automatic transmission fluid CHRYSLER CARAVAN 2003 User Guide
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2003, Model line: CARAVAN, Model: CHRYSLER CARAVAN 2003Pages: 2177, PDF Size: 59.81 MB
Page 588 of 2177
8W-02 COMPONENT INDEX
Component Page
A/C Compressor Clutch Relay............. 8W-42
A/C Compressor Clutch.................. 8W-42
A/C-Heater Control..................... 8W-42
A/C Pressure Sensor.................... 8W-42
Accelerator Pedal Position Sensor.......... 8W-30
Accessory Relay........................ 8W-10
Adjustable Pedals Module................ 8W-30
Adjustable Pedals Relay................. 8W-30
Adjustable Pedals Switch................. 8W-30
Airbag Control Module.................. 8W-43
Ambient Temperature Sensor.............. 8W-49
Antenna............................. 8W-47
ATC Remote Sensor..................... 8W-42
Auto Shut Down Relay.................. 8W-30
Auto Temp Control..................... 8W-42
Automatic Day/Night Mirror.............. 8W-49
Back-Up Lamp Switch................... 8W-51
Battery Temperature Sensor.............. 8W-20
Battery.............................. 8W-20
Blend Door Actuators................... 8W-42
Blower Motor Resistor................... 8W-42
Body Control Module.................... 8W-45
Boost Pressure Sensor................... 8W-30
B-Pillar Switches....................... 8W-61
Brake Fluid Level Switch................ 8W-40
Brake Lamp Switch.................. 8W-30, 51
Brake Transmission Shift Interlock Solenoid . . 8W-31
Cabin Heater Assist..................... 8W-30
Camshaft Position Sensor................ 8W-30
CD Changer.......................... 8W-47
Center Dome Lamp..................... 8W-44
Center High Mounted Stop Lamp........... 8W-51
Cinch/Release Motors................... 8W-61
Clockspring................ 8W-30, 33, 41, 43, 47
Clutch Pedal Interlock Switch.......... 8W-10, 30
Clutch Pedal Upstop Switch............... 8W-30
Combination Relays..................... 8W-54
Controller Antilock Brake................ 8W-35
Crank Case Ventilation Heater............ 8W-30
Crankshaft Position Sensor............... 8W-30
Cylinder Lock Switches.................. 8W-39
Data Link Connector.................... 8W-18
Defogger Relay........................ 8W-48
Door Ajar Switches..................... 8W-39
Door Lock Motor/Ajar Switches............ 8W-61
Door Courtesy Lamps................... 8W-44
Door Lock Switches..................... 8W-61
Dosing Pump......................... 8W-30
Driver Airbag Squibs.................... 8W-43
Driver Seat Belt Switch.................. 8W-43
DVD Screen.......................... 8W-47
DVD/CD Changer...................... 8W-47
ECM/PCM Relay....................... 8W-30
EGR Solenoid......................... 8W-30
Electronic Control Unit.................. 8W-64
Engine Control Module.................. 8W-30
Component Page
Engine Coolant Temp Sensor.............. 8W-30
Engine Oil Pressure Sensor............... 8W-30
Engine Oil Pressure Switch............... 8W-30
EVAP/Purge Solenoid.................... 8W-30
Evaporator Temperature Sensor............ 8W-42
Floor Console Lamp..................... 8W-44
Floor Console Power Outlet............... 8W-41
Fog Lamps........................... 8W-50
Front Blower Module.................... 8W-42
Front Blower Motor Relay................ 8W-42
Front Blower Motor..................... 8W-42
Front Cigar Lighter..................... 8W-41
Front Control Module................... 8W-10
Front Fog Lamp Relay................... 8W-50
Front Intrusion Sensor.................. 8W-39
Front Reading Lamps/Switch.............. 8W-44
Front Washer Pump Motor............... 8W-53
Front Wiper High/Low Relay.............. 8W-53
Front Wiper On/Off Relay................ 8W-53
Fuel Heater Relay...................... 8W-30
Fuel Heater.......................... 8W-30
Fuel Injectors......................... 8W-30
Fuel Pressure Sensor.................... 8W-30
Fuel Pressure Solenoid.................. 8W-30
Fuel Pump Module..................... 8W-30
Fuel Pump Relay....................... 8W-30
Full Open Switches..................... 8W-61
Fuses............................... 8W-10
Fuselink............................. 8W-10
Grounds............................. 8W-15
Generator............................ 8W-20
Glow Plugs........................... 8W-30
Glow Plug Relay....................... 8W-30
Headlamp Leveling Motors............... 8W-50
Headlamp Switch...................... 8W-50
Headlamp Washer Pump Motor............ 8W-53
Headlamp Washer Relay................. 8W-53
Headlamps........................... 8W-50
Heated Seat Backs..................... 8W-63
Heated Seat Cushions................... 8W-63
Heated Seat Modules.................... 8W-63
High Beam Lamps...................... 8W-50
Hood Ajar Switch...................... 8W-39
Horn Relay........................... 8W-41
Horn Switch.......................... 8W-41
Horns............................... 8W-41
Idle Air Control Motor................... 8W-30
Ignition Coil.......................... 8W-30
Ignition Switch........................ 8W-10
Inlet Air Temperature Sensor.............. 8W-30
Input Speed Sensor..................... 8W-31
Instrument Cluster..................... 8W-40
Instrument Panel Switch Bank.... 8W-44, 52, 53, 63
Integrated Power Module................. 8W-10
Knock Sensor......................... 8W-30
Lamp Assemblies...................... 8W-51
RS8W-02 COMPONENT INDEX8W-02-1
ProCarManuals.com
Page 662 of 2177
8W-15 GROUND DISTRIBUTION
Component PageA/C Compressor Clutch......................8W-15-8, 9
A/C-Heater Control......................8W-15-10, 12
Adjustable Pedals Module.....................8W-15-11
Airbag Control Module.......................8W-15-13
Auto Temp Control.........................8W-15-10
Automatic Day/Night Mirror...................8W-15-23
Back-Up Lamp Switch......................8W-15-4, 8
Battery.............................8W-15-2, 3, 4
Body Control Module.......................8W-15-24
Brake Fluid Level Switch.....................8W-15-19
Brake Lamp Switch........................8W-15-19
Cabin Heater Assist.........................8W-15-9
Center Dome Lamp........................8W-15-23
Center High Mounted Stop Lamp.................8W-15-28
Clutch Pedal Interlock Switch...................8W-15-19
Clutch Pedal Upstop Switch....................8W-15-20
Controller Antilock Brake...................8W-15-2, 3, 4
Crank Case Ventilation Heater...................8W-15-9
Crankshaft Position Sensor.....................8W-15-4
Data Link Connector...................8W-15-2, 3, 4, 19
Dosing Pump............................8W-15-9
Driver Door Courtesy Lamp..................8W-15-16, 22
Driver Door Lock Switch....................8W-15-16, 22
Driver Heated Seat Cushion....................8W-15-18
Driver Heated Seat Module....................8W-15-18
Driver Power Seat Switch.....................8W-15-18
Driver Power Window Switch...................8W-15-16
Driver Power Window Switch...................8W-15-22
DVD/CD Changer.........................8W-15-11
Engine Control Module.......................8W-15-4
Floor Console Lamp........................8W-15-27
Floor Console Power Outlet....................8W-15-27
Front Blower Module.......................8W-15-12
Front Cigar Lighter........................8W-15-10
Front Control Module....................8W-15-8, 9, 20
Front Reading Lamps/Switch...................8W-15-23
Fuel Heater............................8W-15-27
Fuel Heater Relay..........................8W-15-4
Fuel Pump Module.........................8W-15-27
G100..............................8W-15-2, 3, 4
G101..............................8W-15-2, 3, 4
G102..............................8W-15-5, 6, 7
G103...............................8W-15-8, 9
G200............................8W-15-10, 11, 12
G201................................8W-15-13
G202................................8W-15-14
G300........................8W-15-15, 17, 18, 19, 20
G301..........................8W-15-21, 22, 23, 24
G302............................8W-15-25, 26, 27
G303..............................8W-15-27, 28
Generator..............................8W-15-8
Headlamp Switch.........................8W-15-10
Headlamp Washer Pump Motor..................8W-15-7
High Note Horn..........................8W-15-6 7
Hood Ajar Switch.........................8W-15-20
Instrument Cluster........................8W-15-10
Instrument Panel Switch Bank..................8W-15-11
Integrated Power Module..............8W-15-2, 3, 4, 8, 9, 20
Left B-Pillar Switch........................8W-15-19
Left Cinch/Release Motor.....................8W-15-15
Left Combination Relay......................8W-15-26
Left Cylinder Lock Switch...................8W-15-16 17
Left Door Speaker.........................8W-15-14
Left Fog Lamp..........................8W-15-6, 7
Left Front Door Ajar Switch....................8W-15-17
Left Front Door Lock Motor/Ajar Switch...........8W-15-16, 17
Left Front Park/Turn Signal Lamp.................8W-15-6
Left Full Open Switch.......................8W-15-15
Left Headlamp...........................8W-15-20
Left Headlamp Leveling Motor...................8W-15-7
Left High Beam Lamp.......................8W-15-20
Left Liftgate Flood Lamp.....................8W-15-28
Left Low Beam Lamp.......................8W-15-20
Left Mid Reading Lamp......................8W-15-23
Left Park Lamp..........................8W-15-20
Left Power Mirror.........................8W-15-11
Left Rear Lamp Assembly.....................8W-15-26
Left Rear Reading Lamp......................8W-15-23
Left Rear Speaker.........................8W-15-14
Left Side Impact Airbag Control Module.............8W-15-13
Left Sliding Door Control Module.................8W-15-15
Left Sliding Door Latch Sensing Switch.............8W-15-15
Left Sliding Door Lock Motor...................8W-15-15
Left Sliding Door Lock Motor/Ajar Switch............8W-15-15Component PageLeft Sliding Door Motor......................8W-15-15
Left Stop/Turn Signal Relay....................8W-15-26
Left Turn Signal Lamp......................8W-15-20
Left Visor/Vanity Lamp......................8W-15-23
License Lamp.........................8W-15-25, 28
Lift Pump Motor..........................8W-15-27
Liftgate Ajar Switch........................8W-15-28
Liftgate Cinch/Release Motor...................8W-15-25
Liftgate Cylinder Lock Switch...................8W-15-28
Liftgate Right Pinch Sensor....................8W-15-25
Low Note Horn..........................8W-15-6, 7
Memory Seat/Mirror Module...................8W-15-18
Natural Vacuum Leak Detection Assembly.............8W-15-8
Overhead Console.........................8W-15-23
Oxygen Sensor 1/1 Upstream....................8W-15-2
Oxygen Sensor 1/2 Downstream.................8W-15-2, 8
Passenger Door Courtesy Lamp................8W-15-17, 22
Passenger Door Lock Switch.................8W-15-17, 22
Passenger Heated Seat Cushion..................8W-15-24
Passenger Heated Seat Module..................8W-15-24
Passenger Power Seat Switch...................8W-15-24
Passenger Power Window Switch...............8W-15-17, 22
Power Folding Mirror Switch...................8W-15-12
Power Liftgate Module.......................8W-15-25
Power Liftgate Motor.......................8W-15-25
Power Mirror Switch........................8W-15-12
Power Outlet............................8W-15-10
Power Window Switch.......................8W-15-16
Powertrain Control Module...................8W-15-2, 3
Radiator Fan No. 1.........................8W-15-5
Radiator Fan No. 2.........................8W-15-5
Radiator Fan Relay.........................8W-15-5
Radiator Fan Relay No. 3......................8W-15-5
Radio................................8W-15-14
Rear Auto Temp Control Switch..................8W-15-19
Rear Blower Front Control Switch................8W-15-12
Rear Blower Motor Power Module..............8W-15-12, 27
Rear Blower Rear Control Switch.................8W-15-19
Rear Dome Lamp.........................8W-15-23
Rear Power Outlet.........................8W-15-27
Rear Window Defogger Grid....................8W-15-28
Rear Wiper Motor.........................8W-15-28
Remote Keyless Entry Module...................8W-15-11
Right B-Pillar Switch.......................8W-15-24
Right Cinch/Release Motor....................8W-15-21
Right Combination Relay.....................8W-15-26
Right Cylinder Lock Switch....................8W-15-22
Right Door Speaker........................8W-15-14
Right Fog Lamp.........................8W-15-6, 7
Right Front Door Ajar Switch...................8W-15-22
Right Front Door Lock Motor/Ajar Switch............8W-15-22
Right Front Park/Turn Signal Lamp................8W-15-6
Right Full Open Switch......................8W-15-21
Right Headlamp..........................8W-15-20
Right Headlamp Leveling Motor..................8W-15-7
Right High Beam Lamp......................8W-15-20
Right Liftgate Flood Lamp....................8W-15-28
Right Low Beam Lamp......................8W-15-20
Right Mid Reading Lamp.....................8W-15-23
Right Park Lamp..........................8W-15-20
Right Power Mirror........................8W-15-11
Right Rear Lamp Assembly....................8W-15-27
Right Rear Reading Lamp.....................8W-15-23
Right Rear Speaker........................8W-15-14
Right Side Impact Airbag Control Module............8W-15-13
Right Sliding Door Control Module................8W-15-21
Right Sliding Door Latch Sensing Switch.............8W-15-21
Right Sliding Door Lock Motor..................8W-15-21
Right Sliding Door Lock Motor/Ajar Switch...........8W-15-21
Right Sliding Door Motor.....................8W-15-21
Right Stop/Turn Signal Relay...................8W-15-26
Right Turn Signal Lamp......................8W-15-20
Right Visor/Vanity Lamp.....................8W-15-23
Sentry Key Immobilizer Module..................8W-15-11
Speed Control Servo.........................8W-15-8
Sunroof Module..........................8W-15-26
Sunroof Switch...........................8W-15-23
Traction Control Switch......................8W-15-11
Trailer Tow Connector.......................8W-15-26
Transmission Control Module....................8W-15-3
Transmission Control Relay...................8W-15-2, 3
Washer Fluid Level Switch....................8W-15-6, 7
Wiper Module...........................8W-15-19
RS8W-15 GROUND DISTRIBUTION8W-15-1
ProCarManuals.com
Page 982 of 2177
8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Clutch............... 8W-80-6
A/C Pressure Sensor.................. 8W-80-6
A/C-Heater Control C1 (MTC).......... 8W-80-6
A/C-Heater Control C2 (MTC).......... 8W-80-7
Accelerator Pedal Position Sensor
(Diesel).......................... 8W-80-7
Adjustable Pedals Module
(Except Export)................... 8W-80-7
Adjustable Pedals Relay
(Except Export)................... 8W-80-8
Adjustable Pedals Switch
(Except Export)................... 8W-80-8
Airbag Control Module (ORC).......... 8W-80-8
Ambient Temperature Sensor (Except
Base)........................... 8W-80-9
ATC Remote Sensor (ATC)............. 8W-80-9
Auto Temp Control C1................ 8W-80-9
Auto Temp Control C2................ 8W-80-9
Auto Temp Control C3............... 8W-80-10
Automatic Day/Night Mirror (Premium/
Luxury)........................ 8W-80-10
Autostick Switch (Except Export)....... 8W-80-10
Back-Up Lamp Switch (MTX).......... 8W-80-10
Battery Temperature Sensor (2.4L/
Diesel)......................... 8W-80-11
Blower Motor Resistor C1 (MTC)....... 8W-80-11
Blower Motor Resistor C2 (MTC)....... 8W-80-11
Body Control Module C1.............. 8W-80-11
Body Control Module C2.............. 8W-80-12
Body Control Module C3.............. 8W-80-13
Body Control Module C4.............. 8W-80-14
Body Control Module C5.............. 8W-80-15
Boost Pressure Sensor (Diesel)......... 8W-80-15
Brake Fluid Level Switch............. 8W-80-16
Brake Lamp Switch................. 8W-80-16
Brake Transmission Shift Interlock Solenoid
(EATX) ......................... 8W-80-16
C100............................. 8W-80-16
C100............................. 8W-80-17
C101............................. 8W-80-17
C101............................. 8W-80-18
C102 (2.4L)........................ 8W-80-18
C102 (2.4L)........................ 8W-80-18
C102 (3.3L/3.8L).................... 8W-80-19
C102 (3.3L/3.8L).................... 8W-80-19
C103 (Diesel)...................... 8W-80-19
C103 (Diesel)...................... 8W-80-20
C106 (Export)...................... 8W-80-20
C106 (Export)...................... 8W-80-20
C107 (Export)...................... 8W-80-20
C107 (Export)...................... 8W-80-21
C110 (2.4L)........................ 8W-80-21Component Page
C110 (2.4L)........................ 8W-80-21
C111 (2.4L)........................ 8W-80-21
C111 (2.4L)........................ 8W-80-22
C200............................. 8W-80-22
C200............................. 8W-80-24
C201............................. 8W-80-26
C201............................. 8W-80-26
C202............................. 8W-80-26
C202............................. 8W-80-26
C203 (United Kingdom).............. 8W-80-27
C203 (United Kingdom).............. 8W-80-27
C204 (Premium).................... 8W-80-27
C204 (Premium).................... 8W-80-27
C300 (LHD)....................... 8W-80-28
C300 (LHD)....................... 8W-80-28
C300 (RHD Except Lowline)........... 8W-80-29
C300 (RHD Lowline)................ 8W-80-29
C300 (RHD)....................... 8W-80-29
C301 (Base/Power Locks)............. 8W-80-30
C301 (Base/Power Locks)............. 8W-80-30
C301 (LHD Premium/Memory)......... 8W-80-30
C301 (LHD Premium/Memory)......... 8W-80-30
C301 (RHD/LHD Premium Except
Memory)........................ 8W-80-31
C301 (RHD/LHD Premium Except
Memory)........................ 8W-80-31
C302 (Except RHD Memory).......... 8W-80-31
C302 (Except RHD Memory).......... 8W-80-31
C302 (RHD Memory)................ 8W-80-32
C302 (RHD Memory)................ 8W-80-32
C303 (LHD)....................... 8W-80-32
C303 (LHD)....................... 8W-80-33
C303 (RHD)....................... 8W-80-33
C303 (RHD)....................... 8W-80-33
C304............................. 8W-80-34
C304............................. 8W-80-34
C305............................. 8W-80-34
C305............................. 8W-80-34
C306............................. 8W-80-35
C306............................. 8W-80-35
C307 (Heated Seats)................. 8W-80-35
C307 (Heated Seats)................. 8W-80-35
C308............................. 8W-80-36
C308............................. 8W-80-36
C309............................. 8W-80-36
C309............................. 8W-80-37
C310 (Front Console)................ 8W-80-37
C310 (Front Console)................ 8W-80-37
C311 ............................. 8W-80-37
C311 ............................. 8W-80-38
C312............................. 8W-80-38
C312............................. 8W-80-39
RS8W-80 CONNECTOR PIN-OUTS8W-80-1
ProCarManuals.com
Page 1190 of 2177
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Install a new oil filter.
(11) Fill engine with specified amount of approved
oil.
(12) Connect negative battery cable.
(13) Start engine and check for any leaks.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN IIis used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTVis a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKERis an anaerobic type
gasket material. The material cures in the absence of
air when squeezed between two metallic surfaces. It
will not cure if left in the uncovered tube. The
anaerobic material is for use between two machined
surfaces. Do not use on flexible metal flanges.
MOPARtBED PLATE SEALANTis a unique
(green-in-color) anaerobic type gasket material that
is specially made to seal the area between the bed-plate and cylinder block without disturbing the bear-
ing clearance or alignment of these components. The
material cures slowly in the absence of air when
torqued between two metallic surfaces, and will rap-
idly cure when heat is applied.
MOPARtGASKET SEALANTis a slow drying,
permanently soft sealer. This material is recom-
mended for sealing threaded fittings and gaskets
against leakage of oil and coolant. Can be used on
threaded and machined parts under all tempera-
tures. This material is used on engines with multi-
layer steel (MLS) cylinder head gaskets. This
material also will prevent corrosion. MopartGasket
Sealant is available in a 13 oz. aerosol can or 4oz./16
oz. can w/applicator.
SEALER APPLICATION
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
Neveruse the following to clean gasket surfaces:
²Metal scraper
²Abrasive pad or paper to clean cylinder block
and head
²High speed power tool with an abrasive pad or a
wire brush (Fig. 3)
RSENGINE 2.4L9-11
ENGINE 2.4L (Continued)
ProCarManuals.com
Page 1263 of 2177
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ommended.
Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage per cylinder.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
STANDARD PROCEDURE
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING PLASTIGAGE
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 3). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.
(3) Remove the bearing cap and compare the
width of the flattened Plastigage with the metric
scale provided on the package. Locate the band clos-est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Compare clearance measurements to specs found in
engine specifications (Refer to 9 - ENGINE - SPECI-
FICATIONS).Plastigage generally is accompa-
nied by two scales. One scale is in inches, the
other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install the proper crankshaft bearings to
achieve the specified bearing clearances.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN IIis used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTVis a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKERis an anaerobic type
gasket material. The material cures in the absence of
air when squeezed between two metallic surfaces. It
will not cure if left in the uncovered tube. The
Fig. 3 Plastigage Placed in Lower ShellÐTypical
1 - PLASTIGAGE
9 - 84 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)
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Page 1439 of 2177
FLUID
STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT INJURY
FROM MOVING PARTS AND TO ENSURE ACCU-
RATE FLUID LEVEL READING.
The fluid level can be read on the exterior of the
power steering fluid reservoir. The fluid level should
be within the ªFILL RANGEº when the fluid is at
normal ambient temperature, approximately 21ÉC to
27ÉC (70ÉF to 80ÉF) (Fig. 17).
Before removing the power steering filler cap, wipe
the reservoir filler cap free of dirt and debris. Do not
overfill the power steering system.Use only
MopartATF+4 Automatic Transmission Fluid
(MS-9602) in the power steering system.For
additional information on Automatic Transmission
Fluid, (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION).
CAUTION: Use only MoparTATF+4 Automatic Trans-
mission Fluid (MS-9602). Use of other MoparT
power steering fluids (MS5931 and MS9933) should
be avoided to ensure peak performance of the
power steering system under all operating condi-
tions.
FLUID COOLER
DESCRIPTION
All models (except 2.5L Diesel) are equipped with a
cooler for the power steering system fluid. The power
steering fluid cooler is located on the front suspen-sion cradle crossmember reinforcement (Fig. 18).
There are two different size coolers depending on
model and options. There is a standard 6-inch and an
8-inch.
OPERATION
The purpose of the power steering fluid cooler is to
keep the temperature of the power steering system
fluid from rising to a level that would affect the per-
formance of the power steering system.
The cooler used on this vehicle is referred to as a
fluid-to-air type cooler. This means that the air flow
across the tubes (and fines surrounding them) of the
cooler is used to extract the heat from the cooler
which it has absorbed from the power steering fluid
flowing through it. The cooler is placed in the power
steering fluid return line, between the steering gear
and the power steering fluid reservoir.
REMOVAL
(1) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(3) Remove the hose clamps at the cooler and
remove the hoses from the cooler inlet and outlet
tubes.
(4) Remove the 2 bolts attaching the power steer-
ing cooler cradle crossmember reinforcement (Fig.
18). Remove the cooler.
Fig. 17 Power Steering Fluid Reservoir
Fig. 18 Power Steering Cooler
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
19 - 44 PUMPRS
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Page 1448 of 2177
TRANSMISSION/TRANSAXLE
TABLE OF CONTENTS
page page
POWER TRANSFER UNIT..................1
T850 MANUAL TRANSAXLE...............2141TE AUTOMATIC TRANSAXLE............116
POWER TRANSFER UNIT
TABLE OF CONTENTS
page page
POWER TRANSFER UNIT
DESCRIPTION..........................1
OPERATION............................3
DIAGNOSIS AND TESTING
SEAL IDENTIFICATION..................3
FLUID LEAK DIAGNOSIS................3
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
INSPECTION..........................4
STANDARD PROCEDURE - PTU FLUID
CHANGE.............................5
REMOVAL.............................5
INSTALLATION..........................6
ADJUSTMENTS
OUTPUT FLANGE SHIM SELECTION.......7
SPECIFICATIONS
TORQUE.............................7
SPECIAL TOOLS
SDP POWER TRANSFER UNIT............8
DIFFERENTIAL CARRIER SEAL
REMOVAL.............................9
INSTALLATION..........................9
END COVER BALL BEARING
REMOVAL.............................9INSTALLATION.........................10
END COVER SEAL
REMOVAL.............................11
INSTALLATION.........................11
HALF SHAFT INNER SEAL
REMOVAL.............................12
INSTALLATION.........................12
INPUT SHAFT COVER SEAL
REMOVAL.............................13
INSTALLATION.........................14
INPUT SHAFT END SEAL
REMOVAL.............................15
INSTALLATION.........................16
INPUT SHAFT SEAL
REMOVAL.............................17
INSTALLATION.........................18
OUTER HALF SHAFT SEAL
REMOVAL.............................19
INSTALLATION.........................19
REAR COVER O-RING
REMOVAL.............................19
INSTALLATION.........................20
POWER TRANSFER UNIT
DESCRIPTION
The Power Transfer Unit (P.T.U.) is attached to a
modified automatic transaxle case where the right
half shaft extension housing would normally be
located.
The Power Transfer Unit is sealed from the trans-
axle and has its own oil sump. The Unit uses MopartSAE 80W-90 Gear and Axle Lubricant (MS-9020) and
holds 1.15 liters (1.22 quarts).
Service of the Power Transfer Unit is limited to:
²Fluid Change
²Seals
²Gaskets
²One ball bearing
²Output flange
If the ring gear and pinion, any tapered roller
bearings, case, covers, or pinion carrier fail the entire
unit must be replaced.
RSTRANSMISSION/TRANSAXLE21-1
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Page 1503 of 2177
SPECIFICATIONS - T850 MANUAL TRANSAXLE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Transaxle TypeConstant-mesh, fully synchronized 5-speed with integral
differential
Lubrication MethodSplash oil collected in case passage and oil trough and
distributed to mainshafts via gravity
Fluid Type ATF+4 (Automatic Transmission FluidÐType 9602)
GEAR RATIOS
GEAR RATIO (2.4L Gas) RATIO (2.5L TD)
1st 3.65 3.65
2nd 2.05 2.05
3rd 1.39 1.37
4th 1.03 0.97
5th 0.83 0.76
Reverse 3.47 3.47
Final Drive Ratio 3.77 3.77
Overall Top Gear 3.12 2.67
INPUT SHAFT
BLOCKER RING WEAR GAP
3rd Gear 0.856-1.539 mm (0.0338-0.0606 in.)
4th Gear 0.762-1.631 mm (0.030-0.064 in.)
GEAR END PLAY
3rd Gear 0.099-0.505 mm (0.004-0.020 in.)
4th Gear 0.048-0.457 mm (0.002-0.018 in.)
21 - 56 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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Page 1563 of 2177
41TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
41TE AUTOMATIC TRANSAXLE
DESCRIPTION........................117
OPERATION..........................119
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - 41TE
TRANSAXLE GENERAL DIAGNOSIS......119
DIAGNOSIS AND TESTING - ROAD TEST . . 119
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS...................120
DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS...................122
DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE . . 123
REMOVAL............................124
DISASSEMBLY........................125
ASSEMBLY...........................144
INSTALLATION........................166
SCHEMATICS AND DIAGRAMS
41TE TRANSAXLE HYDRAULIC
SCHEMATICS.......................169
SPECIFICATIONS - 41TE TRANSAXLE......181
SPECIAL TOOLS
41TE AUTOMATIC TRANSAXLE.........183
ACCUMULATOR
DESCRIPTION........................188
OPERATION..........................189
AUTOSTICK SWITCH
DESCRIPTION........................189
OPERATION..........................189
DRIVING CLUTCHES
DESCRIPTION........................190
OPERATION..........................190
FINAL DRIVE
DISASSEMBLY........................190
ASSEMBLY...........................195
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL BEARING
PRELOAD..........................199
FLUID
STANDARD PROCEDURE
FLUID LEVEL AND CONDITION CHECK . . . 201
STANDARD PROCEDURE - FLUID AND
FILTER SERVICE.....................203
GEAR SHIFT CABLE
REMOVAL............................204
INSTALLATION........................205
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT.......206HOLDING CLUTCHES
DESCRIPTION........................207
OPERATION..........................207
INPUT CLUTCH ASSEMBLY
DISASSEMBLY........................208
ASSEMBLY...........................216
OIL PUMP
DESCRIPTION........................230
OPERATION..........................230
DISASSEMBLY........................230
ASSEMBLY...........................232
PLANETARY GEARTRAIN
DESCRIPTION........................232
OPERATION..........................232
SEAL - OIL PUMP
REMOVAL............................232
INSTALLATION........................233
SHIFT INTERLOCK SOLENOID
DESCRIPTION........................233
OPERATION..........................233
DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK
SOLENOID..........................235
REMOVAL............................235
INSTALLATION........................236
SOLENOID/PRESSURE SWITCH ASSY
DESCRIPTION........................237
OPERATION..........................237
REMOVAL............................238
INSTALLATION........................239
SPEED SENSOR - INPUT
DESCRIPTION........................239
OPERATION..........................240
REMOVAL............................240
INSTALLATION........................240
SPEED SENSOR - OUTPUT
DESCRIPTION........................241
OPERATION..........................241
REMOVAL............................241
INSTALLATION........................242
TORQUE CONVERTER
DESCRIPTION........................242
OPERATION..........................245
REMOVAL............................247
INSTALLATION........................247
TRANSMISSION CONTROL RELAY
DESCRIPTION........................247
OPERATION..........................248
21 - 116 41TE AUTOMATIC TRANSAXLERS
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Page 1564 of 2177
TRANSMISSION RANGE SENSOR
DESCRIPTION........................248
OPERATION..........................248
REMOVAL............................249
INSTALLATION........................249
TRD LINK
DESCRIPTION........................249
OPERATION..........................249VALVE BODY
DESCRIPTION........................250
OPERATION..........................250
REMOVAL............................251
DISASSEMBLY........................252
ASSEMBLY...........................257
INSTALLATION........................262
41TE AUTOMATIC
TRANSAXLE
DESCRIPTION
The 41TE (Fig. 1) is a four-speed transaxle that is
a conventional hydraulic/mechanical assembly with
an integral differential, and is controlled with adap-
tive electronic controls and monitors. The hydraulic
system of the transaxle consists of the transaxle
fluid, fluid passages, hydraulic valves, and various
line pressure control components. An input clutch
assembly which houses the underdrive, overdrive,
and reverse clutches is used. It also utilizes separate
holding clutches: 2nd/4th gear and Low/Reverse. The
primary mechanical components of the transaxle con-
sist of the following:
²Three multiple disc input clutches
²Two multiple disc holding clutches
²Four hydraulic accumulators
²Two planetary gear sets
²Hydraulic oil pump
²Valve body
²Solenoid/Pressure switch assembly
²Integral differential assemblyControl of the transaxle is accomplished by fully
adaptive electronics. Optimum shift scheduling is
accomplished through continuous real-time sensor
feedback information provided to the Powertrain
Control Module (PCM) or Transmission Control Mod-
ule (TCM).
The PCM/TCM is the heart of the electronic control
system and relies on information from various direct
and indirect inputs (sensors, switches, etc.) to deter-
mine driver demand and vehicle operating condi-
tions. With this information, the PCM/TCM can
calculate and perform timely and quality shifts
through various output or control devices (solenoid
pack, transmission control relay, etc.).
The PCM/TCM also performs certain self-diagnos-
tic functions and provides comprehensive information
(sensor data, DTC's, etc.) which is helpful in proper
diagnosis and repair. This information can be viewed
with the DRB scan tool.
RS41TE AUTOMATIC TRANSAXLE21 - 117
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