transmission CHEVROLET DYNASTY 1993 Service Manual

first separator plate and watch carefully for the pis-
ton to move forward. The piston should return to its
original position after the air pressure is removed.
UNDERDRIVE CLUTCH
Because this clutch piston cannot be seen, its oper-
ation is checked by function. Air pressure is applied
to the low/reverse and the 2/4 clutches. This locks
the output shaft. Use a piece of rubber hose wrapped
around the input shaft and a pair of clamp-on pliers
to turn the input shaft. Next apply air pressure to
the underdrive clutch. The input shaft should not ro-
tate with hand torque. Release the air pressure and
confirm that the input shaft will rotate.
FLUID LEAKAGE-TORQUE CONVERTER HOUSING
AREA
(1) Check for source of leakage.
Since fluid leakage at or around the torque con-
verter area may originate from an engine oil leak,
the area should be examined closely. Factory fill
fluid is dyed red and, therefore, can be distinguished
from engine oil. (2) Prior to removing the transaxle, perform the
following checks: When leakage is determined to originate from the
transaxle, check fluid level prior to removal of the
transaxle and torque converter. High oil level can result in oil leakage out the vent
in the manual shaft. If the fluid level is high, adjust
to proper level. After performing this operation, inspect for leak-
age. If a leak persists, perform the following opera-
tion on the vehicle to determine if it is the torque
converter or transaxle that is leaking.
LEAKAGE TEST PROBE
(1) Remove torque converter housing dust shield.
(2) Clean the inside of torque converter housing
(lower area) as dry as possible. A solvent spray fol-
lowed by compressed air drying is preferable. (3) Fabricate and fasten test probe (Fig. 4) securely
to convenient dust shield bolt hole. Make certain
torque converter is cleared by test probe. Tool must be
clean and dry. (4) Run engine at approximately 2,500 rpm with
transaxle in neutral, for about 2 minutes. Transaxle
must be at operating temperature. (5) Stop engine and carefully remove tool.
(6) If upper surface of test probe is dry, there is no
torque converter leak. A path of fluid across probe
indicates a torque converter leak. Oil leaking under the
probe is coming from the transaxle torque converter
area. (7) Remove transaxle and torque converter assembly
from vehicle for further investigation. The fluid should
be drained from the transaxle. Re install oil pan (with
MOPAR tAdhesive Sealant) at specified torque.
Possible sources of transaxle torque converter area
fluid leakage are: (1) Torque converter hub seal.
² Seal lip cut, check torque converter hub finish.
² Bushing moved and/or worn.
² Oil return hole in pump housing plugged or omitted.
² Seal worn out (high-mileage vehicles).
(2) Fluid leakage at the outside diameter from pump
housing O-ring. (3) Fluid leakage at the front pump to case bolts.
Check condition of washers on bolts and use new bolts,
if necessary. (4) Fluid leakage due to case or front pump housing
porosity.
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
² Torque converter weld leaks at the out side (periph-
eral) weld.
² Torque converter hub weld.
Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter. If the torque converter must be replaced, refer
to Torque Converter Clutch Break-in Procedure
in this section. This procedure will reset the
transmission control module break-in status.
Failure to perform this procedure may cause
transaxle shutter.
AIR PRESSURE TEST OF TRANSAXLE
Fabricate equipment needed for test as shown in
Figures 5 and 6. The transaxle should be prepared for pressure test as
follows after removal of the torque converter: (1) Plug dipstick tube and plug oil cooler line fitting.
Remove vent from manual shaft and in stall a 1/8 inch
pipe plug.Fig. 4 Leak Locating Test Probe Tool
Ä TRANSAXLE 21 - 97

CAUTION: Prevent manual shaft rotation during in-
stallation and removal. (2) With rotary motion, install converter hub seal
cup over input shaft. It must go through the con-
verter hub seal until the cup bottoms against the
pump gear lugs. Secure with cup retainer strap using
starter upper hole and opposite bracket hole. (3) Attach and clamp hose from nozzle of Tool
C-4080 to the upper cooler line fitting position in
case.
CAUTION: Do not, under any circumstances, pres-
surize a transaxle to more than 10 psi.
(4) Pressurize the transaxle using Tool C-4080 un-
til the pressure gauge reads 8 psi. Position transaxle
so that pump housing and case front may be covered
with soapy solution of water. Leaks are sometimes
caused by porosity in the case or pump housing. If a leak source is located, that part and all associ-
ated seals, O-rings, and gaskets should be replaced
with new parts.
GEARSHIFT LINKAGE ADJUSTMENT
Normal operation of the transmission range switch
(PRNDL) and park/neutral position switch provides a
quick check to confirm proper manual linkage adjust-
ment. Move the selector level slowly upward until it
clicks into the ``P'' Park notch in the selector gate. If
the starter will operate the ``P'' position is correct. After checking ``P'' position, move selector toward
``N'' Neutral position until lever drops in the ``N''
stop. If the starter will also operate at this point the
gearshift linkage is properly adjusted.
CAUTION:When it is necessary to disassemble link-
age cable from levers, which use plastic grommets
as retainers, the grommets should be replaced with
new grommets. Use a prying tool to force rod from
grommet in lever, then cut away old grommet. Use
pliers to snap new grommet into lever and rod into
grommet.
(1) Set parking brake.
(2) Place gearshift lever in P(PARK) position.
(3) Loosen clamp bolt on gearshift cable bracket.
(4) Column shift: Insure that preload adjustment
spring engages fork on transaxle bracket. (5) Pull the shift lever by hand to the front detent
position (PARK) and tighten lock screw to 11 N Im
(100 in. lbs.). Gearshift linkage should now be prop-
erly adjusted. (6) Check adjustment as follows:(a) Detent position for neutral and drive should
be within limits of hand lever gate stops. (b) Key start must occur only when shift lever is
in park or neutral positions.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum tran-
saxle case and valve body can be repaired by the use
of Heli-Coils, or equivalent. This repair consists of
drilling out the worn-out damaged threads. Then tap
the hole with a special Heli-Coil tap, or equivalent,
and installing a Heli-Coil insert, or equivalent, into
the hole. This brings the hole back to its original
thread size. Heli-Coil, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
COOLERS AND TUBES REVERSE FLUSHING
When a transaxle failure has contaminated the
fluid, the oil cooler(s) must be flushed and the cooler
bypass valve in the transaxle must be replaced. The
torque converter must also be replaced with an ex-
change unit. This will insure that metal particles or
sludged oil are not later transferred back into the re-
conditioned (or replaced) transaxle.
Fig. 5 Torque Converter Hub Seal Cup
Fig. 6 Hub Seal Cup Retaining Strap
21 - 98 TRANSAXLE Ä

CAUTION: If the vehicle is equipped with two oil
coolers (one in the radiator tank, one in front of the
radiator) they must be flushed separately. Do not
attempt to flush both coolers at one time. (1) Disconnect the cooler lines at the transmission.
(2) Using a hand suction gun filled with mineral
spirits, reverse flush the cooler. Force mineral spirits
into the From Cooler line of the cooler (Fig. 7) and
catch the exiting spirits from the To Coolerline.
Observe for the presence of debris in the exiting
fluid. Continue until fluid exiting is clear and free
from debris.
(3) Using compressed air in intermittent spurts,
blow any remaining mineral spirits from the cooler,
again in the reverse direction. (4) To remove any remaining mineral spirits from
the cooler, one (1) quart of automatic transmission
fluid should be pumped through the cooler before re-
connecting. (5) If at any stage of the cleaning process, the
cooler does not freely pass fluid, the cooler must be
replaced.
OIL COOLER FLOW CHECK
After the new or repaired transmission has been
installed, filled to the proper level with automatic
transmission fluid. The flow should be checked using
the following procedure: (1) Disconnect the From coolerline at the trans-
mission and place a collecting container under the
disconnected line. (2) Run the engine at curb idle speed , with the
shift selector in neutral. (3) If the fluid flow is intermittent or it takes more
than 20 seconds to collect one quart of automatic
transmission fluid, the cooler should be replaced. CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(4) If flow is found to be within acceptable limits,
reconnect the cooler line. Then fill transmission to
the proper level, using the approved type of auto-
matic transmission fluid.
TRANSAXLE REMOVAL AND INSTALLATION
Transaxle removal does NOT require engine re-
moval. See Group 7-Cooling, to drain engine cooling sys-
tem and remove coolant return extension (3.0 liter
engine only). (1) The transaxle and torque converter must be re-
moved as an assembly; otherwise, the torque con-
verter drive plate, pump bushing or oil seal may be
damaged. The drive plate will not support a load;
therefore, none of the weight of the transaxle should
be allowed to rest on the drive plate during removal. (2) Disconnect negative battery cable.
(3) Disconnect transaxle shift linkage.
(4) Install engine support fixture and support en-
gine (Fig.1).
(5) Remove upper bell housing upper bolts.
(6) Raise vehicle. Remove front wheels. Refer to
Suspension, Group 2 to remove wheel hub nut and
both drive shafts. (7) Remove left plastic splash to gain access to the
transaxle (Fig. 2). (8) Remove torque converter dust shield to gain ac-
cess to torque converter bolts (Fig. 3). (9) Mark torque converter and drive plate with
chalk, for reassembly. Remove torque converter
mounting bolts. (10) Disconnect electrical connectors at transmis-
sion range switch and Park/Neutral Position Switch
(Fig. 4).
Fig. 7 Cooler Line Location
Fig. 1 Engine Support Fixture (Typical)
Ä TRANSAXLE 21 - 99

(11) Remove front engine mount insulator and
bracket (Fig. 5). (12) On vehicles equipped with D.I.S. ignition sys-
tem, remove crankshaft position sensor from bell
housing. For installation procedure refer to section
8D of this service manual.
CAUTION: Failure to remove the crankshaft position
sensor from the bell housing could damage the
sensor or torque converter drive plate during trans-
mission removal or installation.
(13) Remove starter bolts and set starter aside. Do
not allow the starter to hang from battery cable (Fig.
6). (14) Position transmission jack securely under
transaxle (Fig. 7). (15) With transmission jack in position, remove
the left transmission mount (Fig. 8). (17) Carefully lower the transaxle assembly from
vehicle (Fig. 9). When installing transaxle, reverse the above proce-
dure.
Fig. 2 Remove Left Splash Shield
Fig. 3 Remove Torque Converter Dust Shield
Fig. 4 Disconnect transmission range switch and Park/Neutral Position Switch
Fig. 5 Remove Front Engine Mount
21 - 100 TRANSAXLE Ä

If the torque converter has been replaced, refer
to Torque Converter Clutch Break-in Procedure
in this section. This procedure will reset the transmission control module break-in status.
Failure to perform this procedure may cause
transaxle shutter. Check and/or adjust gear shift cable.
Refill transaxle with MOPAR tATF PLUS (Auto-
matic Transmission Fluid) Type 7176.
SOLENOID ASSEMBLY-REPLACE
Fig. 9 Lower Transaxle Assembly
Fig. 1 Input Speed Sensor
Fig. 6 Remove Starter Assembly
Fig. 7 Position Transmission Jack
Fig. 8 Remove Left Transmission Mount
Ä TRANSAXLE 21 - 101

TRANSMISSION RANGE SWITCH
The transmission range switch is the white switch
located on the front of the transaxle, just above the
transaxle oil pan. CAUTION: Switch seal washer must be seated prop-
erly before tightening switch. Failure to do so may
result in leakage of transmission fluid (Fig. 6).
PARK/NEUTRAL POSITION SWITCH
The Park/Neutral Position Switch is the black
switch located to the right of the transmission range
switch.
CAUTION: Switch seal washer must be seated prop-
erly before tightening switch. Failure to do so may
result in leakage of transmission fluid (Fig. 7).
SPEED SENSOR-INPUT
CAUTION: When disconnecting speed sensor con-
nector, be sure that the weather seal does not fall
off or remain in old sensor.
The input speed sensor is located to the right of the
manual shift lever.
Fig. 2 Input Speed Sensor Removed
Fig. 3 Sound Cover
Fig. 4 Attaching Screws
Fig. 5 Solenoid Assembly
Fig. 6 Transmission Range Switch
21 - 102 TRANSAXLE Ä

SPEED SENSOR-OUTPUT
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 located to the left of the
manual shift lever (Fig. 8).
TRANSMISSION CONTROL MODULE
When replacing a transmission control module, do
not interchange transmission control modules with
previous year transmission control modules. If a
same year transmission control module is being used
from a different vehicle, the following procedures
must be performed before operating the transaxle:
² Quick Learn Procedure
² Torque Converter Clutch Break-in Procedure
² Electronic Pinion Procedure
The transmission control module is located on the
passenger side of the engine compartment. It is held
in place by four mounting screws. If the transmission control module has been
replaced, the following procedures must be per-
formed:
² ``Quick Learn Procedure''. This procedure will al-
low the transmission control module to learn the
characteristics of the vehicle.
² ``Electronic Pinion Procedure''. This procedure will
reprogram settings within the transmission control
module to compensate for different tire sizes and fi-
nal drive ratios.
² ``Converter Clutch Break-In Procedure'' This proce-
dure will reset the torque converter clutch status.
REMOVAL AND INSTALLATION
(1) Loosen 60 way retaining screw, located in the
center of the 60 way connector. Then disconnect the
60 way connector on transmission control module. (2) Remove transmission control module mounting
screws and lift module from vehicle. To install, reverse removal procedure.
TRANSAXLE QUICK LEARN PROCEDURE
The quick learn procedure requires the use of the
DRB II scan tool and the 1993 DRB II scan tool car-
tridge. This program allows the electronic transaxle sys-
tem to recelebrate itself to provide the best possible
transaxle operation. The quick learn procedure
should be performed if any of the following proce-
dures are performed:
² Transaxle Assembly Replacement
² Transmission Control Module Replacement
² Solenoid Pack Replacement
² Clutch Plate and/or Seal Replacement
² Valve Body Replacement or Recondition
(1) Plug the DRB II scan tool into the blue CCD
Buss connector. The connector is located under the
instrument panel on the drivers side of the vehicle. (2) Insert the 1993 DRB II scan tool cartridge into
the DRB II scan tool. (3) The red and green lights on the DRB II scan
tool will light up and then begin flashing. Wait until
the lights stop flashing before continuing with this
procedure. (4) Press the number 4 key on the DRB II scan
tool key pad. Item number 4 will not appear on the
DRB II scan tool screen unless you scroll down. It is
not necessary to scroll down to be able to choose item
4. (5) Press the number 2 on the DRB II scan tool
key pad (Transmission). (6) Press the number 1 on the DRB II scan tool
key pad. Wait for the DRB II scan tool to perform the
following three tests before continuing (These tests
are done automatically by the DRB II scan tool).
² Buss Test
² Initialize
² Controller Part Number
Fig. 7 Park/Neutral Position Switch
Fig. 8 Output Speed Sensor
Ä TRANSAXLE 21 - 103

(7) Press the number 5 on the DRB II scan tool
key pad (Adjustments). (8) Press the number 3 on the DRB II scan tool
key pad (Quick Learn). Then follow the instructions
on the DRB II scan tool screen.
PINION FACTOR PROCEDURE
The vehicle speed readings for the speedometer are
taken from the output speed sensor. Because of dif-
ferent tire sizes and final drive ratios, the transmis-
sion control module must be calibrated to reflect the
different combinations of equipment. A procedure has
been developed called Pinion Factor. It allows the
technician to set the transmission control module ini-
tial setting so that the speedometer readings will be
correct. Failure to perform this procedure will cause a ``No
Speedometer Operation'' condition. This procedure must be performed if the transmis-
sion control module has been replaced. To properly read or reset the Pinion Factor, it is
necessary to use a DRB II scan tool. Perform the fol-
lowing steps with the DRB II scan tool to read or re-
set the Pinion Factor: (1) Plug the DRB II scan tool into the blue CCD
Bus connector. The connector is located under the in-
strument panel on the drivers side of the vehicle. (2) Insert the 1993 DRB II scan tool cartridge into
the DRB II scan tool. (3) The red and green lights on the DRB II scan
tool will light up and then begin flashing. Wait until
the lights stop flashing before continuing with this
procedure. (4) Press the number 4 key (Select System) on the
DRB II scan tool key pad. Item number 4 will not ap-
pear on the DRB II scan tool screen unless you scroll
down. It is not necessary to scroll down to be able to
choose item 4. (5) Press the number 2 on the DRB II scan tool
key pad (Transmission). (6) Press the number 1 on the DRB II scan tool
key pad. Wait for the DRB II scan tool to perform the
following three tests before continuing (These tests
are done automatically by the DRB II scan tool).
² Bus Test
² Initialize
² Transmission Control Module Part Number
(7) Press the number 5 on the DRB II scan tool
key pad (Adjustments). (8) Press the number 2 on the DRB II scan tool
key pad (Pinion Factor). Then follow the instructions
on the DRB II scan tool screen.
TORQUE CONVERTER CLUTCH BREAK-IN
PROCEDURE
A torque converter clutch break-in program is be-
ing used on all models with a 41TE. This program
will properly condition the torque converter clutch. This will eliminate shudder during partial torque
converter clutch operation on a new torque converter.
If the torque converter is replaced, the new clutch
within the torque converter will require break-in.
The current break-in status stored in the transmis-
sion control module will have to be reset to the start
of break-in with the DRB II scan tool. If a new transmission control module is put on the
vehicle, the status will be at the start of break-in.
This status is acceptable regardless of the mileage on
the torque converter. No modification of the break-in
status is required. To properly service these vehicles, it is necessary to
use a DRB II scan tool to read or reset the break-in
status. Perform the following steps with the DRB II
scan tool to reset the break-in status: (1) Plug the DRB II scan tool into the blue CCD
Bus connector. The connector is located under the in-
strument panel on the drivers side of the vehicle. (2) Insert the 1993 DRB II scan tool cartridge into
the DRB II scan tool. (3) The red and green lights on the DRB II scan
tool will light up and then begin flashing. Wait until
the lights stop flashing before continuing with this
procedure. (4) Press the number 4 key (Select System) on the
DRB II scan tool key pad. Item number 4 will not ap-
pear on the DRB II scan tool screen unless you scroll
down. It is not necessary to scroll down to be able to
choose item 4. (5) Press the number 2 on the DRB II scan tool
key pad (Transmission). (6) Press the number 1 on the DRB II scan tool
key pad. Wait for the DRB II scan tool to perform the
following three tests before continuing (These tests
are done automatically by the DRB II scan tool).
² Bus Test
² Initialize
² Transmission Control Module Part Number
(7) Press the number 5 on the DRB II scan tool
key pad (Adjustments). (8) Press the number 1 on the DRB II scan tool
key pad (Reset LU Clutch). The DRB II scan tool will
display one of three screens. (a) LU Clutch Break-in Status: Start
(b) LU Clutch Break-in Status: In-progress
Press ENTER to Reset Break-in status (c) LU Clutch Break-in Status: CompletePress
ENTER to Reset Break-in status
If screen (a) appears, the transmission control mod-
ule is at the beginning of its break-in program. No
further action is required. If screen (b) appears, the transmission control mod-
ule is in the middle of a its break-in program. Press
the enter key on the DRB II scan tool key pad to re-
turn the status to the start of break-in.
21 - 104 TRANSAXLE Ä

If screen (c) appears, the transmission control mod-
ule has completed its break-in status program. Press
the enter key on the DRB II scan tool key pad to return
the status to the start of break-in. (9) After pressing the enter key a second time in step
8 a screen will appear that says ``RESET LU CLUTCH
ARE YOU SURE ?''. Press the enter key on the DRB II
scan tool key pad. The DRB II scan tool will then carry
out the reset command. (10) After the DRB II scan tool completes the reset
command, a screen will appear saying ``LU Clutch
Break-in Status has been RESET to Start''. This screen
will indicate that the reset procedure has been success-
fully completed. (11) Disconnect the DRB II scan tool from the blue
CCD Bus connector.
TRANSAXLE RECONDITION
Tag all clutch pack assemblies, as they are
removed, for reassembly identification.
CAUTION: Do not intermix clutch discs or plates as
the unit might then fail.
Fig. 1 Oil Pan Bolts
Fig. 2 Oil Pan
Fig. 3 Oil Filter
Fig. 4 Valve Body Attaching Bolts
Fig. 5 Push Park Rod Rollers from Guide Bracket
Ä TRANSAXLE 21 - 105

41TE ON-BOARD DIAGNOSTICS INDEX
page page
CCD Bus .............................. 145
Diagnostic Trouble Code Charts ............ 146
Diagnostic Trouble Codes ................. 145
DRB II Scan Tool ....................... 146 General Information
...................... 145
Limp-In Mode .......................... 145
On-Board Diagnostics Information ........... 145
GENERAL INFORMATION
The information in this manual is designed to help
the technician understand and repair the transaxle
with the aid of the built in on-board diagnostics. Chrysler Corporation has developed a com-
plete set of diagnostic manuals which cover the
diagnosis of the 41TE transaxle. They have been
designed to make transaxle diagnosis accurate
and simple. Use these manuals with the DRB II
scan tool and the latest cartridge, when diagnos-
ing transaxle problems.
ON-BOARD DIAGNOSTICS INFORMATION
The 41TE transaxle is controlled and monitored by
the transmission control module. The transmission
control module monitors critical input and output
circuits within the transaxle. Some circuits are tested continuously; others are
checked only under certain conditions. Each circuit
monitored by the transmission control module has a
corresponding fault message assigned to it that can be
read with the DRB II scan tool. If the on-board diagnostic system senses that one of
the circuits is malfunctioning, the corresponding code
is stored in memory. If the malfunction goes away after
the code is stored, the transmission control module will
erase the code after 75 key cycles.
CCD BUS
In order to diagnose the 41TE transaxle, diagnostic
trouble codes in the transmission control module's
memory should be read. Use the Diagnostic Readout
Box (DRB II) scan tool to read codes. If more than one
diagnostic trouble code exists, diagnostic priority
should be given to the most recent code. With CCD bus
bias and communication problems, the DRB II scan
tool displays an appropriate message. Diagnostic
trouble codes might not be accessible until the bus
problem is fixed. The following is a list of probable
causes for a bus problem:
² Open or short to ground/battery in either or both
CCD bus wires (pins 4 and 43).
² Open or short to ground/battery in either or both
41TE transaxle's bias wires (pin 5 and 44) on vehicles
requiring the transaxle to bias the bus.
² Open or short to ground/battery in the diagnostic
connector bus wire. ²
Internal failure of any module connected to the bus.
The CCD bus should have 2.5 volts (+2.5 volts on
CCD+ and -2.5 volts on CCD-). The bus error message displayed by the DRB II scan
tool should be helpful in diagnosing the CCD bus. For more information on diagnosing CCD bus prob-
lems, refer to the 1993 Diagnostic Procedures Manual
(non-communication with the CCD bus). All other
problems refer to the 1993 Body Vehicle Communica-
tions Diagnostic Procedures Manual.
DIAGNOSTIC TROUBLE CODES
Diagnostic Trouble Codes are two-digit numbers that
identify which circuit is malfunctioning. A code can be
set for hydraulic and mechanical reasons as well as for
electrical problems. In most cases, codes do not pin-
point which specific component is defective. Diagnostic trouble codes can only be read with
the use of the DRB II scan tool or equivalent.
HARD FAULTS
Any Diagnostic trouble code that comes back within
3 engine starts (reset count 3 or less) is a ``Hard Fault''.
This means that the defect is there every time the
transmission control module checks that circuit.
SOFT FAULTS
A ``Soft Fault'' is one that occurs intermittently. It is
not there every time the transmission control module
checks the circuit. Most soft faults are caused by wiring
or connector problems. Intermittent defects must be
looked for under the specific conditions that caused
them.
LIMP-IN MODE
The transmission control module continuously
checks for electrical and internal transaxle problems.
When a problem is sensed, the transmission control
module stores a diagnostic trouble code. All but twelve
of these codes cause the transaxle to go into the
``Limp-in mode''. While in this mode, electrical power is
taken away from the transaxle. When this happens,
the only transaxle ranges that will function are:
Ä TRANSAXLE 21 - 145