automatic transmission CHRYSLER CARAVAN 2002 Repair Manual

FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL AND
CONDITION CHECK
NOTE: The transmission and differential sump have
a common oil sump with a communicating opening
between the two.
FLUID LEVEL CHECK
The torque converter fills in both the P Park and N
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate.The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground. This will assure complete oil level sta-
bilization between differential and transmis-
sion.The fluid should be at normal operating
temperature (approximately 82 C. or 180 F.). The
fluid level is correct if it is in the HOT region (cross-
hatched area) on the fluid level indicator (Fig. 165).
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, the air bubbles can cause overheat-
ing, fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and servo operation.
Foaming can also result in fluid escaping from thetransaxle dipstick where it may be mistaken for a
leak.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. MopartATF+4 (Automatic
Transmission Fluid-Type 9602) when new is red in
color. The ATF is dyed red so it can be identified from
other fluids used in the vehicle such as engine oil or
antifreeze. The red color is not permanent and is not
an indicator of fluid condition. As the vehicle is
driven, the ATF will begin to look darker in color and
may eventually become brown.This is normal.
ATF+4 also has a unique odor that may change with
age. Consequently,odor and color cannot be used
to indicate the fluid condition, or the need for a
fluid change.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
STANDARD PROCEDURE - FLUID AND FILTER
CHANGE
NOTE: For the recommended maintenance (fluid/fil-
ter change) intervals for this transaxle, (Refer to
LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
NOTE: Only fluids of the type labeled MoparTATF+4
(Automatic Transmission Fluid) Type 9602 should
be used. A filter change should be made at the time
of the transmission oil change. The magnet (on the
inside of the oil pan) should also be cleaned with a
clean, dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Place a drain con-
tainer with a large opening, under transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Remove oil filter-to-valve body screws (Fig.
166).
(4) Remove oil filter and gasket (Fig. 167).
(5) Install a new filter and gasket (Fig. 167).
(6) Clean the oil pan and magnet. Reinstall pan
using new MopartSilicone Rubber Adhesive Sealant.
Torque oil pan bolts to 19 N´m (165 in. lbs.).
(7) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid-Type 9602) through the dipstick
opening.
Fig. 165 Fluid Level Indicator Markings
1 - TRANSAXLE DIPSTICK
RS31TH AUTOMATIC TRANSAXLE21-99
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(8) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(9) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ªADDº mark on the dip-
stick (Fig. 168).
(10) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/FLUID - STANDARD PROCEDURE)(11) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
DIPSTICK TUBE FLUID SUCTION METHOD
(ALTERNATIVE)
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (VaculaŸ
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Pour four quarts of MopartATF+4 (Automatic
Transmission FluidÐType 9602) through the dipstick
opening.
(7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ªADDº mark on the dip-
stick (Fig. 168).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/FLUID - STANDARD PROCEDURE)
(10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
Fig. 166 Oil Filter Screws
1 - SCREWDRIVER HANDLE
2 - SPECIAL TOOL L-4553
3 - OIL FILTER SCREWS (2)
4 - OIL FILTER
Fig. 167 Oil Filter and Gasket
1 - OIL FILTER
2 - GASKET
3 - VALVE BODY
Fig. 168 Dipstick Markings
1 - TRANSAXLE DIPSTICK
21 - 100 31TH AUTOMATIC TRANSAXLERS
FLUID (Continued)
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ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT
Lift and rotate the gearshift hand lever into the
park (P) gate position and remove the ignition key.
This confirms the shift lever is in the gated park (P)
position.
After confirming the park gate position, turn the
ignition switch . If the starter will operate, the park
gate position is correct. Move the shift lever into the
neutral (N) position. If the starter will operate in this
position, the linkage is properly adjusted. If the
starter fails to operate in either position, linkage
adjustment is required.
(1) Park the vehicle on level ground and set the
parking brake.
(2) Place the gearshift lever in park (P) gate posi-
tion and remove key.
(3) Loosen the cable adjustment screw at the
transaxle operating lever (Fig. 181).
(4) Pull the transaxle operating lever fully forward
to the park detent position.
(5) Release the park brake, then rock the vehicle
to assure it is in park lock. Reset the park brake.
(6) Tighten the cable adjustment screw to 8 N´m
(70 in. lbs.). Gearshift cable should now be properly
adjusted.
(7) Verify PRNDL indicator still displays the corre-
sponding gear completely. If not, readjustment of
PRNDL may be required.
(8) Check adjustment by using the preceding pro-
cedure.
GOVERNOR
DESCRIPTION
The governor assembly is fastened to the transaxle
transfer shaft. It consists of a governor body, weight,
valve, and shaft.
OPERATION
The governor meters hydraulic pressure, and this
metered pressure is used to signal the transmission
when it is time for a shift to occur. It does this by
balancing governor pressure on one side of a shift
valve, and throttle pressure on the other. When gov-
ernor pressure increases far enough to overcome the
throttle pressure on the valve, a shift occurs.
With the gearshift selector in a forward driving
range, line pressure flows from the manual valve and
down to the governor valve. When the output shaft
starts to rotate with vehicle motion, the governor
weight assembly will start to move outward due to
centrifugal force. As the weight is moved outward, it
will pull the valve with it until the land of the valve
uncovers the line pressure port. As the port begins to
become uncovered, governor pressure is metered. As
the vehicle's speed continues to increase, the weight
assembly will be at a point at which governor pres-
sure is acting on the left side of the reaction area of
the valve. This produces sufficient force to compress
the spring and allow the outer weight to move out
against the outer governor body retaining ring. At a
very high speed, the governor valve will be opened as
far as possible. In this condition, it is possible for
governor pressure to meet, but not to exceed, line
pressure. Generally governor pressure ranges from
0-100 psi from idle to maximum speed, and rises pro-
portionally with the increase in output shaft speed.
Governor pressure and throttle pressure are acting
upon the shift valves to determine when a shift will
occur. Governor pressure is a direct indication of road
speed, and throttle pressure is an indication of
engine load. When both parameters have been met
by the throttle and governor pressures, an upshift or
downshift will occur.
CLEANING
Thoroughly clean all the governor parts in a suit-
able cleaning solution but do not use any type of
caustic cleaning agents.
The governor weight components and the governor
valve, must slide freely in their bores when clean and
dry. Minor surface scratches and burrs can be
smoothed with crocus cloth.
INSPECTION
The aluminum governor valve and outer weight
have a hard coating on them. Check condition of this
Fig. 181 Gearshift Cable Adjustment
1 - SHIFT CABLE ADJUSTMENT
2 - SHIFT CABLE
21 - 104 31TH AUTOMATIC TRANSAXLERS
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coating carefully. Do not reuse either part if the coat-
ing is damaged.
Inspect the governor weight spring for distortion.
Replace the spring, if distorted, collapsed, or broken.
Clean the filter in solvent and dry it with compressed
air. Replace the filter, if damaged. Inspect the park
gear for chipped or worn gear teeth or damaged ring
grooves. Replace the gear, if damaged.
Check the teeth on the park gear for wear or dam-
age. Replace the gear if necessary. Inspect the metal
seal rings on the park gear hub. Replace the rings
only if severely worn, or broken.
OIL PUMP
DESCRIPTION
The oil pump is located in the pump housing inside
the bell housing of the transmission case. The oil
pump consists of an inner and outer gear, a housing,
and a cover that also serves as the reaction shaft
support (Fig. 182).
OPERATION
As the torque converter rotates, the converter hub
rotates the inner and outer gears. As the gears
rotate, the clearance between the gear teeth
increases in the crescent area, and creates a suction
at the inlet side of the pump. This suction drawsfluid through the pump inlet from the oil pan. As the
clearance between the gear teeth in the crescent area
decreases, it forces pressurized fluid into the pump
outlet and to the valve body.
STANDARD PROCEDURE - OIL PUMP VOLUME
CHECK
Measuring the oil pump output volume will deter-
mine if sufficient oil flow to the transmission oil
cooler exists, and whether or not an internal trans-
mission failure is present.
Verify that the transmission fluid is at the proper
level. Refer to the Fluid Level Check procedure in
this section. If necessary, fill the transmission to the
proper level with MopartATF +4, type 9602, Auto-
matic Transmission Fluid.
(1) Using hose cutters or a suitable blade, cut the
To coolerline off flush with the cooler inlet fitting
and place a collecting container under the open line.
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.
(2) Run the engineat curb idle speed, with the
shift selector in neutral.
(3) If one quart of transmission fluid is collected in
the container in 20 seconds or less, oil pump flow vol-
ume is within acceptable limits. If fluid flow is inter-
Fig. 182 Oil Pump Assembly
1 - REACTION SHAFT SUPPORT
2 - INNER GEAR
3 - PUMP BODY4 - PUMP BUSHING
5 - OUTER GEAR
RS31TH AUTOMATIC TRANSAXLE21 - 105
GOVERNOR (Continued)
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mittent, or it takes more than 20 seconds to collect
one quart of fluid, (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 31TH - DIAGNOSIS
AND TESTING) for further diagnosis.
(4) Re-connect theTo coolerline to the transmis-
sion cooler inlet using a service splice kit. Refer to
instructions included with the kit.
(5) Refill the transmission to proper level. (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 31TH/FLUID - STANDARD PROCEDURE)
DISASSEMBLY
(1) Remove reaction shaft support-to-pump body
bolts.
(2) Remove reaction shaft support, and the inner
and outer pump gears (Fig. 183).
CLEANING
Clean pump and support components with solvent
and dry them with compressed air.
INSPECTION
(1) Check condition of the seal rings and thrust
washer on the reaction shaft support. The seal rings
do not need to be replaced unless cracked, broken, or
severely worn.
(2) Visually inspect the pump and support compo-
nents. Replace the pump assembly if the seal ring
grooves or machined surfaces are worn, scored, pit-
ted, or damaged. Replace the pump assembly if the
gears if pitted, worn chipped, or damaged.
(3) Inspect the pump bushing. Then check the
reaction shaft support bushing. Replace the pump
assembly if either bushing is heavily worn, scored or
damaged.
(4) Clearance between outer gear and reaction
shaft housing should be 0.010 to 0.063 mm (0.0004 to
0.0025 in.). Clearance between inner gear and reac-
tion shaft housing should be 0.010 to 0.063 mm
(0.0004 to 0.0025 in.). Both clearances can be mea-
sured at the same time by installing the gears in the
pump body and measure pump component clearances
as follows:
Fig. 183 Oil Pump Assembly
1 - REACTION SHAFT SUPPORT
2 - INNER GEAR
3 - PUMP BODY4 - PUMP BUSHING
5 - OUTER GEAR
21 - 106 31TH AUTOMATIC TRANSAXLERS
OIL PUMP (Continued)
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(5) Reinstall gears to pump body and measure
outer gear-to-pocket clearance with a feeler gauge
(Fig. 184).Outer gear-to-pocket clearance should
be within 0.045-0.141 mm (0.0018-0.0056 in.).
(6) Measure both inner and outer gear side clear-
ance with PlastigageŸ. If PlastigageŸ is not avail-
able, measure across the pump body with a straight
edge and feeler gauge.
(a) Position an appropriate piece of PlastigageŸ
across both gears.
(b) Align the plastigage to a flat area on the
reaction shaft housing.
(c) Install the reaction shaft support to the
pump housing and torque to 28 N´m (250 in. lbs.).
(d) Separate the reaction shaft housing from the
pump housing and measure the PlastigageŸ fol-
lowing the instructions supplied with it.Inner
and outer gear side clearance should be
within 0.020-0.046 mm (0.0008-0.0018 in.).
ASSEMBLY
(1) Install inner and outer gears to pump body
(Fig. 183). Lubricate gears with MopartATF+4
(Automatic Transmission Fluid-Type 9602).
(2) Install reaction shaft support to pump body
and align holes.
(3) Install and torque reaction shaft support-to-
pump body bolts to 28 N´m (250 in. lbs.).
PARK/NEUTRAL POSITION
SWITCH
DIAGNOSIS AND TESTING - PARK/NEUTRAL
POSITION SWITCH
The park/neutral starting switch is the center ter-
minal of the 3 terminal switch. It provides ground for
the starter solenoid circuit through the selector lever
in only Park (P) and Neutral (N) positions.
(1) To test switch, remove wiring connector from
switch and test for continuity between center pin of
switch and transaxle case. Continuity should exist
only when transaxle is in Park or Neutral.
(2) Check gearshift cable adjustment before replac-
ing a switch which tests bad.
REMOVAL
(1) Unscrew switch from transaxle case allowing
fluid to drain into a container. Move selector lever to
Park, then to Neutral position, and inspect to see the
switch operating lever fingers are centered in switch
opening.
INSTALLATION
(1) Screw the switch with a new seal into trans-
axle case and tighten to 33 N´m (24 ft. lbs.). Retest
switch with the test lamp.
(2) Add fluid to transaxle to bring up to proper
level.
(3) The back-up lamp switch circuit is through the
two outside terminals of the 3 terminal switch.
(4) To test switch, remove wiring connector from
switch and test for continuity between the two out-
side pins.
(5) Continuity should exist only with transaxle in
Reverse position.
(6) No continuity should exist from either pin to
the case.Fig. 184 Measuring Pump Outer Gear-to-Pocket
Clearance
1 - FEELER GAUGE
2 - OUTER GEAR
RS31TH AUTOMATIC TRANSAXLE21 - 107
OIL PUMP (Continued)
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ASSEMBLY
(1) Install low/reverse servo assembly (Fig. 208).
(2) Install low/reverse servo snap ring (Fig. 205).
SHIFT INTERLOCK SOLENOID
DESCRIPTION
The Brake/Transmission Shift Interlock system
consists of an electro-magnetic solenoid mounted to
the steering column (Fig. 209). The solenoid's plunger
consists of an integrated hook, which operates the
shift lever pawl (part of shift lever assembly), and a
plunger return spring (Fig. 210). The solenoid also
has an integrated bracket, which facilitates fastening
to the steering column.
OPERATION
The Brake/Transmission Shift Interlock (BTSI)
Solenoid prevents the transmission shift lever from
being moved out of PARK (P) unless the brake pedal
is applied. The BTSI solenoid is hardwired to and
controlled by the Intelligent Power Module (IPM).
Battery voltage is applied to one side of the solenoid
with the ignition key is in either the OFF, ON/RUN,
or START positions (Fig. 211). The ground side of the
solenoid is controlled by a driver within the IPM. It
relies on voltage supplied from the stop lamp switch
to the stop lamp sense circuit within the IPM to tell
when the brake pedal is depressed. When the brake
pedal is depressed, the ground circuit opens, de-ener-
gizing the solenoid. When the brake pedal is
released, the ground circuit is closed, energizing the
solenoid.
Fig. 208 Low/Reverse Servo Assembly
1 - SERVO PISTON
2 - SPRINGFig. 209 Brake/Transmission Shift Interlock (BTSI)
Solenoid Location
1 - BTSI SOLENOID
Fig. 210 Solenoid Plunger and Return Spring
1 - PLUNGER
2 - RETURN SPRING
3 - BTSI SOLENOID
RS31TH AUTOMATIC TRANSAXLE21 - 115
SERVO - LOW/REVERSE (Continued)
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DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK SOLENOID
For intended BTSI system operation, refer to the
following chart:
ACTION EXPECTED RESPONSE
1. Turn key to the9OFF9
position.1. Shifter CAN be shifted
out of park with brake
pedal applied.
2. Turn key to the
9ON/RUN9position.2. Shifter CANNOT be
shifted out of park.
3. Turn key to the
9ON/RUN9position and
depress the brake pedal.3. Shifter CAN be shifted
out of park.
4. Leave shifter in any
gear and try to return key
to the9LOCK9or9ACC9
position.4. Key cannot be
returned to the9LOCK9or
9ACC9position.
5. Return shifter to
9PARK9and try to remove
the key.5. Key can be removed
(after returning to9LOCK9
position).
6. With the key removed,
try to shift out of9PARK9.6. Shifter cannot be
shifted out of9PARK9.
NOTE: Any failure to meet these expected
responses requires system repair. Refer to the
appropriate Diagnostic Information.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove instrument panel lower shroud (Fig.
214).(3) Remove knee bolster (Fig. 215).
(4) Remove steering column lower shroud.
(5) Disconnect brake/transmission shift interlock
(BTSI) solenoid connector (Fig. 216).
Fig. 214 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 215 Knee Bolster
1 - KNEE BOLSTER
Fig. 216 BTSI Solenoid Connector
1 - BTSI SOLENOID
2 - SOLENOID CONNECTOR
RS31TH AUTOMATIC TRANSAXLE21 - 117
SHIFT INTERLOCK SOLENOID (Continued)
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(5) Install instrument panel lower silencer (Fig.
221).
(6) Connect battery negative cable.
(7) Verify proper shift interlock system operation.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/SHIFT INTERLOCK SOLENOID -
OPERATION)
SOLENOID - TCC
DESCRIPTION
The torque converter clutch (TCC) solenoid is fas-
tened to the transaxle valve body, and its connector
protrudes through the transaxle case (Fig. 222).
OPERATION
The torque converter clutch solenoid is responsible
for controlling application of the torque converter
clutch. It is controlled by the Powertrain Control
Module (PCM), which determines when conditions
are acceptable for torque converter lock-up.
REMOVAL
(1) Remove valve body from transaxle. (Refer to 21
- TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/VALVE BODY - REMOVAL)
(2) Remove three (3) torque converter clutch sole-
noid-to-valve body screws (Fig. 223).
(3) Remove torque converter clutch solenoid (Fig.
223). Note orientation of plug and spring.
Fig. 221 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 222 Torque Converter Clutch Solenoid
1 - TCC SOLENOID WIRING CONNECTOR
RS31TH AUTOMATIC TRANSAXLE21 - 119
SHIFT INTERLOCK SOLENOID (Continued)
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INSTALLATION
(1) Install plug and spring as shown in (Fig. 223).
(2) Install torque converter clutch solenoid to valve
body (Fig. 223) and torque screws to 5 N´m (45 in.
lbs.).
(3) Install valve body to transaxle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/VALVE BODY - INSTALLATION)
THROTTLE VALVE CABLE
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect cable core from throttle lever pin
(Fig. 224).
(3) Disconnect cable retainer from throttle body
bracket (Fig. 224).
Fig. 223 Torque Converter Clutch Solenoid and Regulator/Control Valves
1 - CONVERTER PRESSURE CONTROL VALVE 3 - SCREW (3) 5 - REGULATOR VALVE THROTTLE PRESSURE
PLUG
2 - END COVER 4 - REGULATOR VALVE THROTTLE PRESSURE
PLUG SPRING 6 - SWITCH VALVE
Fig. 224 Throttle Valve Cable at Throttle Body
1 - THROTTLE VALVE CABLE CLIP
2 - THROTTLE BODY LEVER
3 - CABLE RETAINER
21 - 120 31TH AUTOMATIC TRANSAXLERS
SOLENOID - TCC (Continued)
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