When a probl em i s sensed, the transmi ssi on control
modul e stores a di agnosti c troubl e code. Al l but
twel ve of these codes cause the transaxl e to go i nto
the Li mp-i n mode. Whi l e i n thi s mode, el ectri cal
power i s taken away from the transaxl e. When thi s
happens, the onl y transaxl e ranges that wi l l functi on
are:
Park
Neutral
21 - 84 TRANSAXLE
Reverse
Second Gear
No upshi fts or downshi fts are al l owed whi l e i n the
Li mp-i n mode. The posi ti on of the manual val ve al one
al l ows the three ranges that are avai l abl e.
Al though engi ne performance wi l l be reduced whi l e
i n thi s mode, the vehi cl e can be dri ven i n for servi ce.
DRB SCAN TOOL
The DRB scan tool i s a di agnosti c read-out box
desi gned by Chrysl er. I t i s used to gai n access to the
on-board di agnosti cs that are found on al l Chrysl er-
bui l t cars and trucks.
The DRB scan tool has a few di agnosti c capabi l i ti es
by i tsel f. To perform most di agnosti c tests, a program
cartri dge must be i nserted. I t contai ns the di agnosti c
test programs.
There are di agnosti c read-out boxes avai l abl e from
other manufactures that can be used on Chrysl er
vehi cl es. However, the di agnosti c test procedures i n
thi s manual have been desi gned for use wi th the
Chrysl ers DRB scan tool .
The DRB scan tool operates by communi cati ng wi th
the modul e of the vehi cl e system bei ng tested. To
communi cate wi th the transmi ssi on control modul e,
the DRB scan tool must be connected to the bl ue CCD
bus connector. The connector i s l ocated under the
i nstrument panel . Refer to the Usi ng the DRB scan
tool manual or the Di agnosti c Procedures Manual for
i nformati on.
DIAGNOSTIC TROUBLE CODE CHARTS
Bel ow i s a bri ef descri pti on of what each secti on of
the di agnosti c troubl e code charts are addressi ng.
DIAGNOSTIC TROUBLE CODE-Tel l s the code
number and name (as shown on the DRB scan tool ).
BACKGROUND-A bri ef descri pti on of the ci rcui t
that the transmi ssi on control modul e i s moni tori ng.
WHEN CHECKED-The poi nt of ti me or condi ti on
when the transmi ssi on control modul e makes i ts sys-
tem check.
ARMING CONDITIONS-The parameters that
must be met before a code can be set.
FAULT CONDITION-What the transmi ssi on con-
trol modul e saw that i s determi ned to be a probl em.
FAULT SET TIME-The amount of ti me a fai l ure
must occur before a di agnosti c troubl e code i s set i n
memory.
EFFECT-Refers to how the faul t effects transaxl e
operati ons.
POSSIBLE CAUSE-Refers to the systems or ci r-
cui ts whi ch coul d cause the faul t to be recorded.
DIAGNOSTIC TROUBLE CODE 11
TRANSAXLE 21 - 85
DIAGNOSTIC TROUBLE CODE 12
DIAGNOSTIC TROUBLE CODE 13
21 - 86 TRANSAXLE
DIAGNOSTIC TROUBLE CODE 14
DIAGNOSTIC TROUBLE CODE 15
TRANSAXLE 21 - 87
DIAGNOSTIC TROUBLE CODE 16
DIAGNOSTIC TROUBLE CODE 17
21 - 88 TRANSAXLE
DIAGNOSTIC TROUBLE CODE 18
DIAGNOSTIC TROUBLE CODE 19
TRANSAXLE 21 - 89
DIAGNOSTIC TROUBLE CODE 20
21 - 90 TRANSAXLE
DIAGNOSTIC TROUBLE CODE 21-27
TRANSAXLE 21 - 91
DIAGNOSTIC TROUBLE CODE 28
21 - 92 TRANSAXLE
DIAGNOSTIC TROUBLE CODE 29
DIAGNOSTIC TROUBLE CODE 31-32
TRANSAXLE 21 - 93
DIAGNOSTIC TROUBLE CODE 36
DIAGNOSTIC TROUBLE CODE 35
21 - 94 TRANSAXLE
DIAGNOSTIC TROUBLE CODE 37
DIAGNOSTIC TROUBLE CODE 38
TRANSAXLE 21 - 95
DIAGNOSTIC TROUBLE CODE 41-44
21 - 96 TRANSAXLE
DIAGNOSTIC TROUBLE CODE 45
DIAGNOSTIC TROUBLE CODE 46
TRANSAXLE 21 - 97
DIAGNOSTIC TROUBLE CODE 48
DIAGNOSTIC TROUBLE CODE: 48 Torque Management
BACKGROUND: Engine torque management is used during high-torque, high-speed 1-2, 2-3, 4-2, and 3-1
shifts in order to reduce the energy dissipation in the 2-4 clutch and the OD clutch to an
acceptable level.
WHEN CHECKED: Every 7 msec
ARMING CONDITIONS: 1) Throttle must be less than 15 degrees.
2) Turbine input speed must be less than 200 rpm.
3) Engine speed must be less than 1200 rpm.
4) Must be in Reverse, Neutral or 1st Gear.
5) If the transmission control module does not receive, within 1.0 seconds via the CCD,
confirmation that the torque management request signal was read by the engine control
module.
CONDITIONS: When the torque fault management fault counter matures to a value exceeding 15.
SET TIME: 1) If an incorrect response frompowertrain control module on CCD acknowledging request
for torque management test during idle.
2) Event dependent on two sequential requests for torque managed shifts without correct
response from powertrain control module on CCD acknowledging that torque manage-
ment is in progress.
EFFECT: Throttle used for shift point selection is limited to 54 degrees if T/M fault counter is greater
than seven.
POSSIBLE CAUSES: CCD buss communication problem.
9321-441
DIAGNOSTIC TROUBLE CODE 47
21 - 98 TRANSAXLE
DIAGNOSTIC TROUBLE CODE 50-58
TRANSAXLE 21 - 99
DIAGNOSTIC TROUBLE CODE 60-62
21 - 100 TRANSAXLE
42LE HYDRAULIC SCHEMATICS
TRANSAXLE 21 - 101
21 - 102 TRANSAXLE
TRANSAXLE 21 - 103
21 - 104 TRANSAXLE
TRANSAXLE 21 - 105
21 - 106 TRANSAXLE
TRANSAXLE 21 - 107
21 - 108 TRANSAXLE
TRANSAXLE 21 - 109
21 - 110 TRANSAXLE
TRANSAXLE 21 - 111
21 - 112 TRANSAXLE
TRANSAXLE 21 - 113
42LE SPECIFICATIONS
42LE FOUR SPEED AUTOMATIC TRANSAXLE
21 - 114 TRANSAXLE
42LE TORQUE SPECIFICATIONS
TRANSAXLE 21 - 115
MASTER SHIM CHART
21 - 116 TRANSAXLE

S-ar putea să vă placă și