clutch CHRYSLER CARAVAN 2002 Service Manual

(13) Install halfshafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(14) Lower vehicle.
(15) Torque rear mount bracket-to-transaxle verti-
cal bolts (Fig. 98) to 102 N´m (75 ft. lbs.).
(16) Connect back up lamp switch connector.
(17) Connect gearshift cable to manual valve and
left upper mount bracket (Fig. 102).
(18) Connect throttle valve cable to lever and
bracket (Fig. 103).
(19) Connect torque converter clutch connector.
(20) Install fluid level indicator/tube assembly
(Fig. 104).
(21) Raise vehicle on hoist.
(22) Torque rear mount bracket-to-transaxle case
horizontal bolt (Fig. 98) to 102 N´m (75 ft. lbs.).
(23) Torque rear mount thru-bolt to 54 N´m (40 ft.
lbs.).
(24) Lower vehicle.
(25) Connect battery negative cable.
(26) Fill transaxle with ATF+4 transmission fluid.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/FLUID - STANDARD PROCEDURE)
Fig. 102 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 103 Kickdown Cable at TransaxleÐTypical
1 - LEVER
2 - BRACKET
3 - THROTTLE VALVE CABLE
Fig. 104 Fluid Level Indicator Assembly
1 - INDICATOR ASSEMBLY
2 - BOLT
3 - KICKDOWN CABLE BRACKET
4 - SEAL
RS31TH AUTOMATIC TRANSAXLE21-63
31TH AUTOMATIC TRANSAXLE (Continued)
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SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE
GENERAL SPECIFICATIONS
Transaxle TypeThree speed automatic with torque converter and
integral differential
Cooling Method Air to oil heat exchanger
Lubrication Method Pump (internal-external gear-type)
GEAR RATIOS
1st Gear 2.69
2nd Gear 1.55
3rd Gear 1.00
Reverse Gear 2.10
BAND ADJUSTMENT
Kickdown (Front)ÐBacked Off From 8 N²m (72 in. lbs.) 21¤4turns
Low-Reverse (Rear)ÐBacked Off From 5 N²m (41 in.
lbs.)3
1¤2Turns
BEARING SETTINGS (END PLAY & TURNING TORQUE)
Description Metric Standard
Differential Assembly 0.7-1.4 N´m 6-12 in. lbs.
Output Shaft 0-0.3 N´m 0-3 in. lbs.
Transfer Shaft 0.051-0.254 mm 0.002-0.010 in. (end play)
Overall Drag At Output Hub 0.03-1.8 N´m 3-16 in. lbs.
CLUTCH CLEARANCES
Description Metric Standard
Front Clutch (Not Adjustable) 1.27-2.79 mm 0.050-0.110 in.
Rear Clutch 0.71-1.10 mm 0.028-0.043 in.
END PLAY
Description Metric Standard
Input Shaft 0.19-1.50 mm 0.008-0.060 in.
Front Clutch Retainer 0.76-2.69 mm 0.030-0.106 in.
Front Carrier 0.18-1.45 mm 0.007-0.057 in.
Front Annulus Gear 0.09-0.50 mm 0.0035-0.020 in.
Planet Pinion 0.15-0.59 mm 0.006-0.023 in.
Reverse Drum 0.76-3.36 mm 0.030-0.132 in.
21 - 72 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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OIL PUMP CLEARANCE
Description Metric Standard
Outer Gear-to-Pocket 0.045-0.141mm 0.0018-0.0056 in.
Outer Gear Side Clearance 0.020-0.046mm 0.0008-0.0018 in.
Inner Gear Side Clearance 0.020-0.046mm 0.0008-0.0018 in.
THRUST WASHERS
Description Metric Standard
Reaction Shaft Support (No. 1) 1.34-1.62 mm 0.053-0.064 in.
Rear Clutch Retainer (No. 2) 1.53-1.62 mm 0.060-0.064 in.
Output Shaft (No. 3) (Select) 1.96-2.03 mm 0.077-0.080 in
Output Shaft (No. 3) (Select) 2.15-2.22 mm 0.085-0.087 in.
Output Shaft (No. 3) (Select) 2.34-2.41 mm 0.092-0.095 in.
Front Annulus (No. 4) 2.95-3.05 mm 0.116-0.120 in.
Front Carrier (Nos. 5&6) 1.21-1.28 mm 0.048-0.050 in.
Sun Gear-Front (No. 7) 0.85-0.91 mm 0.033-0.036 in
Sun Gear-Rear (No. 8) 0.85-0.91 mm 0.033-0.036 in.
Rear Carrier (Nos. 9&10) 1.21-1.28 mm 0.048-0.050 in.
Rev. Drum (No. 11) 1.53-1.62 mm 0.060-0.064 in.
RS31TH AUTOMATIC TRANSAXLE21-73
31TH AUTOMATIC TRANSAXLE (Continued)
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ACCUMULATOR
DESCRIPTION
The accumulator (Fig. 105) is a hydraulic device
that has the sole purpose of cushioning the applica-
tion of a band or clutch. The accumulator consists of
a dual-land piston and a spring located in a bore in
the transmission case.
OPERATION
Line pressure is directed between the lands of the
piston (Fig. 106), bottoming it against the accumula-
tor plate. The accumulator stays in this position after
the transmission is placed into a Drive position.
When the 1-2 upshift occurs (Fig. 107), line pressure
is directed to the large end of the piston and then to
the kickdown servo. As the line pressure reaches the
accumulator, the combination of spring pressure and
line pressure forces the piston away from the accu-
mulator plate. This causes a balanced pressure situ-
ation, which results in a cushioned band application.
After the kickdown servo has become immovable, line
pressure will finish pushing the accumulator up into
its bore. When the large end of the accumulator pis-
ton is seated in its bore, the band or clutch is fully
applied.
NOTE: The accumulator is shown in the inverted
position for illustrative purposes.
Fig. 105 Accumulator
1 - ACCUMULATOR PISTON
2 - PISTON SPRINGFig. 106 Accumulator in Neutral and Drive Positions
Fig. 107 Accumulator in Second Gear Position
1 - BOTTOM IN BORE
2 - SHUTTLE VALVE
RS31TH AUTOMATIC TRANSAXLE21-79
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BANDS
DESCRIPTION
KICKDOWN (FRONT) BAND
DESCRIPTION
The kickdown, or ªfrontº, band (Fig. 108) holds the
common sun gear of the planetary gear sets. The
front (kickdown) band is made of steel, and faced on
its inner circumference with a friction-type lining.
One end of the band is anchored to the transmission
case, and the other is acted on with a pushing force
by a servo piston. The front band is a single-wrap
design (the band does not completely encompass/
wrap the drum that it holds).
OPERATION
The kickdown band holds the common sun gear of
the planetary gear sets by applying and holding the
front clutch retainer, which is splined to the sun gear
driving shell, and in turn splined directly to the sun
gear. The application of the band by the servo is typ-
ically done by an apply lever and link bar.
OPERATION
LOW/REVERSE (REAR) BAND
DESCRIPTION
The low/reverse band, or ªrearº, band (Fig. 109) is
similar in appearance and operation to the front
band. The rear band is also a single-wrap design (the band does not completely encompass/wrap the
drum that it holds).
OPERATION
The rear band holds the rear planet carrier sta-
tionary by being mounted around and applied to the
low/reverse drum.
ADJUSTMENTS
ADJUSTMENT - FRONT BAND
The front (kickdown) band adjusting screw is
located on the left side of the transmission case
above the manual valve and throttle valve levers.
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly.
(3) Loosen band adjusting screw locknut (Fig. 110).
Then back locknut off 3-5 turns. Be sure adjusting
screw turns freely in case. Apply lubricant to screw
threads if necessary.
(4) Tighten band adjusting screw to 8 N´m (72 in.
lbs.).
(5) Back off front band adjusting screw 2
1¤4turns.
(6) Hold adjuster screw in position and tighten
locknut to 47 N´m (35 ft. lbs.) torque.
(7) Install air cleaner assembly.
(8) Connect battery negative cable.
ADJUSTMENTS - REAR BAND
The transmission oil pan must be removed for
access to the rear (low/reverse) band adjusting screw.
(1) Raise vehicle.
Fig. 108 Front BandÐTypical
1 - FRONT BAND
2 - TRANSMISSION HOUSING
Fig. 109 Rear Band
1 - PLANETARY GEARTRAIN
2 - REAR BAND
3 - LEVER
4 - SERVO
5 - ADJUSTER
21 - 80 31TH AUTOMATIC TRANSAXLERS
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CLUTCH - FRONT
DESCRIPTION
The front clutch assembly (Fig. 119) is composed of
the front clutch retainer, pressure plate, clutch
plates, driving discs, piston, piston return spring,
return spring retainer, and snap-rings. The front
clutch is the forward-most component in the trans-
mission geartrain and is directly behind the oil
pump. It is considered a driving component.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
OPERATION
To apply the clutch, pressure is applied between
the clutch retainer and piston. The fluid pressure is
provided by the oil pump, transferred through the
control valves and passageways, and enters the
clutch through the hub of the reaction shaft support.
With pressure applied between the clutch retainer
and piston, the piston moves away from the clutch
retainer and compresses the clutch pack. This action
applies the clutch pack, allowing torque to flow
through the input shaft into the driving discs, and
into the clutch plates and pressure plate that are
lugged to the clutch retainer. The waved snap-ring is
used to cushion the application of the clutch pack. In
some transmissions, the snap-ring is selective and
used to adjust clutch pack clearance.
When pressure is released from the piston, the
spring returns the piston to its fully released position
and disengages the clutch. The release spring also
helps to cushion the application of the clutch assem-
bly. When the clutch is in the process of being
released by the release spring, fluid flows through a
vent and one-way ball-check-valve located in the
clutch retainer. The check-valve is needed to elimi-
nate the possibility of plate drag caused by centrifu-
gal force acting on the residual fluid trapped in the
clutch piston retainer.
DISASSEMBLY
(1) Remove front clutch waved snap ring using a
suitable screwdriver (Fig. 114).
(2) Remove waved snap ring and reaction plate
(Fig. 115).
Fig. 114 Front Clutch Waved Snap Ring
1 - WAVED SNAP RING
2 - SCREWDRIVER
3 - FRONT CLUTCH ASSEMBLY
Fig. 115 Thick Steel Plate and Waved Snap Ring
1 - WAVED SNAP RING
2 - THICK STEEL PLATE
3 - FRONT CLUTCH RETAINER
21 - 82 31TH AUTOMATIC TRANSAXLERS
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(3) Remove clutch pack (Fig. 116).
(4) Using tool C3575A, compress front clutch
return spring and remove snap ring (Fig. 117).(5) Remove retainer, return spring and piston (Fig.
118) (Fig. 119).
Fig. 116 Front Clutch (4-Disc Shown)
1 - FRONT CLUTCH RETAINER
2 - CLUTCH PLATES
3 - DRIVING DISCS
Fig. 117 Front Clutch Return Spring Snap Ring
1 - COMPRESSOR TOOL C-3575-A
2 - FRONT CLUTCH RETAINER
3 - SNAP RING
4 - SNAP RING PLIERS
Fig. 118 Front Clutch Return Spring and Piston
1 - LIP SEALS
2 - PISTON
3 - RETURN SPRING RETAINER
4 - SNAP RING
5 - PISTON RETURN SPRING
6 - FRONT CLUTCH RETAINER
RS31TH AUTOMATIC TRANSAXLE21-83
CLUTCH - FRONT (Continued)
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ASSEMBLY
(1) Install front clutch piston, return spring, and
retainer (Fig. 119) (Fig. 120).
Fig. 119 Front Clutch Assembly
1 - SNAP RING (WAVE) 5 - SEAL 9 - SPRING
2 - REACTION PLATE 6 - CLUTCH RETAINER 10 - SNAP RING
3 - CLUTCH DISC 7 - SEAL 11 - SPRING RETAINER
4 - CLUTCH PLATE 8 - PISTON
21 - 84 31TH AUTOMATIC TRANSAXLERS
CLUTCH - FRONT (Continued)
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(2) Compress front clutch return spring using Tool
C3575A and install snap ring (Fig. 121).(3) Install front clutch pack (Fig. 122).
(4) Install reaction plate and waved snap ring (Fig.
123) (Fig. 124).
Fig. 120 Front Clutch Return Spring and Piston
1 - LIP SEALS
2 - PISTON
3 - RETURN SPRING RETAINER
4 - SNAP RING
5 - PISTON RETURN SPRING
6 - FRONT CLUTCH RETAINER
Fig. 121 Front Clutch Return Spring Snap Ring
1 - COMPRESSOR TOOL C-3575-A
2 - FRONT CLUTCH RETAINER
3 - SNAP RING
4 - SNAP RING PLIERS
Fig. 122 Front Clutch (4-Disc Shown)
1 - FRONT CLUTCH RETAINER
2 - CLUTCH PLATES
3 - DRIVING DISCS
Fig. 123 Thick Steel Plate and Waved Snap Ring
1 - WAVED SNAP RING
2 - THICK STEEL PLATE
3 - FRONT CLUTCH RETAINER
RS31TH AUTOMATIC TRANSAXLE21-85
CLUTCH - FRONT (Continued)
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(5) Using feeler gauge, measure front clutch clear-
ance (Fig. 125).Front clutch clearance should be
within 1.27-2.79 mm (0.050-0.110 in.) and is not
adjustable.
CLUTCH - REAR
DESCRIPTION
The rear clutch assembly (Fig. 132) is composed of
the input shaft, rear clutch retainer, pressure plate,
clutch plates, driving discs, piston, Belleville spring,
and snap-rings. The Belleville spring acts as a lever
to multiply the force applied on to it by the apply pis-
ton. The increased apply force on the rear clutch
pack, in comparison to the front clutch pack, is
needed to hold against the greater torque load
imposed onto the rear pack. The rear clutch is
directly behind the front clutch and is considered a
driving component.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
OPERATION
To apply the clutch, pressure is applied between
the clutch retainer and piston. The fluid pressure is
provided by the oil pump, transferred through the
control valves and passageways, and enters the
clutch through the hub of the reaction shaft support.
With pressure applied between the clutch retainer
and piston, the piston moves away from the clutch
retainer and compresses the clutch pack. This action
applies the clutch pack, allowing torque to flow
through the input shaft into the driving discs, and
into the clutch plates and pressure plate that are
lugged to the clutch retainer. The waved snap-ring is
used to cushion the application of the clutch pack. In
some transmissions, the snap-ring is selective and
used to adjust clutch pack clearance.
When pressure is released from the piston, the
spring returns the piston to its fully released position
and disengages the clutch. The release spring also
helps to cushion the application of the clutch assem-
bly. When the clutch is in the process of being
released by the release spring, fluid flows through a
vent and one-way ball-check-valve located in the
clutch retainer. The check-valve is needed to elimi-
nate the possibility of plate drag caused by centrifu-
gal force acting on the residual fluid trapped in the
clutch piston retainer.
Fig. 124 Front Clutch Waved Snap Ring
1 - WAVED SNAP RING
2 - SCREWDRIVER
3 - FRONT CLUTCH ASSEMBLY
Fig. 125 Measuring Front Clutch Plate Clearance
1 - FEELER GAUGE
2 - FRONT CLUTCH ASSEMBLY
21 - 86 31TH AUTOMATIC TRANSAXLERS
CLUTCH - FRONT (Continued)
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