Diagrama Transmision LHS, Intrepid, Condord, Newyorker

8/11/2019 Diagrama Transmision LHS, Intrepid, Condord, Newyorker

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TRANSAXLE

CONTENTS

page page

42LE FOUR SPEED AUTOMATIC TRANSAXLE . . 142LE HYDRAULIC SCHEM ATICS . . . . . . . . . . 1 01

42LE ON-BOARD DIAGNOSTICS . . . . . . . . . . . 8442LE SPECIFICATIONS . . . . . . . . . . . . . . . . . . 1 14

42LE FOUR SPEED AUTOMATIC TRANSAXLE

INDEX

page page

42LE General Diagnosis . . . . . . . . . . . . . . . . . . . . 3Air Pressure Test of Transaxle Sump . . . . . . . . . . 20

Aluminum Thread Repair . . . . . . . . . . . . . . . . . . . 23Back Up Lamp Diagnosis . . . . . . . . . . . . . . . . . . . 25Bearing Adjustment Procedures . . . . . . . . . . . . . . 82Clutch Air Pressure Tests . . . . . . . . . . . . . . . . . . . 17Coolers and Tubes Reverse Flushing . . . . . . . . . . 23Determining No. 4 Thrust Plate Thickness

(Input Shaft End Play) . . . . . . . . . . . . . . . . . . . . 63Differential Carrier-Recondition . . . . . . . . . . . . . . . 82Differential Recondition . . . . . . . . . . . . . . . . . . . . 66Drive Sprocket Height Adjustment Procedure . . . . 65Floor Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Fluid and Filter Change-Transmission Sump . . . . . . 9Fluid Drain and Refill-Differential Sump . . . . . . . . . 10Fluid Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Fluid Level and Condition . . . . . . . . . . . . . . . . . . . . 9

Gearshift Linkage—Column Shift . . . . . . . . . . . . . 10Gearshift Linkage—Floor Shift . . . . . . . . . . . . . . . 13General Information . . . . . . . . . . . . . . . . . . . . . . . . 1Hydraulic Pressure Tests . . . . . . . . . . . . . . . . . . . 16Input Clutches-Recondition . . . . . . . . . . . . . . . . . . 51Long Stub Shaft Seal Replacement . . . . . . . . . . . 21

Low/Reverse Clutch Clearance . . . . . . . . . . . . . . . 51Manual Valve Lever Position Sensor . . . . . . . . . . . 23

Oil Cooler Flow Check . . . . . . . . . . . . . . . . . . . . . 23Oil Pump Seal Replacement . . . . . . . . . . . . . . . . . 33Output Shaft Bearing Preload Shim Selection . . . . 49Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Selection of Lubricants . . . . . . . . . . . . . . . . . . . . . . 9Short Stub Shaft Seal Replacement . . . . . . . . . . . 22Snubber Gap Measurement . . . . . . . . . . . . . . . . . 65Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . 24Special Additives . . . . . . . . . . . . . . . . . . . . . . . . . . 9Speed Sensor-Input . . . . . . . . . . . . . . . . . . . . . . . 27Speed Sensor-Output . . . . . . . . . . . . . . . . . . . . . . 27Torque Converter Clutch Break-In Procedure . . . . 34Transaxle Disassemble/Reassemble . . . . . . . . . . . 35Transaxle Quick Learn Procedure . . . . . . . . . . . . . 35Transaxle Removal and Installation . . . . . . . . . . . . 32Transfer Chain Length Measurement . . . . . . . . . . 63Transfer Shaft Seal Replacement . . . . . . . . . . . . . 30Transmission Control Module . . . . . . . . . . . . . . . . 25Transmission Control Relay . . . . . . . . . . . . . . . . . 24Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

GENERAL INFORMATIONThe 42LE F our Speed Tra nsa xle uses fully-a da ptive

controls. Adaptive controls ar e t hose wh ich perform

t h e ir f u n ct ion s b a se d on r e a l-t im e f ee d ba ck se n sor

information. The transaxle is conventional in the use

of h y d r a u lica l ly a p p lied clu t ch e s t o sh ift a p la n e t a r y

g ea r t r a in . I t u ses e le ct r o n ics t o con t r o l vir t u a lly a l lother functions.

42LE TRANSAXLE IDENTIFICATION

The 42LE transaxle identification code is printed on

a bar code label. The label is located on the transaxle

case (Fig. 1).

IN-VEHICLE SERVICE

The following is a list of transaxle components that

ar e serviceable in the vehicle:

Fig. 1 Identification Tag Location

TRANSAXLE 21 - 1



• Valve Body Assembly

• Solenoid Pack

• Manua l Valve Lever P osit ion S ensor (MVLP S)

• Input Speed Sensor

• Output S peed Sensor

• Tra nsfer Cha in

• Chain Sprockets

• S h o r t (Rig h t ) S t u b S h a f t S e a l

• L on g (lef t ) S t u b S h a f t a n d B a ll B e a r in g

OPERATION Th e 42L E t r a n s a x l e p r ov id es f or w a r d r a t i os of

2 .84 , 1. 57 , 1 .0 0, a n d 0 .6 9. Th e t o r q u e co n ve r t e r

c l u t c h i s a v a i l a b l e i n 2 n d , d i r e c t , o r o v e r d r i v e g e a r .

The Reverse ratio is 2.21. The shift lever is conven-

t i on a l w i t h s ix p os it i on s (P , R , N , O D , 3, a n d L ).

Wh e n O D i s s e le ct e d t h e t r a n s a x l e s h i f t s n o r m a l l y

t h r ou g h a l l f ou r s pe ed s w i t h t h e t o rq u e con v er t e r

c l u t c h o p e r a t i o n a l i n t h i r d a n d o v e r d r i v e ; t h i s p o s i -

tion is recommended for most driving. The 3 position

i s t a i l or e d fo r u s e i n h i ll y or m o un t a i n ou s d r i vi n g .

W h e n 3 i s s e l e c t e d , t h e t r a n s m i s s i o n u s e s o n l y 1 s t ,

2nd, and direct gears with 2nd-direct shift delayed to

4 0 m p h o r g r e a t e r . W h e n o p e r a t i n g i n 3 o r L p o s i -

t i on s t o r q u e co n ve r t e r cl u t ch a p p l ic a t i on o ccu r s i n

d ir e ct g ea r . Th i s i m pr ov es t r a n s m i s si on cool in g

w hen t owing tr a ilers a nd/or driving on st eep gra des.

I f h ig h e ng in e coola n t t e mp er a t u r e occu r s, t h e

torque converter clutch will also engage in 2nd gear.

Th e L p os i t ion p r ov i de s m a x i m u m e n g in e b r a k i n gf or d es ce n di n g s t e ep g r a d e s. U n l i ke m os t cu r r en t

t r a n s a x le s, u ps h if t s a r e p r ov id ed t o 2n d or d ir e ct

g e a r a t p e a k e n g i n e s p e e d s i f t h e a c c e l e r a t o r i s d e -

pressed. This provides eng ine over-speed prot ection

a n d m a x i m u m p e r for m a n ce .

CLUTCH AND GEAR

The 42LE transaxle consists of:

• Three m ultiple-disc input clutches

• Tw o mult iple-disc gr ounded clut ches

• Four hydraulic accumulators

• Two planeta ry gear sets

Th i s p rov id es f ou r f or w a r d r a t i os a n d a r ev er s e

r a t io. Th e clu t ch a p p ly p ist on s h a ve a cen t r i f u ga lly

balanced oil cavit ies so that quick response and good

contr ol can be a chieved. A push/pull pist on is incorpo-

ra ted for tw o of th e three input clutches.

CAUTION: Some clutch packs appear similar, butthey are not the same. Do not interchange clutchcomponents as they might fail.

HYDRAULICS

The hyd raulics of t he t ran saxle provide:

• Manua l shift lever select function• Main line pressure regulation

• Torque convert er flow cont rol

• Tra nsa xle oil cooler flow cont rol

O il f low t o t h e f r ict ion e le m en t s is con t r o lled d i-

r e ct ly b y f ou r solen oid va lves. Th e h y d r a u lics a lso

include a logic-controlled solenoid switch valve. I t

locks out the 1st gea r rea ction element with the a ppli-

ca t ion of 2n d, d ir ect , o r over d r ive g ea r e le m en t s. I t

a lso r e d ir e ct s t h e 1st g e a r so le n o id o u t p u t so t h a t i t

can control torque converter clutch opera tion. To re-

gain access t o 1st gear, a special sequence of solenoid

com m a n ds m u st b e u sed t o u n lock a n d m ov e t h e

solenoid switch valve. This precludes a ny applicat ion

of the 1st gear reaction element with other elements

a p pl ie d. I t a l s o a l low s on e s ol en oi d t o con t r ol t w o

friction elements.

Small, high-rate accumulators are provided in each

controlled friction element circuit. These serve to ab-

sorb the pressure responses, a nd a llow the controls t o

read and respond to changes that are occurring.

SOLENOIDS

Since the solenoid valves perform all control func-

t i on s , t h es e v a l v es m u s t b e d u r a b le a n d t ol er a n t of

Fig. 2 Left Side View of Transaxle

Fig. 3 Right Side View of Transaxle

21 - 2 TRANSAXLE



dirt particles. For that reason hardened-steel poppet

a n d b a l l v a l v es a r e u s ed . Th es e a r e f r ee f r om a n y

close operating clearances, and the solenoids operate

the valves directly. Direct operation means that these

u n it s m u st h a ve ver y h ig h o u t pu t . Th e y m u st close

a g a i n s t t h e s i z ea b l e f low a r e a s a n d h i gh l in e p r es -

s u r es . F a s t r es pon s e i s a l s o r e q ui r ed t o m ee t t h e

control requirements.Two of t he solenoids ar e normally-venting a nd tw o

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

default mode of operat ion. With no electrical power,

t h e t r a n s m is s ion p rov id es 2n d g ea r i n O D , 3 , or L

shift lever posit ions. All other shift lever posit ions

w il l f u n ct ion n or m a lly. Th e choice of 2n d g e a r w a s

made to provide adequate performance while st ill ac-

commodating highway speeds.

SENSORS

Th e r e a r e t h r e e p r e ssu r e sw it ch es w h ich id en t i f y

solenoid application. The pressure switches are incor-

pora ted in an assembly with the solenoids. Two speed

se n sor s r e a d in pu t (t o r q u e con ver t e r t u r b in e) a n d

output (parking spra g) speeds. There is a lso a m anua l

va lve lever p osit ion sen sor (M VL P S ) w h ich sen se s

manual valve posit ion.

Engine speed, thrott le posit ion, temperature, etc. ,

a r e a l s o o bs er v ed . S om e of t h e se s i gn a l s a r e r ea d

d ir ect ly f r om t h e e n gin e con t r o l se n sor s; ot h e r s a r e

read from a multiplex circuit with the engine control-

ler.

ADAPTIVE CONTROLS

Th e se con t r o ls f u n ct ion b y r e a d in g t h e in pu t a n doutput speeds over 140 t imes a second and respond-

in g t o e a ch n e w r e a d in g. Th is p r ovide s t h e f r ict ion

e le m en t con t r o l n e ed e d t o m a k e sm oot h clu t ch -t o -

clu t ch sh if t s f o r a l l g e a r ch a n g e s w it h o u t t h e u se o f

over r u n n in g clut ch es. As w it h m ost a u t o m a t ic t r a n -

sa x les, a l l sh ift s in volve r e le a sin g o n e e lem e n t a n d

applying a different element. In simplified terms, the

u ps h if t l og ic a l l ow s t h e r el ea s i n g e le me nt t o s li p

b a ck w a r d s s li gh t l y t o en s u re t h a t i t d oe s n o t h a v e

e xcess ca p a cit y ; t h e a p p ly e le m en t is f il led u n t i l i t

b e g in s t o m a k e t h e sp e e d ch a n g e t o t h e h ig h e r g e a r ;

i t s a p p ly p r e ssu r e is t h e n co n t r o lle d t o m a in t a in t h e

d e sir e d r a t e o f sp e e d ch a n g e u n t i l t h e sh if t is co m -plete. The key to providing excellent shift quality is

precision; for exam ple, as mentioned, the release ele-

m en t f or u ps hift s i s a l low ed t o s lip b a ckw a r ds

sl ig h t ly ; t h e a m ou n t of t h a t s l ip is t y p ica l ly le ss t h a n

a t o t a l of 20 d e g r ee s. To a ch ie ve t h a t p r ecision , t h e

t r a n sm ission con t r o l m o d u le lea r n s t h e ch a r a ct er is-

tics of the part icular t ran saxle tha t it is controlling. I t

learns:

• The release ra te of the releasing element.

• The a pply t ime of the a pplying element.

• The ra te t he a pply element builds pressure.

This method achieves more precision than would be

possible with exacting tolerances. I t can also adapt to

any changes that occur with age or environment.

F or k ick d ow n sh ift s , t h e con t r o l log ic a l low s t h e

r e le a sin g e lem e n t t o sl ip . Th e n con t r o ls t h e r a t e a t

w h ich t h e in pu t (a n d e n gin e) a cce le r a t e . Wh e n t h e

low e r g ea r sp ee d is a ch ieved , t h e r e le a sin g e le m en t

r e a p plies t o m a in t a in t h a t sp ee d u n t i l t h e a p ply e le-m e n t is f i lled . Th is p r ovid es q u ick r e sp on se a n d a

smooth torque excha nge since the r elease element can

control the rate of torque increase. This control can

m a k e a n y p ow e r t r a in f ee l m o r e r e sp on sive w it h o u t

increasing harshness.

Adaptive controls respond to input speed cha nges.

Th e y com p en sa t e f or cha n g e s in e n gin e or f r ict ion

element torque. This provide consistent shift quality

for t he life of th e tra nsa xle.

DIAGNOSTICS

Th e se con t r ols a lso p r ovid e com p r eh e n sive, on -

b oa r d t r a n sa x le d ia g n ost ics. Th e in for m a t io n a va il-a b l e c a n a i d i n t r a n s a x le d ia g n os is . F or e xa m p le ,

apply element buildup ra te indicat es solenoid perfor-

m a n ce . Also in clu d ed a r e se lf -d ia g n ost ic f u n ct ion s

which allow the technician to test the electronic con-

trols. The t ran smission control m odule m onitors it s

cr it ica l f u n ct ion s, r e cor d s a n y m a lf u n ct ion s, a n d t h e

n u m b er of e n gin e st a r t s sin ce t h e la st m a lf u n ct ion .

The technician can use this information in the event

of a customer complaint . Refer to th e 42LE Tran saxle

Dia gnostic P rocedure Ma nua l for specifics.

42LE GENERAL DIAGNOSIS

CAUTION: Before attempting any repair on the 42LE

Four Speed Automatic Transaxle, always check forproper shift linkage adjustment. Also check for diag-nostic trouble codes with the DRB scan tool and the42LE Transaxle Diagnostic Procedure Manual.

42L E a u t om a t i c t r a n sa x le m a l fu n ct i on s m a y b e

caused by these general conditions:

• Poor engine performance

• Improper adjustments

• Hydraulic malfunctions

• Mecha nical ma lfunctions

• Electronic malfunctionsWh e n d ia g n o sin g a p r ob lem a lw a y s b eg in w it h r e -

cording the complaint . The complaint should be de-

f in e d a s sp ecif ic a s p ossible. I n clu d e t h e f ol low in g

checks:

• Temperat ure a t occurrence (cold, h ot, both)

• Dynamic conditions (acceleration, deceleration, up-

shift, cornering)

• Elements in use when condition occurs (what gear

is tra nsa xle in during condition)

• Road and weather conditions

• Any other useful diagnostic informa tion.

TRANSAXLE 21 - 3



After noting all conditions, check the easily acces-

sible varia bles:

• Fluid level and condition

• Shift linkage adjustment

• Diagnostic trouble code inspection

Then perform a road test to determine if the prob-

l em h a s b een cor r ect e d or t h a t m or e d ia g n os is i s

necessary. If the problem exists after the preliminary

t e st s a n d cor r e ct ion s a r e com p le t ed , h y d r a u lic p r e s-

sure checks should 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



FLUID LEVEL AND CONDITIONThe transmission and differential have separate

oil sumps. T he transmission sump requires auto-

matic transmission fluid. The differential sump re-

quires petroleum based hypoid gear lube.

TRANSMISSION SUMP

Th e t r a n sm ission su m p h a s a d ipst ick t o ch e ck oilsim ila r t o m o st a u t om a t ic t r a n sm ission s. I t is lo ca t e d

on the left side of the engine. Be sure to wipe all dirt

from dipstick handle before removing.

The torque converter fills in both the P Park and N

N e u t r a l p o sit io n s. Pla ce t h e se le ct o r le ve r in P Pa r k

t o b e su r e t h a t t h e f lu id le ve l ch eck is a ccur a t e . The

engine should be running at idle speed for at

least one minute, with the vehicle on level

ground. Th e f lu id s h ou ld b e a t n or m a l op er a t i n g

t e m pe r a t u r e (a p p r ox im a t e ly 82 C . or 180 F.). Th e

fluid level is correct if it is in the HOT region (cross-

hatched area) on the oil level indicator (Fig. 1).

L ow f luid leve l ca n ca u se a va r ie t y o f con d it ion s

b e ca u se i t a l lo w s t h e p u m p t o t a k e in a ir a lo n g w it h

t h e f lu id . A s i n a n y h y d r a u li c s y s t em , a i r b u bb les

m a k e t h e f lu id sp on g y, t h e r ef or e , p r essu r es w il l b e

low an d build up slowly.

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

h i gh . Wh en t h e t r a n s a x le h a s t oo m u c h f lu id , t h e

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

which occur with a low fluid level.

I n e it h e r ca se , a ir b u b b les ca n ca u se over h e a t in g

a nd/or fluid oxidat ion, and va rnishin g. This can inter-

f e r e w it h n o r m a l va lve , clu t ch , a n d a ccu m u la t o r o p -

e ra t i on . F oa m i n g ca n a l s o r e s ul t i n f lu id es ca p in gf r om t h e t r a n sa x le ven t w h e r e i t m a y b e m ist a k en f o r

a le a k .

Along with fluid level, it is important to check the

condition of the fluid. When the fluid smells burned,

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

part icles, a complete tra nsa xle recondition is needed.

B e sure t o exam ine the fluid on the dipstick closely. If

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

sample for a double check.

After the fluid has been checked, seat the dipstick

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

The transmission fluid level should be inspected at

least every six months.

DIFFERENTIAL SUMP

Th e d iff er e n t ia l su m p is ch ecke d se pa r a t e ly f r om

the tra nsmission. A fill plug locat ed on th e side of the

transaxle must be removed to check fluid level (Fig.

2). The fluid should be level with the bottom of the fillh ol e. Th e d if fe re nt i a l ca p a ci t y i s . 946 l it e rs (32

ounces).

I n s pe ct t h e d if fe re nt i a l a r e a d u ri n g e ng in e oi l

ch a n g es f or a n y lea k s. I f lea k a g e is p r ese n t , d e t er -

m i n e t h e s ou r ce of t h e l e a k a n d r ep a ir a s r eq u ir ed .

Remove the fill plug and verify the proper level. Ad-

just if needed.

SELECTION OF LUBRICANTSIt is importa nt t ha t t he proper lubrican ts be used in

t h e 42L E t r a n s a x le . M op a r ATF P l u s (Au t om a t i c

Tra nsmiss ion F luid-Type 7176) should be used in th e

t r a n sm issio n sid e o f t h e t r a n sa x le . S u b st i t u t e f lu id s

can induce torque converter clutch shudder.

Th e d i ff er en t i a l s i de of t h e t r a n s a x le s h ou ld b e

filled with Mopar petroleum based hypoid gear lubri-

cant 80W-90. S ynthetic gea r lubricant s should not be

used.

SPECIAL ADDITIVESChrysler C orpora tion does not recommend t he a ddi-

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

fluid listed above. An exception to this policy is the

use of special dyes to a id in detecting fluid leaks. The

u se o f t r a n sm ission se a ler s sh ou ld b e a void ed , s in ce

they may adversely affect seals.

FLUID AND FILTER CHANGE-TRANSMISSIONSUMP

Only fluids of the type labeled Mopar ATFPlus (Automatic Transmission fluid) Type 7176should 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) Ra ise vehicle on a hoist (See Lubrication, G roup

0). P l a ce a d r a in con t a in er w i t h a l a r ge op en in g ,

under transaxle oil pan.(2) L oosen p a n b olt s a n d t a p t h e p a n a t on e cor n e r

to break it loose allowing fluid to drain, then remove

the oil pan.

(3) I n st a l l a n e w f i l t e r a n d o-r in g o n b ot t o m o f t h e

va lve b od y a n d t ig h t en r e t a in in g scr e w s t o 5 N m (40

in. lbs.).

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

using new Mopar Silicone Adhesive sealan t . Tighten

oil pan bolts t o 19 Nm (165 in. lbs.).

(5) P our four qua rts of Mopar ATF P lus (Automat ic

Tran smission Fluid) Type 7176 t hrough the dipstick

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

m in u t e. Th e n , w it h p a r k in g a n d se rvice b r a k es a p -

plied, move selector lever momenta rily t o each posi-

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

(7) Add sufficient f luid to bring the level 1/4 inch

above the bottom hole of the dipstick. Room temperature

oil (70°F.) set at this level will expand (when heated to

180°F.) to a level within the hot range (Fig. 3).

R ech eck t h e f lu id l ev el a f t er t h e t r a n sa x le h a s

reached normal operating temperature (180°F.).

To prevent dirt from entering tra nsaxle, ma ke certa in

tha t dipst ick is full seated int o the dipst ick opening.

FLUID DRAIN AND REFILL-DIFFERENTIAL SUMPThe differential f luid can be drained a nd filled w ith-

ou t h a vin g t o r e m ove t h e t r a n sa x le f r o m t h e ve h icle.

Use only Mopar 80W-90 petroleum based hypoid gear

lubricant when replacing fluid.

REMOVAL

(1) Raise vehicle on hoist.

(2) Re m ove d iff er e n t ia l d r a in p lu g loca t e d on t h e

bottom of the differential housing. Allow the fluid to

d r a in in t o o il d r a in p a n .

(3) Remove differential f ill plug located on the dif-

ferential side cover. This will assist the flow of f luid

from the dr ain plug hole.

INSTALLATION

(1) I n s t a l l d r a i n p lu g i n t o d if fe re nt i a l h ou s in g .

Tighten dra in plug to 7 N m (60 in. lbs.)

(2) Fill differential with Mopar 80W-90 or equiva-

lent petroleum based hypoid gea r lubrican t . The fluid

should be level with the bottom of the fill hole. The

differential capacity is .946 liters (32 ounces).

CAUTION: Overfilling the differential can result in oilfoaming and/or oil loss from the differential vent.

(3) I nsta ll differentia l f ill plug. Tighten fill plug t o

47 N m (35 ft. lbs.).

GEARSHIFT LINKAGE— COLUMN SHIFTTh e g e a r sh ift l in ka g e sh ou ld b e a d ju st e d i f a n y of

the following repairs or situa tions a re encountered:

• Tra nsa xle replacement.• Valve body repair.

• Shift cable replacement.

• Column shifter replacement.

• Interlock cable replacement.

• When there is no cranking in Park or Neutral.

If the following conditions are encountered, the in-

terlock cable is out of adjustment. Refer to Interlock

Cable Adjustment procedure.

• When the transaxle can be shifted without the key

in t he ignit ion.

• I f t h e k ey ca n b e r e mov ed w i t h t h e s h if t er i n

reverse.

• When the key can not be removed with the shifter

in t he park posit ion.

REMOVAL

(1) Re m ove u n d er p a n e l si le n ce r /d u ct a sse m b ly

(Fig. 1).

Fig. 3 Dipstick Markings

Fig. 1 Panel Removal

21 - 10 TRANSAXLE



(2) Remove column cover screw s (Fig. 2).

(3) Ti lt col um n d ow n a n d r em ov e u pp er h a l f of

column cover (Fig. 3).

(4) Raise column up and remove tilt lever (Fig. 4).

(5) With key removed, remove lower column cover

(Fig. 5).

(6) Remove cable from shift pin (Fig. 6).

(7) Remove cable reta iner clip from shift cable con-

duit bracket (Fig. 7).

CAUTION: Column must be tilted fully upward toremove 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) F r om u n d er h ood s id e of d a s h p a n el , u n s ea t

grommet and pull cable from interior of vehicle.

(9) Ra i se v eh icl e on h oi st a n d u n bol t f il l t u be

b r a ck e t . Ro t a t e f i l l t u b e t o g a in a cce ss t o sh if t ca b le

clamp (Fig. 8).

(10) Loosen shift cable clam p on tra nsa xle.

(11) D iscon n e ct sh ift e r ca b le f r om sh ift lever a s-

sembly at tra nsa xle (Fig. 9).

(12) Remove cable from underneath vehicle.

INSTALLATION (1) Route new cable from underside of vehicle. The

ca b le m u st b e r o u t e d b e t w e e n t h e e n g in e b lo ck a n d

the h eater return tube (Fig. 10).

( 2) S n a p n e w t r a n sa x le ca b le o n t o t r a n sa x le sh if t

lever assembly.

(3) S et s h if t l ev er a s s em b ly i n p a r k p os it i on a t

transaxle. This is the most rearward posit ion.

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) Pla ce co n d u it e n d f i t t in g in cla m p a n d t ig h t e n

mounting bolt .

(5) R ot a t e f i ll t u b e t o or ig in a l loca t ion . I n st a l l a n d

tighten fill t ube bracket bolt .

(6) Route tra nsa xle shift cable through hole in dash

panel.

(7) Install cable grommet in dash panel.

(8) Ro ut e t r a n sa x le sh if t ca b le a lo ng st e er in g col-

umn (Fig. 11).

(9) Connect transaxle shift cable to shift cable con-

duit bracket and secure with new clip.(10) At t a c h s h if t ca b l e (w i t h s h if t l ev er i n p a r k

p os i t ion ) t o a t t a ch i ng s t u d (p in ) b y s n a p pi n g i n t o

place.

(11) E n g a g e t h e p a r k s pr a g . S h i ft t h e t r a n s a x le

leve r t o p a r k . M o ve t h e st e er in g colu m n t o f u l l t i lt

d o w n w a r d . P u t t h e c o l u m n s h i f t e r i n p a r k w i t h k e y

removed.

Fig. 8 Fill Tube Bracket Bolt Removal

Fig. 9 Cable Removal

Fig. 10 Shift Cable Routing


21 - 12 TRANSAXLE



(12) Adjust cable by rotating the adjuster into lock

position (Fig. 12). The adjuster will click when lock is

fully a djusted.

(13) Re in st a l l u p pe r a n d low e r st e er in g colu m n

shrouds. Then inst all underpa nel silencer/duct.

(14) C heck shifter for proper operation. It should

operate smoothly with out binding. The engine sta rter

should cran k in P ark or Neutral posit ions only.

ADJUSTMENT

(1) Remove upper steering column shroud.

(2) Rotat e cable adjuster into unlock posit ion. Use a

st r a ig h t b la d e scr e w d r iver t o u n lock a d ju st er (F ig .

13).

(3) M a ke s u r e t h a t t h e t r a n s a x le s h if t l ev er (a t

t r a n sa x le ) is in t h e p a r k p o sit io n a n d t h e p a r k sp r a g

is fully 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) Tilt the steering column to the full down posi-

tion.

( 5) Pla ce sh if t e r in t h e p a r k p o sit io n w it h t h e k e y

removed.

(6) Ad ju st b y r ot a t in g a d ju st er in t o lock p osit ion

(Fig. 12).

(7) Reinstall upper steering column shroud.

(8) C h eck sh ift e r f or p r op er op er a t io n . I t sh ou ldoperate smoothly without binding. The vehicle should

crank in Park or Neutral only.

GEARSHIFT LINKAGE— FLOOR SHIFTTh e g e a r sh ift l in ka g e sh ou ld b e a d ju st e d i f a n y of

the following repairs or situa tions a re encountered:

• Tra nsa xle replacement.

• Valve body repair.

• Shift cable replacement.

• Floor Shifter Replacement

• Interlock cable replacement.

• When t here is no cran king in park or neutra l.

If the following conditions are encountered, the in-terlock cable is out of adjustment. Refer to Interlock

Cable Adjustment procedure.

• When the transaxle can be shifted without the key

in t he ignit ion.

• I f t h e k ey ca n b e r e mov ed w i t h t h e s h if t er i n

reverse.

• When the key can not be removed with the shifter

in t he park posit ion.

REMOVAL

(1) Remove shift handle (Fig. 1).

(2) Remove console bezel from vehicle (Fig. 2).

(2) Loosen nut on shift cable adjust lever (Fig. 3).

(3) Remove retaining clip from shift cable conduit

bracket.

(4) Disconnect shifter cable from cable at tach stud

(pin).

(5) R em ov e ca b l e f r om cen t e r con s ol e r ou t i ng .

Leave fla t on floor 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 side of da sh panel unseat grom-

met and remove cable from interior of vehicle.

(7) Ra ise vehicle on h oist an d disconnect fill t ube

bracket from transaxle. Rotate fill tube to gain access

to shift cable clamp.

(8) Loosen bolt that clamps shift cable to transaxle.

(9) Disconnect shifter cable from shift lever assem-

b ly a t t r a n sa x le .

(10) Remove cable from underneath vehicle.

INSTALLATION

(1) Re r ou t e n e w ca b le f r om u n d er sid e of ve h icle.

Th e ca b le m u st b e r o u t ed b et w e e n t h e e n gin e b lock

and the heater return tube (Fig. 5).

( 2) S n a p n e w t r a n sa x le ca b le o n t o sh if t le ve r a s-

sembly.

(3) S e t s h if t l ev er a s s em b ly i n p a r k p os i t ion a t


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) Pla ce co n d u it e n d f i t t in g in cla m p a n d t ig h t e n

mounting bolt .

(5) R ot a t e f i ll t u b e t o or ig in a l loca t ion . I n st a l l a n d

tighten fill tube bra cket bolt .

(6) Route tra nsa xle shift cable through hole in dash

panel.

(7) Install cable grommet in dash panel.

(8) Route t ra nsa xle shift ca ble under A/C duct, over

ce n t r a l d ist r ib u t io n d u ct , t h r o u g h su p p o r t st r u t a n d

air bag mounting bracket. Then route over carpeting

an d down to the shifter bra cket. (Fig. 6).(9) Place shifter in the Park posit ion.

(10) Rou t e ca b le t h r o ug h h ole in sh ift e r b r a cke t

a n d a t t a ch t o ca b le a t t a ch in g st u d ( p in ) b y sn a p p in g

into place.

(11) I n st a l l a n e w cl ip on t o t h e ca b le a t t h e sh if t e r

bracket.

(12) Tighten the adjuster nut.

(13) Reinstall console bezel a nd shifter ha ndle.

Fig. 2 Console Bezel Removal

Fig. 3 Shift Cable Adjust Lever Nut

Fig. 4 Fill Tube Bracket Bolt Removal


21 - 14 TRANSAXLE



(14) C heck shifter for proper operation. It should

operate smoothly without binding. The vehicle should


ADJUSTMENT

(1) Remove shifter handle and console bezel.

(2) Loosen nut on shifter cable adjuster (Fig. 7).

(3) S et s h if t l ev er a s s em b ly i n p a r k p os it i on a t



(4) P lace shifter in par k posit ion.

(5) P lace ignit ion in lock w ith key removed.

(6) Tighten adjuster nut at shifter (Fig. 7).

(7) Reinstall console bezel and shifter ha ndle.

(8) C h eck sh ift e r f or p r op er op er a t ion . I t sh ou ld

operate smoothly without binding. The vehicle should


FLOOR SHIFTER

REMOVAL

(1) Remove shifter handle and console bezel.

(2) Loosen adjuster nuts on interlock adjuster and

shifter adjuster.

(3) D iscon n e ct sh ift e r ca b le f r om ca b le a t t a ch in g

stu d (pin).

(4) D iscon n e ct in t e r lock ca b le f r om sh ift e r b a se

s l ot . B e ca r e fu l n ot t o b r e a k t a b on i n t er l ock ca b l e

conduit end fitting (Fig. 8).

(5) Remove the three floor pan at taching nuts from

the int erior of the sh ifter base.

(6) Remove shifter assembly from vehicle.

INSTALLATION (1) Install new shifter . Make sure eyelet of shifter

cable is inside of shifter housing.

(2) I n s t a l l t h r ee f loor p a n a t t a ch i ng n u t s t o h ol d

shifter base.

(3) P la ce sh if t le ver a n d t r a n sa x le in p a r k .


(4) Wit h t h e ig n it ion in t h e lock p osit ion , a t t a ch

shift ca ble eyelet to cable a t ta ching st ud (pin).

(5) Slip interlock cable core wire into interlock ad-justment lever groove. Make sure the interlock cable

slug is seat ed in th e groove.

(6) Slip interlock cable conduit end fit t ing into base

a n d sn a p in t o p la ce.

CAUTION: Both the shift cable and the interlockcable 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 TESTPrior to performing a road test , verify that the fluid

level , f luid con d it ion , a n d l in ka g e a d ju st m en t h a ve

been approved.

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

a t e d in e a ch p o sit io n t o ch e ck f o r sl ip p in g a n d a n y

variat ion in shift ing.

If the vehicle operates properly at highway speeds,but has poor acceleration, the converter stator over-

r u n n in g cl u t ch m a y b e s li pp in g . I f a c ce ler a t i on i s

normal, but high thrott le opening is needed to main-

t a in h ig h w a y sp ee d s, t h e con ver t e r st a t o r clu t ch m a y

h a ve se iz e d . B o t h o f t h e se st a t o r d e f e ct s r e q u ir e r e -

placement of the torque converter and thorough tran-

saxle cleaning.

An e ng in e m i ss cou ld b e a t t r i bu t ed t o a cr a c ke d

d r iv e p la t e . A c r a ck ed d r iv e p la t e cou ld ca u s e t h e

camshaft posit ion sensor and crankshaft posit ion sen-

sor sig n a ls t o b e ou t of sy n ch r on iz a t ion . Th is cou ld

cause a no-sta rt condition.A sl ip pin g clu t ch ca n b e d e t er m in ed b y op er a t in g

the transaxle in all selector posit ions. Then compar-

i n g w h i ch i n t er n a l u n it s a r e a p pl ie d i n t h os e p os i-

t ions. The Elements in Use Chart provides a basis for

r oa d t e st a n a ly sis .

The process of elimination can be used to detect any

u n it w h ich sl ip s a n d t o con f irm p r op er op er a t ion of

g o o d u n it s . Ro a d t e st a n a ly sis ca n d ia g n o se sl ip p in g

u n it s , b u t t h e c a u s e o f t h e m a l f un ct i on ca n n ot b e

d e t e r m in e d . Pr a ct ica l ly a n y co n d it io n ca n b e ca u se d

by leaking hydra ulic circuits or st icking va lves.

HYDRAULIC PRESSURE TESTSP r e s su r e t e s t in g i s a v er y i m por t a n t s t ep i n t h e

diagnostic procedure. These tests usually reveal the

cause of most t ran saxle problems.

B e f or e p er f or m in g p r essu r e t e st s , b e ce rt a in t h a t

fluid level and condition, and shift cable adjustments

h a ve b ee n ch e ck ed a n d a p p r ove d. F lu id m u st b e a t

operating temperature (150 to 200 degrees F.).Install an engine tachometer, raise vehicle on hoist

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

chometer so it can be read.

U sin g sp ecia l a d a p t er s (L -4559), a t t a ch 300 p si

gauges to ports required for test being conducted.

Test port locat ions a re sh own in (Figure 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) Att a ch pressure g a uge to t he low/reverse clutch

t a p .

(2) Move selector lever to the L position.

(3) Al low v eh icl e w h eel s t o t u rn a n d i ncr ea s ethrott le opening to a chieve a n indicat ed vehicle speed

to 20 mph.

(4) Low/reverse clutch pressure s hould rea d 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 underdrive clutch tap.

(2) Move selector lever to the 3 position.

(3) Al low v eh icl e w h eel s t o t u rn a n d i ncr ea s e

thrott le opening to a chieve a n indicat ed vehicle speed

of 30 mph.

(4) Underdrive clutch pressure should 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) Atta ch gauge t o the overdrive clutch ta p.

(2) Move selector lever to the OD position.

(3) Al low v eh icl e w h eel s t o t u rn a n d i ncr ea s e


of 20 mph.

(4) Overdrive clutch pressure should read 74 to 95psi.

(5) M ove select or lever t o t h e 3 p osit ion a n d in -

crease indicated vehicle speed to 30 mph.

(6) The vehicle should be in second gear and over-

drive clutch pressure should be less t han 5 psi.

TEST FOUR-SELECTOR IN OD

This test checks the 2/4 clutch hydraulic cir-

cuit.

(1) Att a ch ga uge to th e 2/4 clutch ta p.


(3) Allow vehicle front wheels to turn and increasethrott le opening to a chieve a n indicat ed vehicle speed

of 30 mph.

(4) The 2/4 clutch pressure should read 75 to 95

psi.

TEST FIVE-SELECTOR IN OD

These tests checks the torque converter clutch

hydraulic circuit.

(1) Attach gauge to the torque converter clutch off

pressure tap.


(3) Al low v eh icl e w h eel s t o t u r n a n d i ncr ea s e


of 50 mph.

CAUTION: Both wheels must turn at the same

speed.

(4) Torque converter clutch off pressure should be

less than 5 psi.

(5) N ow a t t a ch t h e g a u g e t o t h e t o r q u e con ver t e r

clutch on pressure tap.

(6) Move selector to the OD position.

(7) Al low v eh icl e w h eel s t o t u r n a n d i ncr ea s e


of 50 mph.

(8) Ve r if y t h e t o r q u e con ver t e r clu t ch is a p p lied

mode using the RPM display of the DRB scan tool.

(9) torque converter clutch on pressure should be

60-90 psi.

TEST SIX-SELECTOR IN R This test checks the reverse clutch hydraulic

circuit.(1) Attach gauge to the reverse clutch tap.

(2) Move selector lever to the R position.

(3) Re a d r e ve r se clu t ch p r essu r e w it h ou t p u t st a -

tionary (foot on bra ke) and thrott le opened t o achieve

1500 rpm.

(4) Reverse clutch pressure should read 165 to 235

psi.

TEST RESULT INDICATIONS

(1) If proper line pressure is found in any one test ,

t h e p u m p a n d p r e ssu r e r e g u la t o r a r e w o r k in g p r o p -erly.

(2) Low pressure in all posit ions indicates a defec-

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

tor valve.

(3) C lu t ch cir cuit lea k s a r e in d ica t e d i f p r essu r es

do not fa ll wit hin t he specified pressure ra nge.

(4) If the overdrive clutch pressure is greater than

5 psi in st ep (6) of Test Three, a worn reaction sha ft

seal r ing is indicated.

CLUTCH AIR PRESSURE TESTSInoperative clutches can be located by substituting

air pressure for fluid pressure. The clutches may bet e st ed b y a p p ly in g a ir p r essu r e t o t h e ir r e sp ect ive

p a ssa g e s a f t e r t h e va lve b od y h a s b e en r e m oved . U se

Special Tool 6599-1 a nd 6599-2 t o perform test (Fig.

2).

To ma ke a ir pressur e test s, proceed a s follows :

The compressed air supply must be free of alldirt and moisture. Use a pressure of 30 psi.

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

recondition.

Apply air pressure to the holes in the special tool,

on e a t a t im e .

TRANSAXLE 21 - 17



L ist en f or t h e clu t ch t o a p ply. I t w il l g ive a sl ig h t

t h u d s o un d . I f a l a r g e a m ou n t of a i r i s h ea r d es ca p -

i n g, t h e t r a n s a x le m u s t b e r em ov ed f r om v eh i cl e,

disassembled and all seals inspected.

OVERDRIVE CLUTCH

Ap ply a ir p r essu r e t o t h e ove rd r ive clut ch a p p ly

p a ssa g e a n d w a t ch f or t h e p u sh/p u ll p ist o n t o m o ve

forwa rd. The piston should return to its st ar t ing posi-t ion wh en the a ir pressure is removed.

UNDERDRIVE CLUTCH

B ecause this clutch piston ca nnot be seen, its opera-

tion is checked by function. Air pressure is applied to

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

ou t pu t s h a f t . U s e a p ie ce of r u bb er h os e w r a p pe d

a r o u n d t h e in p u t sh a f t a n d a p a ir o f cla m p - o n p lie r s

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

underdrive clutch (Fig. 3). The input shaft should not

r ot a t e w it h h a n d t o r q u e. Re lea se t h e a ir p r essu r e a n d

con f ir m t h a t t h e in p ut sh a f t w il l r ot a t e .

REVERSE CLUTCH

Apply air pressure to the reverse clutch apply pas-

sage an d w at ch for the push/pull piston t o move rear-

wa rd. The piston sh ould return to its sta rt ing posit ion

when the air pressure is removed.

2/4 CLUTCH

A p p ly a ir p r e ssu r e t o t h e f e e d h o le lo ca t e d o n t h e

2/4 clutch retainer. Look in the area where the 2/4

p is t on con t a c t s t h e f ir s t s ep a r a t or p la t e a n d w a t c h

42LE PRESSURE CHECK SPECIFICATIONS

Fig. 2 Air Pressure Test Plate

21 - 18 TRANSAXLE



ca r ef u lly f or t h e 2/4 p ist o n t o m ove r e a r w a r d . Th e

piston should return to its original posit ion after the

air pressure is removed.

LOW/REVERSE CLUTCH

Apply air pressure t o t he low/reverse clutch feed

hole passa ge. Look in the area where t he low/reverse

piston contacts t he first separa tor plate. Wat ch care-

f u ll y f or t h e p is t on t o m ov e f or w a r d . Th e p is t on

s h ou ld r et u r n t o i t s or i gi n a l p os it i on a f t e r t h e a i r

pressure is removed.

FLUID LEAKAGET h e 42L E is a d u a l su m p t r a n sa x le . T h e t r a n sa x le

u s es b ot h a u t om a t i c t r a n s a x le f lu id (ATF ) f or t h e

m a in su m p a n d h y p o id g e a r lu b e f o r t h e d if f e r e n t ia ls u m p. Wh en d ia g n os in g a l ea k , i t i s i m por t a n t t o

dist inguish which type of f luid is leaking. Factory fill

ATF is dyed red, while differential hypoid oil is brown

in color a nd ha s a dist inctive odor.

Th er e a r e t w o s ea l s a t t h e b ou n da r y of t h e t w o

su m p s. T h e r e is a w e e p h o le in t h e r ig h t sid e o f t h e

t r a n sa x le ca se ( F ig . 4) w h ich ven t s t h e a r e a b et w e e n

t h e t w o s e a l s . I f o i l i s l e a k i n g f r o m t h e w e e p h o l e ,

t h er e i s a t l ea s t on e s e a l l ea k i n g. N ev er p lu g t h e

weep hole to correct a leaking condition. P lugging the

weep hole could result in contaminating one or both

transaxle sumps, low oil level, poor transaxle perfor-

m a n ce o r t r a n sa x le f a i lu r e . I n o r d e r t o co r r e ct ly r e -

p a ir t h is t y p e of le a k t h e t r a n sa x le m u st b e r e m oved

f r om t h e v eh i cl e a n d b ot h t r a n s f er s h a f t s ea l s r e-

placed. Refer t o Tran sfer Sh aft Seal Replacement pro-

cedure in this section.

FLUID LEAKAGE-TORQUE CONVERTER

HOUSING AREA

(1) Check for source of leakage. Fluid leaka ge from

t h e t o r q u e co n ve r t e r a r e a m a y o r ig in a t e f r o m a n e n -

gine oil leak, a differential oil leak or an ATF oil leak.

The area should be examined closely.

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

following checks:

• When leakage is determined to be automatic trans-mission fluid, check fluid level prior to removal of the

transaxle and torque converter.

• High oil level can result in oil leaka ge out the vent.

If t he fluid level is high, adjust to proper level.

• After performing this operation, inspect for leak-

age. If a leak persists, perform the following operation

on the vehicle. This will determine if it is the torque

converter or transaxle that is leaking.

LEAKAGE TEST PROBE

(1) Remove torque converter housing dust shield.

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

(low e r a r e a ) a s d r y a s p ossible. A so lven t sp r a y f ol-

lowed by compressed air drying is preferable.

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

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

torque converter is cleared by test probe. Tool must be

clean and dry.

Fig. 3 Testing Underdrive Clutch Fig. 4 Weep Hole Location

Fig. 5 Leak Locating Test Probe Tool

TRANSAXLE 21 - 19



(1) P lu g d ipst ick t u b e a n d p lu g oi l cooler l in e f i t -

t ings.

CAUTION: Prevent manual shaft rotation during in-

stallation and removal.

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

cu p o ve r in p u t sh a f t , a n d t h r o u g h t h e co n ve r t e r h u b

s ea l . Th e cu p m u s t b ot t om a g a i n s t t h e p um p g ea r

l ug s . S e cu r e w i t h cu p r e t a i n er s t r a p u s in g s t a r t e r

upper hole and opposite bracket hole.

(3) Plug cooler lines.

(4) R e m ov e t h e r em ot e v en t h os e f r om t h e m a i n

su m p ve n t f i t t in g . T h e n a t t a ch a n d cla m p h o se f r o m

nozzle of tool C-4080 or 7700 to t he vent fitt ing.

CAUTION: Do not, under any circumstances, pres-

surize a transaxle to more than 10 psi.

(5) P ressurize th e tra nsa xle using Tool C-4080 or

7700 u n t i l t h e p r e ssu r e g a u g e r e a d s 8 p si . Po sit io nt r a n s a x le s o t h a t p um p h o us i ng a n d ca s e f r on t m a y

b e cover e d w it h soa p y solu t ion of w a t e r. L e a k s a r e

som e t im es ca u sed b y p or osit y in t h e ca se o r p u m p

housing.

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

a t e d se a ls , O - r in g s, a n d g a sk e t s sh o u ld b e r e p la ce d

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

TRANSAXLE DIFFERENTIAL SUMP SIDE

(1) Leave stub shafts secured in the differential.

(2) Remove the remote vent hose from the differen-

t i a l v en t f it t i n g. Th en a t t a ch a n d cl a m p h o s e f r om

nozzle of tool C-4080 or 7700 to t he vent fitt ing.

CAUTION: Do not, under any circumstances, pres-surize a transaxle to more than 10 psi.

(3) P ressurize the differential to 8 psi.

( 4) Po sit io n t r a n sa x le so t h a t t h e d if f e r e n t ia l a r e a

of the transaxle can be covered with a soapy solution

of w a t e r. B e s u r e t o cov er t h e ca s e w i t h s ol u t ion t o

check for case porosity.

(5) Look for bubbles to appear in the soapy solution

t h a t w a s a p p lie d t o t h e t r a n sa x le . T h is w il l in d ica t e

the leak point .

I f a le a k so u r ce is lo ca t e d , t h a t p a r t a n d a l l a sso ci-a t e d se a ls , O - r in g s, a n d g a sk e t s sh o u ld b e r e p la ce d

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

LONG STUB SHAFT SEAL REPLACEMENTI f i t h a s b e e n d i a g n o s e d t h a t t h e l o n g s t u b s h a f t

seal is leaking, the following procedure can be used to

replace failed seal. This procedure will allow the re-

placement of the seals without having to set backlash

and measure differential bearing turning 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 requirereplacement, this procedure cannot be used. Referto Differential Recondition section of this manual.

(1) Remove tra nsa xle from vehicle. Refer to Tran -

saxle Removal and Installat ion procedure in this sec-

tion.

(2) Remove long st ub sha ft from t ran saxle (Fig. 1).

(3) I n de x t h e i n ne r d if fe re nt i a l a d ju s t er w i t h a

cross hair as shown in figure 2.

CAUTION: If short stub shaft has corrosion, usecaution when removing differential cover. Inspectseal and shaft for damage after removal of cover.Replace shaft and/or seal as required.

(4) I n de x ou t er a d ju s t er (F i g. 3). R em ov e l ock

bracket and back out adjuster exactly one revolution.

Then remove differentia l cover.

(5) Remove t he inner adjuster lock bra cket. Then

remove th e inner ad juster.

Fig. 1 Long Stub Shaft Removal

Fig. 2 Indexing Inner Adjuster

TRANSAXLE 21 - 21



(9) I n s t a l l ou t er a d ju s t er i n t o t r a n s a x l e ca s e a n d

t ig h t e n a d ju st er w it h in 10 ft . lb s. o f t h e t o r q u e r ea d -

ing recorded in step five.

(10) Ro t a t e r in g g ea r t h r e e o r f ou r r e volu t ion s in

both directions to seat differential bearings.

(11) Continue t ightening outer adjuster until index

marks line up (original location).

(12) Insta ll a djuster lock.

(13) I n s t a l l n ew d r iv es h a f t r et a i n in g ci r cl ip a n do-ring on st ub sha ft . Then reinsta ll driveshaft .

(14) C h e ck f lu id le vel in d iff er e n t ia l a n d a d ju st a s

required.

(15) Road test and recheck for leaks as required.

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

sa x le ca se a n d va lve b od y ca n b e r e pa ir e d b y t h e u se

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

d r il li n g o u t t h e d a m a g e d t h r ea d s , t a p pi n g t h e h ol e

w it h a sp ecia l He li-C o il t a p , o r e q u iva le n t . Th e n in -

s t a l li n g a H e li -C oi l i n ser t , or eq u iv a l en t , i n t o t h e

tapped hole. This brings the hole back to its originalthread size.

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

r e a d ily a va i la b le f r o m m o st a u t o m ot ive p a r t s su p pli-

ers.

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

fluid, t he oil cooler(s) m ust be flushed. The cooler

b y p a ss va lve in t h e t r a n sa x le m u st b e r e p la ce d . T h e

t o r q u e con ve rt e r m u st a lso b e r e p la ced w it h a n e x-

ch a n g e u n it . T h is w il l in su r e t h a t m e t a l p a r t icle s o r

sludged oil are not transferred back into the recondi-

tioned (or replaced) transaxle.

CAUTION: If vehicle is equipped with two oil coolersthey must be flushed separately. Do not attempt to

flush both coolers at one time.

Use the following procedure to flush cooler:

(1) Disconnect the cooler lines at the t ra nsa xle.

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

spirits, reverse flush the cooler. This is done by forc-

ing mineral spirits into the From Cooler l ine of t he

cooler (Fig. 8). Catch the exit ing spirits from the To

Cooler line. Observe for the presence of debris in the

exit ing fluid. Continue until f luid exit ing is clear and

free from debris.

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

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

aga in in t he reverse direction.

(4) To remove remaining mineral spirits from the

cool er, p um p on e (1) q u a r t of t r a n s m is s ion f lu id

thr ough t he cooler. This should be done prior t o recon-

necting the hoses to the transaxle.

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

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

replaced.

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

installed, oil cooler flow should be checked using the

following procedure:

(1) Disconnect the From cooler l in e a t t h e t r a n s -

m ission a n d p la ce a collect in g con t a in er u n d er t h e

disconnected line.

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

shift selector in neutra l.

(3) I f f lu id f low is in t e r m it t en t or t a k es m or e t h a n

20 se con d s t o colle ct on e q u a r t of f lu id , t h e cooler

should be replaced.

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

(4) I f f low is f ou n d t o b e w it h in a cce pt a b le l im it s ,

reconnect the cooler line. Then fill transmission to the

proper level, using t he a pproved ty pe of tra nsmission

fluid.

MANUAL VALVE LEVER POSITION SENSORThe Manual Valve Lever Posit ion Sensor (MVLPS)

in t e r p r e t s t h e p o sit io n o f t h e m a n u a l va lve . T h is in -

Fig. 7 Stub Shaft Corrosion

Fig. 8 Cooler Line Identification

TRANSAXLE 21 - 23



(2) Remove power distribution center plastic cover.

(3) Pull relay out of power distribution center (Fig.

4).

To inst a ll, reverse removal procedure.

TRANSMISSION CONTROL MODULEThe transmission control module is located in the

e n gin e com p a r t m e n t b et w e e n t h e lef t f r on t f en d e r

a n d t h e b a t t e r y . I t is h e ld in p la ce b y f o u r m o u n t in g

scr e w s. Th e b a t t e r y m u st b e m o ve d t o g a in a cce ss t o

the tra nsmission control module.

If the transmission control module has beenreplaced, refer to Quick Learn Procedure. T hisprogram will allow the transmission controlmodule to learn the characteristics of the ve-hicle.

REMOVAL

(1) L o ose n b a t t e r y h old -d ow n cla m p a n d sl id e t h e

b a t t e r y t o t h e r ig h t .

(2) L oose n 60 w a y r e t a in in g scr ew , lo ca t e d in t h e

center of the 60 way connector. Then disconnect the

60 way connector on transmission control module.

(3) Remove transmission control module mounting

screws an d lift module from vehicle.

INSTALLATION

(1) Install transmission control module and t ighten

mounting screws.

(2) Install 60 way connector. Then t ighten 60 way

retaining screw to 4 Nm (35 in. lbs.).

( 3) Pla ce b a t t e r y b a ck in i t s o r ig in a l lo ca t io n a n dtighten ba ttery hold-down clamp.

BACK UP LAMP DIAGNOSISTh e b a ck-u p la m p s a r e con t r olled b y t h e M a n u a l

Valve Lever Position Sensor (MVLPS). The following

f low ch a r t w il l a ssist in d ia g n o sin g t h e b a ck -u p la m p

system. Refer to Manual Valve Lever Posit ion Sensor

in this section 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-INPUTTh e in pu t sp ee d se n sor ca n b e se r vice d w it h o u t

ha ving to remove the tra nsaxle from the vehicle.

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 input speed sensor is located on the left side of

t h e t r a n sa x le ca se ( F ig . 5) . T h e se n so r t h r e a d s in t o

t h e t r a n s a x le ca s e . Ti gh t en i n pu t s pee d s en s or t o

20-34 N m (180-300 in. lbs.).

SPEED SENSOR-OUTPUTTh e ou t p u t sp ee d sen sor ca n b e se r vice d w it h o u t

ha ving to remove the tra nsaxle from the vehicle.

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 is located on the left side

of the t ran saxle case (Fig. 5). The sensor threa ds int o

t h e t r a n sa x le ca se . Tig h t en ou t p u t sp ee d se nsor t o

20-34 N m (180-300 in. lbs.).

VALVE BODYT h e va lve b o d y ca n b e r e m o ve d w it h t h e t r a n sa x le

r em a i n in g i n t h e v eh i cl e, or w i t h t h e t r a n s a x le r e-

moved. The illustrations in this procedure shows the

tra nsa xle removed from t he vehicle for clarity.

The solenoid pack a nd Manua l Valve L ever P osit ion

Sensor (MVLPS ) are mounted on t op side of th e va lve

b od y. Th ey w i ll r em a i n a t t a ch ed t o t h e v a l ve b od y

w h e n t h e va lve b o d y is r e m o ve d f r o m t h e t r a n sa x le .

The solenoid pack and MVLPS can only be removed

f r o m t h e va lve b o d y a f t e r t h e va lve b o d y is r e m o ve d

from the transaxle.

REMOVAL AND INSTALLATION

(1) Disconnect the MVLPS wiring connector. The

solenoid wiring connector can remain at tached to the

case.

(2) D iscon n e ct t h e sh ift ca b le f r om t h e sh ift lever

(at the transaxle).

( 3) M o ve t h e sh if t le ve r clo ck w ise a s f a r a s i t w il l

go. This should be one posit ion pa st the L posit ion.

Then remove the shift lever.

(4) Remove tra nsa xle pan bolts (Fig. 1).

(5) Remove tra nsa xle oil pan. When reinsta lling oil

p a n b e s u re t h a t pa n f la n g e i s cl ea n a n d oi l f r ee.Apply a 1/8 inch bead of Mopar Silicone Sea ler onto

oil pa n flange before insta lling.

Fig. 5 Speed Sensor Location Fig. 1 Remove Transaxle Oil Pan Bolts

Fig. 2 Remove Transaxle Oil Pan

TRANSAXLE 21 - 27



(6) Remove oil f ilter from valve body (Fig. 3). I t is

held in place by t wo clips.

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 causetransaxle damage.

(7) Remove valve body bolts (Fig. 4).

(8) C a r e fu ll y r em ov e v a l ve b od y a s s em b ly f r om

tra nsa xle (Fig. 5).

CAUTION: The overdrive and underdrive accumula-tors and springs may fall out when removing thevalve body.

To reinsta ll va lve body, r everse 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



(8) Re m ove d u a l r e t a in er p la t e f r om va lve b od y.

Use special tool 6301 to remove plate (Fig. 14).

(9) Rem ove r e t a in er p la t e f r om va lve b o d y u sin gspecial tool 6302 (Fig. 15).

(10) Tag all springs, a s t hey a re removed, for rea s-

sembly identification (Fig. 16).

C le a n lin e ss t h r o ug h e n t ire d isa sse m b ly a n d a sse m -

b ly of t h e v a l ve b od y ca n n ot b e ov er em p ha s i ze d.

When disassembling, each part should be w ashed in a

su it a b le so lve n t , t h e n d r ied b y com p r essed a ir . Do

not wipe parts with shop towels. A ll m a t in g su r -

f a ces i n t h e v a lv e b od y a r e a c cu r a t el y m a ch in ed ;

therefore, careful handling of all parts must be exer-

cised to a void nicks or burrs.

To reass emble, revers e recondit ion procedur e.

TRANSFER SHAFT SEAL REPLACEMENTI f i t h a s b ee n d i a g n os ed t h a t on e o r b ot h of t h e

t r a n sf e r sh a f t sea ls a r e lea k in g , t h e f o llow in g p r oce -

dure can be used to replace failed seals. This proce-

d u r e w i l l a l l ow t h e t e ch n ici a n t o r ep la c e t h e s ea l s

w it h o ut h a vin g t o se t b a ck la sh a n d m e a su r e d iff er e n -

tial bearing turning torque.

CAUTION: The transfer shaft rear shim, bearingcups 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 sectionof this manual.

(1) Remove tra nsa xle from vehicle. Refer to Tran -

saxle Removal and Installat ion procedure in this sec-

tion.

(2) Remove va lve body from t ran saxle.

(3) Remove solenoid connector from transaxle case.

(4) Remove long stub shaft from transaxle (Fig. 17).

(5) I n de x t h e i n ne r d if fe re nt i a l a d ju s t er w i t h a

cross hair as shown in figure 18.

CAUTION: If short stub shaft has corrosion, usecaution when removing differential cover. Inspectseal and shaft for damage after removal of cover.

Replace shaft and/or seal as required.

(6) I n d e x ou t e r a d ju st er (F ig . 19). Re m ove lock

bracket and back out adjuster exactly one revolution.

Then remove differentia l cover.

(7) Remove t he inner adjuster lock bra cket. Then

remove th e inner ad juster.

CAUTION: Keep the inner adjuster for reinstallation.

( 8) Re m o ve t h e t r a n sf e r sh a f t n u t , r e a r co n e , r e a r

cu p , o i l b a f f le , r e a r sh im , t r a n sf e r sh a f t a n d t r a n sf e r

sh a f t se a ls . Re f er t o a p p r op r ia t e p r oced u r es w it h inthis section for detailed removal and installat ion pro-

cedures if required.

CAUTION: Keep rear shim and rear bearing cupcone for reinstallation.

(9) I n s t a l l t r a n s f er s h a f t , t r a n s f er s h a f t s ea l s , oi l

b a f f le , r e a r cu p , r e a r sh im , r e a r co n e a n d a n e w n u t .

Re fe r t o a p p r op r ia t e p r oced u r es w it h in t h is se ct ion

f or d e t a i le d r e m ova l a n d in st a l la t ion p r oced u r es i f

required.

(10) Inst all a new o-ring onto the inner a djuster.

(11) L u b e in n e r a d ju st e r t h r e a d s a n d o-r in g w it hgear oil and reinstall to the cross haired index marks.

(12) Reinstall the inner adjuster locking bra cket.

(13) I n st a l l t h e d iff er e n t ia l ca r r ier. Th e n in st a l l

stub sh aft seal protector.

(14) Inst all the differential cover/outer adjuster as-

se m b ly w it h M o p a r S i l ico n e S e a la n t a p p lie d . I n st a l l

and t ighten differential cover bolts.

(15) Tighten the outer adjuster 3/4 of a turn. Seat

bearings by turning differential carrier three or four

Fig. 14 Remove or Install Dual Retainer Plate

Fig. 15 Remove or Install Retainer Plate

21 - 30 TRANSAXLE



t u r n s i n b ot h d ir ect i on s . F i n is h t i gh t e ni n g t h e a d -

juster 1/4 tur n to its index ma rk (origina l location).

(16) Reinstall t he outer a djuster locking bra cket.

Fig. 16 Valve Body Components

Fig. 17 Long Stub Shaft Removal

Fig. 18 Indexing Inner Adjuster

TRANSAXLE 21 - 31



TRANSAXLE REMOVAL AND INSTALLATIONTh e t r a n sa x le ca n b e r e m o ve d without h a v i n g t o

remove the engine.

(1) Disconnect battery.

(2) Remove engine air inlet tube.

(3) Disconnect crankshaft position sensor connector

and remove sensor (Fig. 1). The sensor is located on

the upper r ight side of the t ra nsa xle bell housing.

(4) Disconnect tra nsa xle w iring connector located

on the right shock tower (Fig. 2).

(5) Lift vehicle on hoist.(6) Remove front wheels.

(7) Remove strut to steering knuckle bolts on both

sides of the vehicle (Fig. 3).

(8) Re m ove An t i-lock B r a k e S y st e m (AB S ) w h e el

speed sensor (if equipped).

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) U sin g a p r y b a r, d iscon n e ct t h e in n er C V join t

from the tra nsa xle (Fig. 4).

(10) P u ll t o p of k n u ckle a n d d r ive sh a f t ou t w a r d t o

a l low cle a r a n ce d u r in g t r a n sa x le r e m ova l . Th e d r ive

shaft s do not have to be completely removed from t he

vehicle. Do not allow the inner CV joint to hang

unsupported or joint damage may occur.

(11) Remove engine to t ran saxle bra ckets.

(12) Remove tr a nsa xle bell-housing cover.

(13) Re m ove t o r q ue con ver t e r b olt s . Th e t o r q u e

converter is indexed to the flex plate. Ma rk t he torque

converter locat ion to ensure tha t the t orque converter

is reinstalled correctly.

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) U n b olt s t a r t e r a sse m b ly. D o n ot d iscon n e ct

w i r in g or com pl et e ly r em ov e t h e s t a r t e r f r om t h e

veh icle. A llow t h e st a r t e r t o si t b et w e e n t h e e n g in e

a n d t h e f r a m e .

(15) D iscon n e ct t r a n sa x le cooler l in e s a t t h e t r a n -

saxle.

(16) D iscon n e ct t h e g ea r se le ct o r ca b le f r om t h e

t r a n sa x le .

(17) Disconnect the exhaust system at the exhaust

m a n if o ld s a n d r e m o ve t h e e x h a u st sy st e m f r o m t h e

vehicle.

(18) Place a transmission jack under the transaxle.

Secure the transaxle to the jack.

( 19) Ra ise t r a n sa x le sl ig h t ly t o r e l ie ve t h e w e ig h t

on t h e r e a r t r a n sa x le m ou n t .

(20) Remove the tra nsaxle mount through-bolt .(21) Remove rear crossmember mounting bolts.

( 22) Pr y t h e t r a n sa x le m o u n t r e a r w a r d t o se p a r a t e

the mount from the transaxle.

(23) Remove the rear crossmember.

(24) L ow e r t h e r e a r of t h e t r a n sa x le t o g a in a cce ss

to t he bell housing bolts.

(25) Remove bell housing bolts.

(26) Remove dipstick tube from transaxle. Be pre-

p a r e d t o p lu g t h e d ip st ick h o le w h e n r e m o vin g d ip -

st ick t o p r e ve n t f luid f r o m sp il lin g o u t of t h e t r a n -

saxle.

(27) Remove engine to t ran saxle bolts.(28) Th e t r a n sa x le ca n n ow b e lo w e re d f r om t h e

vehicle.

When inst alling t ra nsaxle, reverse the a bove proce-

dure.

The factory torque converters for 3.3 and 3.5 liter

engines are not interchangeable. There w ill be only

on e t o r q u e con ver t e r r e le a se d f or se r vice u se. Th e

service torque converter can be used in either engine

application.

I f t h e t o r q u e co n ve r t e r is b e in g r e p la ce d , a p p ly a

light coat ing of grease to the cra nkshaft pilot hole.

Inspect the driveplate for cracks before reinstalling

t r a n sa x le . I f a n y cr a ck s a r e f o u n d r e p la ce t h e d r ive -

plate. Do not at tempt to repair a cracked driveplate.

Al w a y s u s e n ew t or q u e con v er t er t o d r iv ep la t e

bolts.

If the torque converter has been replaced, re-

fer to Torque Converter Clutch Break-in Proce-

dure in this section. This procedure will resetthe 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 an d/or a djust gear shift ca ble. Refer t o Shift

Linkage in this section for procedure.

When insta lling the tra nsa xle, ensure the fuel tubesat the rea r of the engine do not conta ct the following:

• Ti e r o d a t t a ch m en t p la t e a t t h e p ow e r s t ee ri n g

rack

• E xhaust G as Recirculat ion (EG R) Tube

• Tra nsa xle wiring ha rness

Re fi ll t r a n sa x le w it h M op a r ATF P lu s (Au t om a t ic

Tra nsm ission Flu id) Type 7176.

OIL PUMP SEAL REPLACEMENTThe transaxle must be removed from the vehicle to

replace t his oil seal.

REMOVAL(1) Remove the tra nsa xle from the vehicle.

(2) Remove the t orque converter from th e tra nsaxle

bell housing.

(3) Use special tool C-3981B to remove oil pump

seal (Fig. 5).

Fig. 4 Drive Shaft Removal

Fig. 5 Oil Seal Removal

TRANSAXLE 21 - 33



INSTALLATION

(1) C l ea n a n d i n sp ect oi l p um p s ea l s ea t . Th en

inst a ll sea l u sing special tool C-4193A (Fig. 6).

(2) C lea n a n d i ns pect t or q ue con ver t er h u b. I f

n ick s, scr a t ch e s o r h u b w e a r a r e f o u n d , t o r q u e co n -

verter replacement will be r equired.

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 pilothole. 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) Ap pl y a l ig h t f il m of t r a n s m i ss ion oi l t o t h e

t o r q u e con ve rt e r h u b a n d oi l se a l l ips. Th e n in st a l l

t o r q u e con ver t e r in t o t r a n sa x le. B e su r e t h a t t h e h u b

lugs mesh with the front pump lugs when installing.

(4) Reinstall the transaxle into the vehicle.

TORQUE CONVERTER CLUTCH BREAK-INPROCEDURE

Electronic Modulated Converter Clutch (EMCC) modu-

lates the applicat ion of the t orque converter clutch.

A torque converter clutch break-in program is being

u s ed t o p rop er l y con d it i on t h e t or q u e con v er t er

clutch. This w ill elimina te sh udder during torque con-

verter clutch operation on a new torque converter.

I f t h e t o r q u e con ve rt e r is r e p la ced , t h e n e w clu t ch

with in t he t orque converter will require brea k-in. The

cu r r en t b r ea k -i n s t a t u s s t or ed i n t h e t r a n s m is s ion

con t r ol m od u le w i l l h a v e t o b e r es et t o t h e s t a r t of

break-in with the DRB scan tool.

I f a n e w t r a n sm ission con t r o l m od u le is p u t o n t h e

v eh i cl e, t h e s t a t u s w i l l b e a t t h e s t a r t of b r ea k -i n .

This st at us is acceptable regard less of t he mileage on

the torque converter. No m odificat ion of th e brea k-in

st a t u s is r e q u ir e d .

To properly service t hese vehicles, it is n ecessa ry to

u s e a D R B s ca n t ool t o r e a d or r es et t h e b r ea k -i n

s t a t u s . P e r f or m t h e f ol low i n g s t ep s w i t h t h e D R Bscan t ool to reset th e break-in st at us:

( 1) Plu g t h e D RB sca n t o o l in t o t h e b lu e C C D B u s

connector. The connector is located under the instru-

ment panel on th e drivers side of the vehicle.

(2) Insert t he 1993 DRB scan t ool cartridge into the

DRB scan tool.

(3) The red and green l ights on t he DRB scan tool will

l ig ht u p a nd the n b e g in f la s hi ng . Wa i t u nt i l the l ig hts

stop flashing before continuing with this procedure.

(4) Pr e ss t h e n u m b er 4 k e y o n t h e D RB sca n t o ol

k e y p a d . I t e m n u m b e r 4 w il l n o t a p p e a r o n t h e D RB

scr e en u n less y ou scr oll d o w n . I t is n o t n e ce ssa r y t oscroll down to be able to choose item 4.

(5) P r e ss t h e n u m b e r 2 o n t h e D RB sca n t o ol k e y

pa d (Tra nsm ission).


pad. Wait for t he DR B scan tool to perform the follow-

ing three t ests before continuing.

• B us Test

• Init ialize

• Controller Part Number


pad (Adjustments).


p a d (Re set EM C C ) . Th e D RB sca n t o ol w il l d ispla yone of three screens.

( a ) EM C C B r e a k - in S t a t u s: Start(b ) E M C C B r e a k -i n S t a t u s : In-progress Pr e ss

ENTER to Reset Break-in status

( c) EM C C B r e a k - in S t a t u s: Complete P r e s s E N -

TER to Reset Break-in status

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

n i n g of i t s b r ea k -i n p rog r a m . N o f u r t h er a c t ion i s

required.

If s creen (b) appears, the controller is in the middle

of a i t s b r e a k -in p r og r a m . P r e ss t h e e n t e r k ey o n t h e

D R B s ca n t ool k ey pa d t o r et u rn t h e s t a t u s t o t h e

sta rt of break-in.If screen (c) appears, the controller has completed

it s b r e a k - in st a t u s p r o g r a m . Pr e ss t h e e n t e r k e y o n

t h e D RB sca n t o ol k ey p a d t o r et u r n t h e st a t u s t o t h e

sta rt of break-in.

(9) Af t er p r essin g t h e e n t er k ey a se con d t im e in

s t ep 8 a s cr ee n w i l l a p pea r t h a t s a y s R E S E T E M C C

AR E Y O U S U R E ?. P r es s t h e e n t er k e y o n t h e D R B

scan tool key pad. The DRB scan tool will then carry

out the reset command.

(10) A f t er t h e D RB sca n t o ol com p le t es t h e r e se t

com ma n d, a s cr een w ill a ppea r s a yin g E MC C

Fig. 6 Oil Seal Installation

21 - 34 TRANSAXLE



B r ea k -in S t a t us h a s b een R E S E T t o S t a r t. Th is

screen w ill indicat e tha t the reset procedure has been

successfully completed.

(11) D iscon n e ct t h e D RB sca n t o ol f r om t h e b lue

CC D B us connector.

TRANSAXLE QUICK LEARN PROCEDUREThe quick learn procedure requires the use of the

DRB scan tool and the 1993 DRB scan tool cartridge.

This program allows t he electronic tra nsa xle system

to r ecalibra te itself. This provides th e best possible

t r a n s a x le op er a t i on . Th e q u ick l ea r n p roce du r e

sh ou ld b e p er f or m e d i f a n y of t h e f ol low in g p r oce -

dures a re performed:

• Tra nsa xle Assembly Replacement

• Tra nsmiss ion Contr ol Module Replacement

• Solenoid Pack Replacement

• Clutch P lat e a nd/or Seal Replacement

• Valve Body Replacement or Recondition

To perform the Quick Learn P rocedure, the follow-

ing conditions must be met:• The brakes must be applied

• The engine speed must be above 500 rpm

• T h e t h r o t t le a n g le ( T PS ) m u st b e le ss t h a n 3 d e -

grees

• The shift lever posit ion must stay until prompted

to shift to overdrive

• Th e s h if t l ev er p os it i on m u s t s t a y i n ov er d r iv e

a f t e r t h e S h i ft t o O v er d r iv e p r om pt u n t il t h e D R B

indicates the procedure is complete

• Th e ca l cu la t e d oi l t e m per a t u r e m u s t b e i n t h e

ra nge of 65-130°F. Incorrect values ma y be learned a t

temperatures out of this range.

The preceding conditions must be met to keep theprocedure from being aborted.

( 1) Plu g t h e D RB sca n t o o l in t o t h e b lu e C C D B u s

connector. The connector is located under the instru-

ment panel on t he drivers side of the vehicle.

(2) Insert t he 1993 DRB scan t ool cartridge into the

DRB scan tool.

(3) Th e r e d a n d g r ee n l ig h t s o n t h e D RB sca n t o ol

w il l l igh t u p a n d t h e n b e g in f la sh in g . Wa it u n t i l t h e

lights st op flashing before continuing with this proce-

dure.

( 4) Pr e ss t h e n u m b e r 4 k e y o n t h e D RB sca n t o o l

k e y p a d . I t e m n u m b e r 4 w il l n o t a p p e a r o n t h e D RB

screen unless you scroll down. It is not necessary toscroll down to be able to choose item 4.


pa d (Tra nsm ission).


pad. Wait for t he DR B scan t ool to perform the follow-

ing t hree tests before continuing.

• B us Test

• Init ialize

• Controller Part Number


pad (Adjustments).


pad (Quick Learn). Then follow the instructions on

the DRB scan tool screen.

TRANSAXLE DISASSEMBLE/REASSEMBLEB e f ore disa s s e mblin g t ra n s a x le , m ov e t h e s h i ft lev er

clockwise as far as it will go. This should be one position

past the L position. Then remove the shift lever.

Tag all clutch pack assemblies, as they areremoved, for reassembly identification.

CAUTION: Do not intermix clutch discs or plates as

the unit might then fail.

Measuring input shaft end play before disassembly

w il l u su a lly in d ica t e w h e n a # 4 t h r u st p la t e ch a n g e is

required. The number 4 thrust plate is located behind

t h e over d r ive clu t ch h u b . At t a ch a d ia l in d ica t or t o

transaxle bell housing with its plunger seated against

e n d o f in p u t sh a f t ( F ig . 1) . M o ve in p u t sh a f t in a n d

ou t t o o b t a in e n d p la y r e a d in g. E n d p la y sp ecif ica -

t io n s a r e .13 t o .64 m m ( .005 t o .025 in ch ) . Re co r dindicat or reading for reference when r eassembling the

t r a n sa x le .

Remove both speed sensors from tra nsa xle case (Fig. 2).

Fig. 2 Remove Input and Output Speed Sensor

Fig. 1 Measure Input Shaft End Play

TRANSAXLE 21 - 35



For valve body recondition procedure, refer toValve 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



The number 7 needle bearing has antireversal tabs

a n d i s c om m on w i t h t h e n u m ber 5 a n d n u mb er 2

posit ion. The orientation should allow the bearing to

se a t f la t a g a in st t h e r e a r su n g e a r ( F ig . 26) . A sm a ll

amount of petrolatum can be used to hold the bearing

t o t h e r e a r su n g ea r .

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



St and Tran s U pright on B ell-housing

Chain cover must be free of old sealant , dirt and oil

before a pplying new seala nt . Apply a 1/8 inch bea d of

sealan t to flan ge 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 ontothere shafts. Apply only a slight amount of pressureto the chain spreader to release the chain pressure.If chain sprockets are not spread slightly removal or

installation will be difficult. Overspreading of thechain 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 bluelink must face outward.

When reinsta lling t ra nsa xle drive chain a nd sprock-ets, sprocket height must be checked. Refer to Drive

Sprocket Height Adjustment Procedure in this group.

Remove main sump baffle from transaxle case (Fig.

48).

Wh e n r e in st a l l in g m a in su m p b a f f le a p ply M op a r

Silicone Sealant as shown in figure 49.

CAUTION: Failure to grind and open stakes of theoutput shaft nut and transfer shaft nut will result inthread damage to the shafts during nut removal.

WARNING: WEAR SAFETY GOGGLES WHILE

GRINDING STAKE NUTS.

U sin g a d ie g r in d e r o r e q u iva le n t , g r in d t h e st a k e s

in t h e sh o u ld e r o f t h e sh a f t n u t s a s sh o w n in f ig u r e

50 a n d 51. D o n o t g r in d a l l t h e w a y t h r o u g h t h e n u t

a n d in t o t h e sh a f t . Th e r e a r e t w o st a k e s o n e a ch n u t .

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



U s e s peci a l t ool 6597 a n d h a n d le C -4171 a n d

C-4171-2 to press r ear output sha ft bearing cup rear-

ward (Fig. 56).

Use special tool 5050A to insta ll both front a nd rear

bearing cups (Fig. 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 t h e C e n t er l in e of t h e t r a n s a x le

h a s b ee n r e m ove d. I f t h e con d it ion f or d isa ssem b ly

d i d n ot p er t a i n t o t h e d if fe ren t i a l , i t s d is a s s em b ly

m a y n o t b e r e q u ir e d . I n sp e ct t h e r e a r t r a n sf e r sh a f t

a r e a a n d t h e t r a n s f er s h a f t s e a l a r ea f or con t a m i n a -

tion. If evidence of contamination is present, replace

t h e r ea r t r a n s f er s h a f t b ea r i n g a n d /or t h e t r a n s f er

sh a f t se a l . Re f e r t o t h e Tr ansf e r S ha f t S e al R e m oval S e c-

tion a nd t he Different ial D isa ssembly/Assembly section.

To assem ble tra nsa xle, reverse t he a bove procedure.

B e su r e t o ch e ck b ot h g r ou n d ed clu t ch cle a r a n ces.

B e for e in st a l l in g t h e in pu t clu t ch es r e t a in er, f ol low

t h e i n st r u ct i on s i n Determining No. 4 ThrustPlate 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 SHIMSELECTION

When assembling, the output bearing preload must

b e ch e ck ed a n d /or a d ju st ed i f a n y of t h e f ol low in g

items h ave been replaced:

• Output shaft (rear carrier assembly)

• Output shaft bearings

• Tra nsa xle case

SHIM SELECTION

( 1) I n st a l l r e a r o u t p u t sh a f t b e a r in g co n e a n d sp e -

cial tool 6618A (Fig. 2).

(2) I n st a l l s pe ci a l t ool 6618A (F i g. 3). L i gh t l y

tighten retaining screws. Screws should be below the

plate surface, but do not snug screws.

(3) Turn ca se over on a rbor press so th at the plat e

is resting on the press base

CAUTION: The output shaft will extend through thehole of tool 6618A. Ensure your press table hasclearance for the output shaft.

(4) I n s t a l l s h im on ou t pu t s h a f t (F i g. 4). Ap pl y

sm a ll a m o u n t o f p e t r o la t u m o n t o t h e sh im t o h o ld i t

in p la ce . U se t h e o r ig in a l sh im a s a st a r t in g p oin t . I f

o r ig in a l sh im is n o t a va i la b le , u se t h e t h ick e st sh im

a va ila b le . Ref er t o O u t p u t S h a f t Re a r S h im C h a r t f o r

available sizes.

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) Inst all output sha ft/rear carrier into rear bearing.

The shaft must be pressed into position. Use special tool

MD-998911 (Disc) a nd C-4171 a nd C4171-2 (Ha ndle) t o

press shaft into rear bearing (Fig. 5).

(6) U s in g s p ecia l t o ols 6497 a n d 6498, in s t a l l n e w

ou t p ut s h a f t n u t . D o n ot r e us e o ld ou t pu t s h a f t n u t .

Tighten new output sha ft nut to 271 Nm (200 ft. lbs.).

(7) C h e ck t h e t u r n in g t or q u e o f t h e ou t pu t s h a f t

(F ig . 6). Th e s h a ft s h ou ld h a v e 1 t o 8 i n. l bs . of

t u r n in g t o r q u e. I f t h e t u r n in g t o r q u e is higher than

8 in. lbs., install a thicker shim. If the turning torque

is less than 1 i n . l b . , i n s t a l l a t h i n n e r s h i m . M a k e

sure there is no end play.

CAUTION: Failure to stake shaft nuts could allow

the nuts to back-off during use.

( 8) T h e n e w n u t m u st b e st a k e d a f t e r t h e co r r e ct

t u r n in g t o r q u e is o b t a in e d ( F ig . 7) . U se sp e cia l t o o l

6639 to stake output shaft nut and special tool 6589

t o st a k e t r a n sf e r sh a f t .

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

P r e s s d o w n c l u t c h p a c k w i t h f i n g e r a n d z e r o d i a l

indicator. Low/Reverse clutch pack clearance is

1.04 to 1.65 mm (.042 to .065 inch).S e lect t h e p r op er low /r e ve r se r e a ct ion p la t e t o

achieve specifications:

P r e s s d o w n c l u t c h p a c k w i t h f i n g e r a n d z e r o d i a l

indicator. The 2/4 clutch pack clearance is 0.76 to2.64 mm (.030 to .104 inch). If not within specifica-

tions, the clutch is not assembled properly. There isno 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 reassemblyidentification.

CAUTION: Compress return spring just enough toremove 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

U s e p et r ol a t u m on a l l s ea l s t o e a s e a s s em b ly 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



CAUTION: Compress return spring just enough toremove 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 the input clutch hub. Be sure that snap

ring is fully seated, by pushing with screw-

driver, into snap ring groove all the way

around.

Underdrive clutch pack clearance must be0.91 to 1.47 mm (.036 to .058 inch). S elect t h e

proper reaction plate to achieve specifications:

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 n o t w i t h in

specificat ions, the clutch is not assembled properly.

There is no a djustment for t he OD clutch clear an ce.

The reverse clutch pack clearance is 0.76 to1.24 mm (.030 to .049 inch). Select the proper re-

verse clutch sna p ring to a chieve specificat ions:

All clu t ch cle a r a n ces in t h e in pu t clu t ch r e t a in er

have now been checked a nd approved.

To com p le t e t h e a sse m b ly of t h e in pu t clu t ch r e -

t a in e r, t h e r e ve r se clu t ch a n d t h e over d r ive clu t ch

must be removed from the r etainer.

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 w ith the next pha se of the assembly:

R ei n st a l l ov er d r iv e cl ut ch a n d r ev er s e cl ut ch a s

shown in Figures 20 through 28. Rechecking theseclutch clearances is not necessary, as they wereset 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



(6) B u t t a s ca l e a g a i n st t h e s n u b be r a n d p la c e a

se co n d m a r k o n t h e sca le a t t h e b o t t o m o f t h e ch a in

(Fig. 4).

(7) M e a s u r e t h e d is t a n ce b et w e en t h e t w o m a r k s

p la ce d o n t h e sca le ( F ig . 5) . I f t h e t w o m a r k s o n t h e

sca le a r e m o r e t h a n on e in ch a p a r t , r e pla ce t h e d r ive

chain.

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 t h e t r a n sf er ch a in w a s r e pla ced , r e f er t o S n u b b e r

G a p M ea su r e m en t in t h is sect ion t o ve r i fy cor r e ct

snubber cleara nce.

SNUBBER GAP MEASUREMENTT h e g a p b e t w e e n t h e sn u b b e r f a ce a n d t h e t o p o f

t h e ch a i n s h ou ld b e 0 . 0 to 0.030 i nch w i t h ch a i n

slack removed. The gap can be adjusted by installingsnubbers w ith different off-set mounting holes. The

amount of off-set the mounting holes has will deter-

mine th e posit ion of the chain snubber.

The snubbers can be identified by their color. There

a r e t h r e e d iff er e n t sn u b be r color s a va i la b le (b la ck ,

green and tan). The black snubber will give the most

cl ea r a n c e b e t w ee n t h e ch a i n a n d t h e s n ub be r f a ce .

Th e g r ee n sn u b be r w il l g ive t h e lea st cle a r a n ce b e -

t w e e n t h e ch a in a n d t h e sn u b b er f a ce. Th e t a n sn u b -

ber is t he nominal snubber.

(1) I n se r t scr e w d r ive r in t o t h e 18 m m h ole b e low

t h e c h a i n a n d p ry u p o n c h a i n t o r e m ov e s l a ck i n

chain.

(2) U sin g a f ee le r g a u g e , m e a su r e t h e g a p b e t w e e n

the snubber fa ce and t he top of the chain (Fig. 6).

(3) If the measurement is not within specifications,

insta ll the correct snubber as required.

DRIVE SPROCKET HEIGHT ADJUSTMENT

PROCEDUREA s pa c er b en ea t h t h e ou t pu t s pr ock et i s u s ed t o

posit ion the output sprocket in line with the transfer

sprocket. The sprocket must be within 0.015 of each

o t h e r . I n o r d e r t o d o t h is o p e r a t io n , in st a l l o r ig in a l

spacer over the output shaft . I f original spacer is not

a va ila b le , u se t h e t h ick e st a va i la b le sh im a s a st a r t -

ing point . Refer to Output Sprocket Spacer Chart for

a va ila b le siz e s. T h e n in st a l l t h e t w o sp r o ck e t s w it h -

out the chain.

The chain sprockets are not reversible. The output

sp r o ck e t h a s 32 t e e t h a n d t h e t r a n sf e r sp r o ck e t h a s

33 teeth. Check the height difference using a straight

e dg e (sp ecia l t o ol 6311 or e q u iva le n t ) a n d a se t of

feeler gauges.

I f t h e ou t pu t s pr ock et is low er t h a n t r a ns fer

sp r o ck e t , a d d t h e a m o u n t m e a su r e d t o t h e sh im t h a t

wa s inst alled (Fig. 7).

I f th e output sprocket is higher t han tra nsfer sprocket ,

s ub t ra ct t h e a m ou nt m ea s u red t o t h e s hi m t h a t w a s

insta lled (Fig. 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 RECONDITIONThe va lve body a nd solenoid w iring connector must

be removed from the tra nsa xle in order to r econdition

t h e t r a n sa x le d if f e r e n t ia l . T h e t r a n sf e r sh a f t ca n n o t

b e r e m ov ed w i t h t h e v a l ve b od y i n p la c e. R ef er t o

Valve Body Recondition for removal procedure.

I f a n y b e a r in g s in t h e d if f e r e n t ia l r e q u ir e r e p la ce -

m e n t , a l l t h e b e a r in g s o n t h e d if f e r e n t ia l ca r r ie r a n dtransfer shaft must also be replaced. The differential

a d ju s t er s m u s t a l s o b e r ep la c ed w h e n d i ff er en t i a l

bearings are replaced.

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 ontothere shafts. Apply only a slight amount of pressureto the chain spreader to release the chain pressure.If chain sprockets are not spread slightly removal or

installation will be difficult. Overspreading of thechain sprocket will also make sprocket removal dif-ficult.

CAUTION: When reinstalling drive chain, the bluelink must face outward.

CAUTION: Drive shaft retainer clips and seals lo-

cated on the stub shafts must be replaced beforereinstalling 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



If the carrier requires reconditioning, refer to Dif-

ferentia l C ar rier Recondition.

CAUTION: Failure to grind and open stakes on the

transfer shaft nut will result in thread damage totransfer shaft during nut removal.

WARNING: WEAR SAFETY GOGGLES WHILEGRINDING 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



U sin g a d ie g r in d e r o r e q u iva le n t , g r in d t h e st a k e s

in the shoulder of the shaft nut as shown in figure 16

a n d 17. D o n o t g r in d t h r o u g h t h e t r a n sf e r sh a f t n u t

in t o t h e sh a f t . Th e r e a r e t w o st a k e s o n t h e n u t .

U sin g a sm a ll ch isel , ca r e fu lly op en st a k e s o n n u t

(Fig. 18).

Re m ove t h e t r a n sf er sh a f t n u t .

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 n st a l l sp e cia l t o ol 6577 t o r e m ove r e a r t r a n sf e r

bearin g cup (Fig. 20).

Re m ove t r a n sf e r sh a f t p r eloa d sh im (F ig . 21). I f

t r a n sf e r sh a f t b e a r in g s a r e t o b e r e u se d , t h e o r ig in a l

shim must also be reused.

CAUTION: If the transfer shaft is removed from thetransaxle case for any reason, both seals must be

replaced.

Remove transfer shaft seals (Fig. 23) using special

tool 6310 an d foot 6310-9 (Ta r 960). D o not reuse old

seals. The seals will be pulled out the rea r of t he case.

Re m o ve t h e f r o n t t r a n sf e r sh a f t b e a r in g cu p u sin g

special tool 6495 and handle C-4171 (Fig. 24). Use a

press with special tools 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



S u p por t sp ecia l t o ol P -334 on p r ess t a b le so t h a t

p in ion h e a d of t r a n sf e r sh a f t ca n b e p r essed t h r o ug h

ta ble (Fig. 25).

ASSEMBLE AND BEARING ADJUSTMENT

PROCEDURE

The following steps will determine the correct shim

thickness required to obtain proper pinion depth. All

special tools described in this procedure must be used

to obtain correct results.

CAUTION: Failure to adjust pinion depth correctlycould cause gear noise or transaxle failure.

(1) Install front transfer shaft bearing cup (Fig. 1).

Th e t r a n sf er sh a f t b ea r in g cup m u st b e in st a l led b e-

f or e m a k in g p in ion d e pt h m e a su r em e n t . U se sp ecia l

tool 6494 to install bearing cup. There are no shims

located behind t his bearing cup.

CAUTION: The bearing cup is seated in the casecorrectly 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) Install centering block (special tool 6549-2) into

the t ran saxle case (Fig. 2). S crew centering block into

inner adjuster hole of case until it bottoms. The pegs

on t h e s pe ci a l t ool a r e on l y u s ed f or i n st a l l a t i on .

Orientation with in the case is not required.

( 3) I n st a l l n e w f r o n t b e a r in g ( a ct u a l b e a r in g t o b e

used dur ing reassembly) onto gauge disc (special tool

6549-3) (Fig . 3).

( 4) I n st a l l g a u g e d isc a n d b e a r in g in t o ca se u sin g

gauge disc rod (Fig. 4).

(5) Install centering disc (special tool 6494-2) onto

gauge disc rod (Fig. 5).

(6) Install centering nut as shown in figure 6.

(7) Ha n d t ig h t e n cen t e r in g n u t u n t i l a l l p la y in t h e

tool has been removed.

(8) Install dial indicator into locating block. Then

screw extension rod onto dial indicator.

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



(11) P ivot dial indicat or back a nd forth (Fig. 11) on

centering pin to obta in the shortest dist an ce measure-

m e n t . This will be the highest number readingon dial indicator. Record th e number obta ined. Now

r ot a t e t h e g a u g e d i s c cl ock w i se 1/3 of a t u r n a n d

r e ch e ck r e a d in gs. Re cor d n u m b er ob t a in e d . Rot a t e

t h e g a u g e d isc a n o t h er 1/3 o f a t u r n clockw ise a n d

t a k e a n ot h e r r e a d in g. Aver a g e of t h e t h r e e r e a d in g s.

Re co r d t h is p in io n d e p t h m e a su r e m e n t . I f t h e r e a d -

i n gs d if fe r b y m or e t h a n t w o t h ou s a n d t h s r ech eck

g u a g e d i s c i n s t a l la t i on , i t m a y h a v e b ee n i n st a l l ed

slight ly cocked.(12) To determine t he required shim thickness the

p in ion d e pt h m e a su r em e n t m u st b e a d ju st e d. Th e

p in ion sh im a d ju st m e n t n u m b er is t h e f ir st of seve n

d ig it s in k st a m p e d on t h e sh a n k of t h e t r a n sf e r sh a f t

(Fig. 12). Using the adjustment factor chart , convert

t h e a d ju st m en t n u m b er t o t h e cor r e sp on d in g a d ju st -

ment factor. Utilizing the pinion depth measurement

o b t a in e d in st e p 11, a d d o r su b t r a ct t h e a d ju st m e n t

factor to calculate the required shim thickness. Refer

to pinion head shim chart for shim s elections. This is

t h e sh im t h a t w il l b e in st a l le d b e t w e e n t h e t r a n sf e r

s h a f t p i n i o n h e a d a n d t h e f r o n t t r a n s f e r s h a f t b e a r -

ing. Refer to the following exam ples for further expla-

nation:Example 1 in (MM):

• Measured pinion shim depth: 0.789mm

• Adjustment number on tra nsfer shaft : + 2

• Adjustment factor (mm): -0.051mm

• Shim size needed: 0.789-0.051= 0.738mmExa mple 2 in (IN):

• Measured pinion shim depth: 0.032in

• Adjustment number on tra nsfer shaft : -1

• Adjustment factor (in): + 0.001

• Shim size needed: 0.032+ 0.001= 0.033in

(13) Remove Dial indicator, gauge disc and center-

ing block from t ra nsa xle.

(14) Install shim selected in step 12 of this proce-

dure onto the t ra nsfer sha ft (Fig. 12).

(15) Press front transfer shaft bearing onto transfer

shaft (special tool 6052). The shim must be in place

before pressing on bearing (Fig. 13).

Fig. 9 Zero Dial Indicator

Fig. 10 Mounting Dial Indicator to Centering Block

Fig. 11 Pivot Dial Indicator

ADJUSTMENT FACTOR CHART

TRANSAXLE 21 - 73



At this point the pinion depth has been determined

a n d t h e s h i m h a s b ee n i n s t a l le d o n t o t h e t r a n s f er

shaft . Before the pinion is installed into the transaxle

ca s e , b ea r i n g p re loa d m u s t b e d et e rm i n ed f or t h e

d iff er e n t ia l b ea r in g s. Th e f ol low in g st e ps m u st b e

performed before the pinion is installed.

The following st eps will determine how ma ny foot

pounds a re required on the outer differential adjuster

to obta in t he correct turning torque.

CAUTION: Failure to set differential bearing preload

correctly may cause bearing failure, gear noiseand/or axle shaft seal failure.

(16) Remove outer adjuster with special tool 6503

(Fig. 14).

PINION HEAD SHIM CHART

Fig. 12 Shim Installation

Fig. 13 Bearing Installation

Fig. 14 Outer Adjuster Removal

21 - 74 TRANSAXLE



( 17) Re m o ve o ld st u b sh a f t se a ls . Pr e ss in n e r a d -

ju st e r se a l ou t w it h sp ecia l t o ol 6502B . P r e ss ou t e r

adjuster seal out with special tool 6558.

( 18) I n st a l l n e w st u b sh a f t se a ls in b o t h a d ju st e r s

using special tool 6558 (Fig. 15).

(19) Lube adjuster threads and o-ring with gear oil

before insta lling. Fa ilure to lube threads will result in

t h r e a d d a m a g e t o t h e a d ju st er a n d t r a n sa x le ca se .

(20) Screw in the inner adjuster using special tool

6502B (Fig. 16). The inn er a djuster should be s crewed

in u n t i l u n d e r - f lu sh w it h in sid e o f t h e ca se ( vie w e d

from differential side).

(21) Install differential assembly into the transaxle

case (Fig. 17).

(22) Install differential cover (Fig. 18). Do not apply

si l ico n e se a la n t a t t h is t im e . A ll b o lt s sh o u ld b e in -

st a l le d a n d t ig h t e ne d .

(23) I n st a l l se a l p r ot e ct o r (sp ecia l t o ol 6591) a s

shown in figure 19). Apply a thin film of gear oil on

th e 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 threaddamage to the adjuster and transaxle case.

(24) S cr ew on ou t e r a d ju st e r a n d t ig h t e n a d ju st e rdown finger tight (Fig. 20).

(25) Insert special tool 6548 (Fig. 21). This tool will be

used to check turning torque of the differential assembly.

CAUTION: Differential bearings must be seated be-fore taking turning torque readings. This is done by

rotating the differential three or four turns in bothdirections.

CAUTION: Turning torque of 19 to 23 in. lbs. canonly be obtain when using new bearings. Do notattempt to obtain this turning torque with used bear-

ings.

(26) Tighten outer a djuster with tool 6503 until 19 to

23 in . lbs . o f t u rn in g t o rq u e is o bt a in e d o n t o o l 6548.

Record how many foot pounds were required onthe outer adjuster to obtain the correct turningtorque (Fig. 22). Record the foot pound reading. The

reading t hat you are recording w ill be used in st ep 48 of

this procedure.

Fig. 20 Outer Adjuster Installation Fig. 21 Special Tool 6548

Fig. 22 Determining Turning Torque

21 - 76 TRANSAXLE



CAUTION: Properly seated cups are essential in cor-rectly setting bearing preload.

(35) U se sp ecia l t o ol 6560 t o p r ess cup in t o ca se

(Fig. 30).

(36) I nsta ll Tra nsfer sh aft preload shim (Fig. 31).

U se t h e o r ig in a l sh im t h a t w a s t a k en o u t o f t r a n sa x le

if p o ssib le . I f o r ig in a l sh im is n o t a va i la b le , u se t h e

t h ick est sh im a s a st a r t in g p oin t . Re f er t o Tr a n sf e r

S h a f t Re a r S h im C h a r t f or a va i la b le siz es.

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



CAUTION: Failure to stake the transfer shaft nut

correctly may allow the nut to loosen during tran-

saxle operation. This will cause transaxle failure.

A t t h is p o in t t h e t r a n sf e r sh a f t , n e w o il se a ls , p in -

io n d e p t h a n d t r a n sf e r sh a f t p r e - lo a d h a ve b e e n se t .The following steps will set the backlash between the

t r a n sf e r sh a f t a n d t h e r in g g ea r .

If the carrier requires reconditioning, refer to Dif-

ferentia l Ca rrier Recondition.

(42) I n st a l l ve n t b a f f le . Ap ply se a ler a s sh ow n in

figure 37.

(43) I n st a l l n e w in n er a d ju st er o-r in g . L u b e in n er

a d ju st er t h r e a d s a n d o-r in g . Th e n in st a l l in n e r a d -

juster flush with differential side of case.

(44) I n st a l l d i ff er e n t ia l a sse m b ly (w it h r in g g ea r

at ta ched) into tra nsa xle case (Fig. 38).

(45) Tran sfer shaft to r ing gear backlash should be

0.006 to 0.009 t h ou s a n d s of a n i n ch . To g et t h e

backlash close enough to measure, perform the follow-

in g st e p s. Ho ld t h e t r a n sf e r sh a f t w it h o n e h a n d a n d

rock the ring gear back and forth (Fig. 39). You should

feel some backlash between the gears. I f no backlashis f e lt u se sp ecia l t o ol 6502B t o t u r n t h e in n e r a d -

juster so that it raises the differential assembly. This

w il l in cr e a se b a ck la sh . I f t h e r e is t o m u ch b a ck la sh ,

u se sp ecia l t o ol 6502B t o t u r n t h e in n er a d ju st er so

t h a t i t l ow e r s t h e d i ff er en t i a l a s s em b ly. Th i s w i l l

d ecr ea se b a ckla sh . Re ch e ck t h e b a ckla sh a f t e r e a ch

adjustment.

Fig. 37 Baffle Installation

Fig. 38 Differential Assembly Installation

Fig. 35 Staking New Nuts

Fig. 36 Correctly Staked Nut

21 - 80 TRANSAXLE



I f t h e re i s t oo m u ch b a ck la s h , l oos en t h e ou t er

adjuster with special tool 6503. Then turn the inner

a d ju st er so t h a t i t moves away from the ring gear.After a djusting the inner adjuster, retighten the outer

adjuster to the torque recorded in step 26. The inner

adjuster should be turned in small increments.

I f t h e r e is n ot e n ou g h b a ckla sh , loose n t h e o u t e r

adjuster with special tool 6503. Then turn the innera d j u s t e r s o t h a t i t moves towards the ring gear.After a djusting the inner adjuster, retighten the outer

adjuster to the torque recorded in step 25. The inner

adjuster should be turned in small increments.

(50) O n ce b a ckla sh is w it h in sp ecif ica t ion s, r e -

check the back lash in four spots on the ring gear 90

d eg r ee s a p a r t . Al l f ou r r ea d i n gs s h ou ld b e w i t h in

specifications.

(51) Install inner and outer adjuster locking brack-

ets.

(52) I n s t a l l n ew i n sp ect i on p lu g . U s e a w o od en

block to tap inspection plug into place.

It is easier to fill the differential prior to installingt h e t r a n sa x le b a ck in t o t h e ve h icle . T h e d if f e r e n t ia l

holds 32 ounces of fluid.

DIFFERENTIAL CARRIER-RECONDITION

CAUTION: Ring gear bolts are not reusable. Whenreassembling use new bolts.

CAUTION: When reassembling use a new roll pin

BEARING ADJUSTMENT PROCEDURES

GENERAL RULES ON SERVICING BEARINGS

Ta k e e xt r e m e ca r e w h e n r e m ovin g a n d in st a l l in g

b e a r in g cu p s a n d co n e s. Use only an arbor pressfor installation, a s a h a m m er m a y n ot p roper ly

a l ig n t h e b e a r in g cu p o r co n e . B u r r s o r n ick s o n t h e

b e a r in g se a t w il l g ive a f a lse e n d p la y r e a d in g , w h ile

gauging for proper shims. Improperly seated bearing

cup and cones are subject to low-mileage failure.

B e a r in g cup s a n d con e s sh o u ld b e r e pla ced i f t h e y

show signs of pit t ing or heat distress.

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



42LE ON-BOARD DIAGNOSTICS

INDEX

page page

CCD Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Diagnostic Trouble Code Charts . . . . . . . . . . . . . . 85Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . 84DRB Scan Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 85

General Information . . . . . . . . . . . . . . . . . . . . . . . 84Limp-In Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84On-Board Diagnostics Information . . . . . . . . . . . . . 84

GENERAL INFORMATIONThe information in this manual is designed to help

t h e t e ch n ici a n r ep a ir t h e t r a n s a x le w i t h t h e a i d o f

on-board diagnostics.

Chrysler Corporation has developed a com-plete set of diagnostic manuals which cover thediagnosis of the 42LE transaxle. They have beendesigned to make transaxle diagnosis accurateand simple. Use these manuals with the DRBscan tool and the latest cartridge, when diag-nosing transaxle problems.

ON-BOARD DIAGNOSTICS INFORM ATIONThe 42LE transaxle is controlled and monitored by

t h e t r a n sm ission con t r o l m od u le. Th e t r a n sm ission

con t r o l m od u le m o n it or s cri t ica l in pu t a n d ou t p u t

circuits within the transaxle.

S o m e cir cu it s a r e t e st ed con t in u ou sly; ot h e r s a r e

checked only under certa in conditions. E ach circuit

m on it or e d b y t h e t r a n sm ission con t r o l m o d ule h a s a

corresponding fault message assigned to it . The mes-

sa g e ca n b e r e a d w it h t h e D RB sca n t o ol .

If t he on-board diagnostic system senses tha t one ofthe circuits is ma lfunctioning, the corresponding code

i s s t or ed i n m em or y. I f t h e m a l f un ct i on g oe s a w a y

aft er the code is st ored, th e tra nsmission control mod-

ule will era se th e code a fter 75 key cycles.

CCD BUSIn order to diagnose the 42LE transaxle, diagnostic

t r o ub le cod e s in t h e TC M ’s m e m or y sh ou ld b e r e a d

u sin g t h e D RB sca n t o ol . I f m o r e t h a n on e d ia g n ost ic

t r ou b le cod e e xi st s , d ia g n os t i c p ri or it y s h ou ld b e

given t o the most recent code. With C CD bus bias and

communication problems, however, t he D RB scan tool

d isp la y s a n a p p r o p r ia t e m e ssa g e . D ia g n o st ic t r o u b lecodes might not be accessible until the bus problem is

fixed. The following is a list of probable causes for a

bus problem:

• Open or short to ground/bat tery in either or both

CC D bus w ires (pins 4 and 43).

• Open or short to ground/bat tery in either or both

42LE tra nsa xle’s bia s w ires (pin 5 a nd 44).

• Open or short to ground/bat tery in t he dia gnostic

connector bus wire.

• I n t er n a l f a i lu r e of a n y m od u le con n ect e d t o t h e

bus.

The C CD bus should have 2.5 volts (+ 2.5 volts on

CC D+ an d -2.5 volts on CC D-).

T h e b u s e r r o r m e ssa g e d isp la y e d b y t h e D RB sca n

tool should be helpful in diagnosing the C CD bus.

F or in for m a t ion on d ia g n osin g C C D b u s, r e fe r t o

t h e 1993 D i a g n os t i c P r o ce du r es M a n u a l f or n on -

communication w ith the C CD bus. All other problems

refer to the 1993 Body Vehicle Communications Diag-

nostic Procedures Manua l.

DIAGNOSTIC TROUBLE CODESD ia g n o st ic Tr ou b le C o d es a r e t w o -d ig it n u m b er s

that identify which circuit is malfunctioning. A code

ca n b e s e t f or h y d ra u l ic a n d m e ch a n i ca l r ea s on s a s

well as for electrical problems. In most cases, codes do

not pinpoint which specific component is defective.

Diagnostic trouble codes can only be read

with the use of the DRB scan tool or equivalent.

HARD FAULTS

Any D iagnostic trouble code tha t comes ba ck within

3 engine starts (reset count 3 or less) is a Hard Fault .

Th i s m e a n s t h a t t h e d e fe ct i s t h e r e e v er y t i m e t h etra nsmission control module checks t ha t circuit .

SOFT FAULTS

A S of t F a u lt is o n e t h a t occu r s in t e r m it t e n t ly. I t is

not there every t ime the transmission control module

ch eck s t h e ci r cu it . M os t s of t f a u lt s a r e ca u s ed b y

w ir in g or con n e ct o r p r ob lem s. I n t e r m it t en t d e fe ct s

must be looked for under the specific conditions that

caused them.

LIMP-IN MODETh e t r a n s m i ss ion con t r ol m od u le con t i nu ou s ly

checks for electrical and internal transaxle problems.

When a problem is sensed, th e tra nsmission control

m od u le s t or es a d ia g n os t i c t r ou b le cod e. Al l b u t

t w e lve o f t h e se co d e s ca u se t h e t r a n sa x le t o g o in t o

t h e L im p-in m od e . Wh ile in t h is m od e , e le ct r ica l

p ow e r i s t a k en a w a y f r om t h e t r a n s a x le . Wh en t h i s

h a p p en s, t h e on ly t r a n sa x le r a n g e s t h a t w il l f u n ct ion

a r e :

• P a r k

• N e u t r a l

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• Reverse

• Second Gear

N o u p sh if t s o r d o w n sh if t s a r e a l lo w e d w h ile in t h e

Limp-in mode. The position of the manual valve alone

a llow s t h e t h r e e r a n g e s t h a t a r e a va i la b le.

Although engine performa nce will be reduced while

in t his m ode, t he vehicle can be driven in for service.

DRB SCAN TOOLTh e D R B s ca n t ool i s a d ia g n os t i c r e a d -ou t b ox

d e sig n ed b y C h r y sler. I t is u se d t o g a in a cce ss t o t h e

o n - b o a r d d ia g n o st ics t h a t a r e f o u n d o n a l l C h r y sle r -

built cars and trucks.

The DRB scan tool has a few diagnostic capabilit ies

by itself. To perform most dia gnostic tests, a program

ca r t r id ge m u st b e in ser t e d . I t con t a in s t h e d ia g n o st ic

test programs.

There are diagnostic read-out boxes available from

ot h er m a n u f a ct u r es t h a t ca n b e u s ed on C h r y s le r

vehicles. H owever, the diagnostic test procedures in

t h is m a n u a l h a v e b e en d es ig n ed f or u se w i t h t h eChrysler’s DRB scan tool.

The DR B scan t ool operates by communicating with

t h e m od u le o f t h e veh icle sy st e m b ein g t e st ed . To

com m u n ica t e w it h t h e t r a n sm ission con t r o l m o d u le ,

the D RB scan t ool must be connected to the blue CCD

b u s con n e ct o r. Th e con n e ct o r is loca t e d u n d er t h e

i n s t r u m e n t p a n e l . R e f e r t o t h e U s i n g t h e D R B s c a n

tool manual or the Diagnostic Procedures Manual for

information.

DIAGNOSTIC TROUBLE CODE CHARTSBelow is a brief description of what each section of

the diagnostic trouble code charts are addressing.

•

DIAGNOSTIC TROUBLE CODE-Tells the codenumber and name (as shown on the DRB scan tool).

• BACKGROUND-A brief description of the circuit

tha t the t ra nsmission control module is monitoring.

• WHEN CHECKED-The point of time or condition

when the transmission control module makes it ’s sys-

tem check.

• ARMING CONDITIONS-Th e p a ra m et er s t h a t

must be met before a code can be set .

• FAULT CONDITION-What the transmission con-

trol module saw that is determined to be a problem.

• FAULT SET TIME-T h e a m o u n t o f t im e a f a i lu r e

must occur before a diagnostic trouble code is set in

memory.

• EFFECT-Re f e r s t o h o w t h e f a u lt e f f e ct s t r a n sa x le

operations.

• POSSIBL E CAUSE-Re f e r s t o t h e sy st e m s o r cir -

cuits which could cause t he fa ult t o be recorded.

DIAGNOSTIC TROUBLE CODE 11

TRANSAXLE 21 - 85





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TRANSAXLE 21 - 89



DIAGNOSTIC TROUBLE CODE 21-27

TRANSAXLE 21 - 91




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TRANSAXLE 21 - 95




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DIAGNOSTIC TROUBLE CODE: 48 Torque Management

BACKGROUND: Engine torque management is used during high-torque, high-speed 1-2, 2-3, 4-2, and 3-1shifts in order to reduce the energy dissipation in the 2-4 clutch and the OD clutch to anacceptable 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 controlmodule.

CONDITIONS: When the torque fault management fault counter matures to a value exceeding 15.SET TIME: 1) If an incorrect response from powertrain 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 greaterthan seven.

POSSIBLE CAUSES: CCD buss communication problem.

9321-441


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TRANSAXLE 21 - 99




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42LE HYDRAULIC SCHEMATICS

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TRANSAXLE 21 - 103



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TRANSAXLE 21 - 105



TRANSAXLE 21 - 107



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TRANSAXLE 21 - 109



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TRANSAXLE 21 - 111



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TRANSAXLE 21 - 113



42LE SPECIFICATIONS

42LE FOUR SPEED AUTOMATIC TRANSAXLE

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42LE TORQUE SPECIFICATIONS

TRANSAXLE 21 - 115

Diagrama Transmision LHS, Intrepid, Condord, Newyorker

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