differential CHRYSLER CARAVAN 2002 Workshop Manual

(4) Read pressures on both gauges as throttle lever
on transaxle is moved from full clockwise position to
full counterclockwise position.
(5) Line pressure should read 52 to 58 psi with
throttle lever clockwise. Pressure should gradually
increase to 80 to 88 psi. as lever is moved counter-
clockwise.
(6) Lubrication pressure should be 10 to 25 psi
with lever clockwise and 10 to 35 psi with lever at
full counterclockwise.
(7) This tests pump output, pressure regulation,
and condition of rear clutch and lubrication hydraulic
circuits.
TEST THREE (SELECTOR IN D)
(1) Attach gauges to line and kickdown release
ports.
(2) Operate engine at 1600 rpm for test.
(3) Move selector lever on transaxle two detents
forward from full rearward position. This is selector
D position.
(4) Read pressures on both gauges as throttle lever
on transaxle is moved from full clockwise to the full
counterclockwise position.
(5) Line pressure should read 52 to 58 psi with
throttle lever clockwise. Pressure should gradually
increase to 80 to 88 psi. as lever is moved counter-
clockwise.
(6) Kickdown release is pressurized only in direct
drive and should be same as line pressure within 3
psi, up to kickdown point.
(7) This tests pump output, pressure regulation,
and condition of rear clutch, front clutch, and
hydraulic circuits.
TEST FOUR (SELECTOR IN REVERSE)
(1) Attach 300 psi gauge (C-3292SP) to low-reverse
port.
(2) Operate engine at 1600 rpm for test.
(3) Move selector lever on transaxle four detents
forward from full rearward position. This is selector
R position.
(4) Low/reverse pressure should read 180 to 220
psi with throttle lever clockwise. Pressure should
gradually increase to 260 to 300 psi. as lever is
moved counterclockwise.(5) This tests pump output, pressure regulation,
and condition of front clutch and rear servo hydraulic
circuits.
(6) Move selector lever on transaxle to D position
to check that low/reverse pressure drops to zero.
(7) This tests for leakage into rear servo, due to
case porosity, which can cause reverse band burn out.
TEST RESULT INDICATIONS
(1) If proper line pressure, minimum to maximum,
is found in any one test, the pump and pressure reg-
ulator are working properly.
(2) Low pressure in D, 1, and 2 but correct pres-
sure in R, indicates rear clutch circuit leakage.
(3) Low pressure in D and R, but correct pressure
in 1 indicates front clutch circuit leakage.
(4) Low pressure in R and 1, but correct pressure
in 2 indicates rear servo circuit leakage.
(5) Low line pressure in all positions indicates a
defective pump, a clogged filter, or a stuck pressure
regulator valve.
GOVERNOR PRESSURE
Test only if transaxle shifts at wrong vehicle
speeds when throttle cable is correctly adjusted.
(1) Connect a 100 psi gauge to governor pressure
port. It is located at lower right side of case, below
differential cover (Fig. 2).
(2) Operate transaxle in third gear to read pres-
sures. The governor pressure should respond
smoothly to changes in mph and should return to 0
to 3 psi when vehicle is stopped. High pressure
(above 3 psi) at standstill will prevent the transaxle
from downshifting.
THROTTLE PRESSURE
No gauge port is provided for throttle pressure.
Incorrect throttle pressure should be suspected if
part throttle upshift speeds are either delayed or
occur too early in relation to vehicle speed. Engine
runaway on shifts can also be an indicator of low
throttle pressure setting, or misadjusted throttle
cable.
In no case should throttle pressure be adjusted
until the transaxle throttle cable adjustment has
been verified to be correct.
21 - 34 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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(21) Remove left upper mount thru-bolt (Fig. 14).
(22) Lower engine/transaxle assembly.
(23) Obtain transmission jack and helper.
(24) Remove remaining transaxle-to-engine bolts
and remove transaxle assembly from vehicle.
DISASSEMBLY
CAUTION: If transaxle failure has occured, it is nec-
essary to flush the transaxle oil cooler and lines to
remove debris and particles that could contaminate
and/or fail a new or rebuilt unit. (Refer to 7 - COOL-
ING/TRANSMISSION - STANDARD PROCEDURE)
NOTE: This procedure does not include disassem-
bly of final drive (differential) components. (Refer to
21 - TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/FINAL DRIVE - DISASSEMBLY)
(1)
Measure input shaft end play before disassembly
using Tool 8266 and dial indicator C-3339 (Fig. 15):
(a) Set up tools as shown in (Fig. 15).
(b) Move input shaft in and out to obtain end
play reading. End play specifications are 0.19 to
1.50 mm (0.008 to 0.060 inch).
(c) Record indicator reading for reference when
reassembling the transaxle.
(2)
Remove transaxle oil pan-to-case bolts (Fig. 16).
Fig. 14 Left Rail-to-Mount
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
Fig. 15 Measure Input Shaft End Play using End
Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
Fig. 16 Transaxle Oil Pan Bolts
1 - TRANSAXLE OIL PAN
2 - OIL PAN BOLTS
21 - 40 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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(27) Install Tool C-3752 and adapters L-4437 as
shown in (Fig. 41).
(28) Remove oil pump with slide hammer setup
(Fig. 42). Inspect #1 thrust washer.(29) Remove oil pump gasket (Fig. 43).
(30) Remove kickdown band and strut (Fig. 44).
Fig. 41 Install Tool C-3752 with Adapters L-4437
1 - PUMP
2 - PULLERS TOOL C-3752
3 - ADAPTERS TOOL L-4437
Fig. 42 Oil Pump Removal
1 - FRONT CLUTCH
2 - OIL PUMP ASSEMBLY
Fig. 43 Oil Pump Gasket
1 - SPLIT IN GASKET (DIFFERENTIAL OIL FEED)
2 - PUMP GASKET
3 - PUMP GASKET DIFFERENTIAL OIL FEED CUTOUT
Fig. 44 Kickdown Band and Strut
1 - FRONT CLUTCH
2 - KICKDOWN BAND
3 - OIL RETURN AND FEED HOLE TO DIFFERENTIAL
4 - STRUT
RS31TH AUTOMATIC TRANSAXLE21-47
31TH AUTOMATIC TRANSAXLE (Continued)
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(42) Remove low/reverse band (Fig. 57).
(43)
Remove and inspect #11 thrust washer (Fig. 58).
ASSEMBLY
CAUTION: If transaxle failure has occurred, it is nec-
essary to flush the transaxle oil cooler and lines to
remove debris and particles that could contaminate
and/or fail a new or rebuilt unit. (Refer to 7 - COOLING/
TRANSMISSION - STANDARD PROCEDURE)
NOTE: This procedure does not include assembly
of final drive (differential) components. (Refer to 21- TRANSMISSION/TRANSAXLE/AUTOMATIC - 31TH/
FINAL DRIVE - ASSEMBLY)
NOTE: This procedure does not include assembly
of transfer system (transfer shaft and output shaft)
components. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 31TH/TRANSFER SYSTEM -
INSTALLATION)
(1) Install #11 thrust washer (Fig. 59).
(2) Install low/reverse band (Fig. 60). Do not
install strut or adjust at this time.
Fig. 57 Low/Reverse Band and Strut
1 - #11 THRUST WASHER
2 - LOW-REVERSE BAND
3 - STRUT
Fig. 58 No. 11 Thrust Washer
1 - #11 THRUST WASHER
2 - OUTPUT SHAFT
Fig. 59 No. 11 Thrust Washer
1 - #11 THRUST WASHER
2 - OUTPUT SHAFT
Fig. 60 Low/Reverse Band and Strut
1 - #11 THRUST WASHER
2 - LOW-REVERSE BAND
3 - STRUT
RS31TH AUTOMATIC TRANSAXLE21-51
31TH AUTOMATIC TRANSAXLE (Continued)
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(13) Install rear clutch assembly (Fig. 69). Ensure
that all clutch discs are engaged to front planetary
gear splines or transaxle failure will result.
(14) Install #2 thrust washer (Fig. 69).
(15) Install front clutch assembly (Fig. 70). Ensure
that all clutch discs are engaged to rear clutch
retainer splines or transaxle failure will result.(16) Install kickdown band (Fig. 71). Do not install
strut or adjust at this time.
(17) Install oil pump gasket (Fig. 72).
Fig. 69 No. 2 Thrust Washer and Rear Clutch
1 - REAR CLUTCH ASSEMBLY
2 - #2 THRUST WASHER
Fig. 70 Front Clutch Assembly
1 - REAR CLUTCH ASSEMBLY
2 - FRONT CLUTCH ASSEMBLY
Fig. 71 Kickdown Band and Strut
1 - FRONT CLUTCH
2 - KICKDOWN BAND
3 - OIL RETURN AND FEED HOLE TO DIFFERENTIAL
4 - STRUT
Fig. 72 Oil Pump Gasket
1 - SPLIT IN GASKET (DIFFERENTIAL OIL FEED)
2 - PUMP GASKET
3 - PUMP GASKET DIFFERENTIAL OIL FEED CUTOUT
21 - 54 31TH AUTOMATIC TRANSAXLERS
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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TORQUE SPECIFICATIONS
Description N´m Ft. Lbs. In. Lbs.
Bolt, Differential Bearing Retainer-to-Case 34 Ð 300
Bolt, Differential Cover-to-Case 19 Ð 165
Bolt, Differential Ring Gear-to-Case 95 70 Ð
Bolt, Extension Housing-to-Case 28 Ð 250
Bolt, Drive Plate-to-Crankshaft 95 70 Ð
Bolt, Drive Plate-to-Torque Converter 68 50 Ð
Bolt, Governor-to-Support 7 Ð 60
Bolt, Output Gear Strap 23 17 Ð
Bolt, Oil Pan-to-Case 19 Ð 165
Bolt, Oil Pump-to-Case 31 Ð 275
Bolt, Park Rod Support-to-Case 28 Ð 250
Bolt, Reaction Support-to-Pump Body 28 Ð 250
Bolt, Sprag Retainer-to-Case 28 Ð 250
Bolt, Starter Motor-to-Transaxle 54 40 Ð
Bolt, Transaxle Case-to-Engine Block 95 70 Ð
Bolt, Transfer Gear Cover-to-Case 19 Ð 165
Bolt, Transfer Gear Strap 23 17 Ð
Bolt, Valve Body-to-Case 12 Ð 105
Fitting, Transaxle Oil Cooler-to-Case 7 Ð 60
Screw, Fluid Filter 5 Ð 45
Screw, Cooler Bypass Valve-to-Transfer Plate 5 Ð 40
Screw, Governor Counterweight 28 Ð 250
Screw, Manual Valve Lever-to-Shaft 12 Ð 105
Screw, Speedo Adapter-to-Extension Housing 7 Ð 60
Screw, Valve Body-to-Transfer Plate 5 Ð 45
Nut, Kickdown Band Adjuster Lock 47 35 Ð
Nut, Output Gear-to-Shaft 271 200 Ð
Nut, Reverse Band Adjuster Lock 14 Ð 125
Nut, Transfer Gear-to-Shaft 271 200 Ð
Plug, Pressure Tap 5 Ð 45
Plug, Rear Band Lever Pivot Shaft 7 Ð 60
Switch, Park/Neutral 34 25 Ð
21 - 74 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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Differential Tool L-4436A
Housing Remover Adapter L-4437
Starter Nut L-4439
Transfer Shaft Remover-Installer L-4512
Bearing Cup Remover L-4517
Special Jaw Set L-4518
Installer L-4520
End Play Socket Set 8266
Bearing Splitter P-334
21 - 78 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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(3) Install rear clutch pack (Fig. 137).
(4) Install snap ring using a suitable screwdriver
(Fig. 138).
(5) Using feeler gauges, measure rear clutch clear-
ance (Fig. 139).Rear clutch clearance should be
within 0.71-1.10 mm (0.028-0.043 in.).
FINAL DRIVE
DISASSEMBLY
NOTE: The differential is serviced as an assembly.
Service is limited to bearing cups and cones. Any
other failure must be repaired by differential assem-
bly and transfer shaft replacement.
(1) Remove transfer shaft.
(2) Measure differential bearing turning torque.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/BEARINGS - ADJUSTMENTS)
(3) Remove adapter plate seal.
(4) Remove differential cover-to-transaxle case
bolts (Fig. 140).
Fig. 137 Rear Clutch (4-Disc Shown)
1 - REAR CLUTCH RETAINER
2 - CLUTCH PLATES
3 - THICK STEEL PLATE
4 - SNAP RING (SELECTIVE)
5 - DRIVING DISCS
6 - PRESSURE PLATE
Fig. 138 Rear Clutch Outer Snap Ring
1 - SCREWDRIVER
2 - SNAP RING
3 - REAR CLUTCH ASSEMBLY
Fig. 139 Measuring Rear Clutch Plate Clearance
1 - REAR CLUTCH ASSEMBLY
2 - FEELER GAUGE
3 - SELECTIVE SNAP RING
Fig. 140 Differential Cover Bolts
1 - DIFFERENTIAL COVER
2 - DIFFERENTIAL COVER BOLT
RS31TH AUTOMATIC TRANSAXLE21-91
CLUTCH - REAR (Continued)
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(5) Remove differential cover (Fig. 141). Clean sur-
faces of old adhesive prior to reassembly.
(6) Remove bearing retainer axle seal using slide
hammer C-637 and Tool 7794A, or Tool L-4518.
(7) Remove differential bearing retainer-to-trans-
axle case bolts (Fig. 142).
(8) Remove bearing retainer from transaxle. Use to
L-4435 to aid in removal by rotating retainer out of
assembly (Fig. 143). Clean surfaces of old adhesive
prior to reassembly.
(9) Remove adapter plate-to-transaxle case bolts.WARNING: HOLD ON TO DIFFERENTIAL WHILE
REMOVING EXTENSION HOUSING TO PREVENT IT
FROM ROLLING OUT OF TRANSAXLE.
(10) Remove extension housing from transaxle
case. Use Tool L-4435 to aid in removal by rotating
plate out of assembly. Clean surfaces of old adhesive
prior to reassembly.
(11) Measure and record differential side gear end
play using dial indicator C-3339 and Tool C-4995 as
shown in (Fig. 144) and (Fig. 145).Side gear end
play must be within 0.001-0.013 in. Replace dif-
ferential assembly if outside this range.
Fig. 141 Remove Differential Cover
1 - GOVERNOR PRESSURE PLUG
2 - DIFFERENTIAL COVER
3 - 1/8 INCH BEAD OF R T V SEALANT
4 - DIFFERENTIAL ASSEMBLY
Fig. 142 Differential Bearing Retainer Bolts
1 - DIFFERENTIAL BEARING RETAINER
2 - DIFFERENTIAL BEARING RETAINER BOLTS (6)
Fig. 143 Remove Bearing Retainer Using Tool L-4435
1 - GOVERNOR PRESSURE PLUG
2 - DIFFERENTIAL BEARING RETAINER
3 - SPECIAL TOOL L-4435
Fig. 144 Checking Side Gear End Play
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
4 - SIDE GEAR
21 - 92 31TH AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)
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