check engine CHRYSLER CARAVAN 2005 Service Manual

TRANSMISSION CONTROL
RELAY
DESCRIPTION
The transmission control relay (Fig. 306) is located
in the Intelligent Power Module (IPM), which is
located on the left side of the engine compartment
between the battery and left fender.
OPERATION
The relay is supplied fused B+ voltage, energized by
the PCM/TCM, and is used to supply power to the sole-
noid pack when the transmission is in normal operating
mode. When the relay is ªoffº, no power is supplied to
the solenoid pack and the transmission is in ªlimp-inº
mode. After a controller reset (ignition key turned to the
ªrunº position or after cranking engine), the PCM/TCM
energizes the relay. Prior to this, the PCM/TCM verifies
that the contacts are open by checking for no voltage at
the switched battery terminals. After this is verified,
the voltage at the solenoid pack pressure switches is
checked. After the relay is energized, the PCM/TCM
monitors the terminals to verify that the voltage is
greater than 3 volts.
TRANSMISSION RANGE
SENSOR
DESCRIPTION
The Transmission Range Sensor (TRS) is mounted
to the top of the valve body inside the transaxle andcan only be serviced by removing the valve body. The
electrical connector extends through the transaxle
case (Fig. 307).
The Transmission Range Sensor (TRS) has four
switch contacts that monitor shift lever position and
send the information to the PCM/TCM.
The TRS also has an integrated temperature sen-
sor (thermistor) that communicates transaxle tem-
perature to the TCM and PCM (Fig. 308).
Fig. 306 Transmission Control Relay Location
1 - TRANSMISSION CONTROL RELAY
2 - LEFT FENDER
3 - INTELLIGENT POWER MODULE (IPM)
4 - BATTERY
Fig. 307 Transmission Range Sensor (TRS)
Location
1 - TRANSMISSION RANGE SENSOR
Fig. 308 Transmission Temperature Sensor
1 - TRANSMISSION RANGE SENSOR
2 - TEMPERATURE SENSOR
21 - 130 40TE AUTOMATIC TRANSAXLERS

TRANSAXLE IDENTIFICATION
The 41TE transaxle is identified by a barcode label
that is fixed to the transaxle case as shown in (Fig.
2).
The label contains a series of digits that can be
translated into useful information such as transaxle
part number, date of manufacture, manufacturing
origin, plant shift number, build sequence number,
etc. Refer to (Fig. 3) for identification label break-
down.
If the tag is not legible or missing, the ªPKº num-
ber, which is stamped into the transaxle case behind
the transfer gear cover, can be referred to for identi-
fication. This number differs slightly in that it con-
tains the entire transaxle part number, rather than
the last three digits.
OPERATION
Transmission output is directed to an integral dif-
ferential by a transfer gear system in the following
input-to-output ratios:
First...............................2.84 : 1
Second.............................1.57 : 1
Third..............................1.00 : 1
Overdrive...........................0.69 : 1
Reverse............................2.21 : 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - 4XTE TRANSAXLE
GENERAL DIAGNOSIS
NOTE: Before attempting any repair on a 4XTE four-
speed automatic transaxle, check for diagnostic trou-
ble codes (DTC's) using the DRB scan tool. Refer to
the Transmission Diagnostic Procedures Manual.
Transaxle malfunctions may be caused by these
general conditions:
²Poor engine performance
²Improper adjustments
²Hydraulic malfunctions
²Mechanical malfunctions
²Electronic malfunctions
Diagnosis of these problems should always begin
by checking the easily accessible variables: fluid level
and condition, gearshift cable adjustment. Then per-
form a road test to determine if the problem has been
corrected or that more diagnosis is necessary. If the
problem persists after the preliminary tests and cor-
rections are completed, hydraulic pressure checks
should be performed.
Fig. 2 Transaxle Identification Label
1 - IDENTIFICATION LABEL
Fig. 3 Identification Label Breakdown
1 - T=TRACEABILITY
2 - SUPPLIER CODE (PK=KOKOMO)
3 - COMPONENT CODE (TK=KOKOMO TRANSMISSION)
4 - BUILD DAY (344=DEC. 9)
5 - BUILD YEAR (9=1999)
6 - LINE/SHIFT CODE (3=3RD SHIFT)
7 - BUILD SEQUENCE NUMBER
8 - LAST THREE OF P/N
9 - ALPHA
10 - TRANSAXLE PART NUMBER
11 - P=PART NUMBER
RS41TE AUTOMATIC TRANSAXLE21 - 149
41TE AUTOMATIC TRANSAXLE (Continued)

DIAGNOSIS AND TESTING - ROAD TEST
Prior to performing a road test, verify that the
fluid level, fluid condition, and linkage adjustment
have been approved.
During the road test, the transaxle should be oper-
ated in each position to check for slipping and any
variation in shifting.
If the vehicle operates properly at highway speeds,
but has poor acceleration, the converter stator over-
running clutch may be slipping. If acceleration is nor-
mal, but high throttle opening is needed to maintain
highway speeds, the converter stator clutch mayhave seized. Both of these stator defects require
replacement of the torque converter and thorough
transaxle cleaning.
Slipping clutches can be isolated by comparing the
ªElements in Useº chart with clutch operation
encountered on a road test. This chart identifies
which clutches are applied at each position of the
selector lever.
A slipping clutch may also set a DTC and can be
determined by operating the transaxle in all selector
positions.
ELEMENTS IN USE AT EACH POSITION OF SELECTOR LEVER
Shift Lever
PositionINPUT CLUTCHES HOLDING CLUTCHES
Underdrive Overdrive Reverse 2/4 Low/Reverse
P - PARKX
R - REVERSE X X
N - NEUTRALX
OD -
OVERDRIVE
First XX
Second X X
Direct X X
Overdrive X X
D - DRIVE*
First XX
Second X X
Direct X X
L - LOW*
First XX
Second X X
Direct X X
* Vehicle upshift and downshift speeds are increased when in these selector positions.
The process of elimination can be used to detect
any unit which slips and to confirm proper operation
of good units. Road test analysis can diagnose slip-
ping units, but the cause of the malfunction cannot
be determined. Practically any condition can be
caused by leaking hydraulic circuits or sticking
valves.
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS
Pressure testing is a very important step in the
diagnostic procedure. These tests usually reveal the
cause of most hydraulic transaxle problems.Before performing pressure tests, be certain that
fluid level and condition, and shift cable adjustments
have been checked and approved. Fluid must be at
operating temperature (150 to 200 degrees F.).
Install an engine tachometer, raise vehicle on hoist
which allows front wheels to turn, and position
tachometer so it can be read.
21 - 150 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(2) Move selector lever to the (R) position.
(3) Read reverse clutch pressure with output sta-
tionary (foot on brake) and throttle opened to achieve
1500 rpm.
(4) Reverse and LR clutch pressure should read
165 to 235 psi.
(5) This test checks the reverse clutch hydraulic
circuit.
TEST RESULT INDICATIONS
(1) If proper line pressure is found in any one test,
the pump and pressure regulator are working prop-
erly.(2) Low pressure in all positions indicates a defec-
tive pump, a clogged filter, or a stuck pressure regu-
lator valve.
(3) Clutch circuit leaks are indicated if pressures
do not fall within the specified pressure range.
(4) If the overdrive clutch pressure is greater than
5 psi in Step 4 of Test Three, a worn reaction shaft
seal ring or a defective solenoid assembly is indi-
cated.
(5) If the underdrive clutch pressure is greater
than 5 psi in Step 4 of Test Two A, a defective sole-
noid assembly or PCM/TCM is the cause.
PRESSURE CHECK SPECIFICATIONS
Pressure Taps
Gear Selector
PositionActual GearUnderdrive
ClutchOverdrive
ClutchReverse
ClutchTorque
Converter
Clutch
Off2/4
ClutchLow/
Reverse
Clutch
Park *
PARK 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
REVERSE *
REVERSE 0-2 0-7 165-235 50-100 0-2 165-235
0 mph
NEUTRAL *
NEUTRAL 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
L#
FIRST 110-145 0-5 0-2 60-110 0-2 115-145
20 mph
3#
SECOND 110-145 0-5 0-2 60-110 115-145 0-2
30 mph
3#
DIRECT 75-95 75-95 0-2 60-90 0-2 0-2
45 mph
OD #
OVERDRIVE 0-2 75-95 0-2 60-90 75-95 0-2
30 mph
OD #
OVERDRIVE
WITH TCC0-2 75-95 0-2 0-5 75-95 0-2
50 mph
* Engine speed at 1500 rpm
# CAUTION: Both front wheels must be turning at the same speed.
21 - 152 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

CAUTION: Do not damage the transaxle case and/or
differential retainer sealing surface.
(9) Using the end play measurement that was
determined, add 0.18mm (0.007 inch). This should
give you between 5-18 inch pounds of bearing pre-
load. Refer to the Differential Bearing Shim Chart to
determine which shim to use.
(10) Remove the differential bearing retainer.
Remove the bearing cup.
(11) Install the oil baffle. Install the proper shim
combination under the bearing cup.
(12) Install the differential bearing retainer. Seal
the retainer to the housing with MopartSilicone
Rubber Adhesive Sealant. Torque bolts to 28 N´m
(250 in. lbs.).
(13) Using Miller Special Tool L-4436-A and an
inch-pound torque wrench, check the turning torque
of the differential (Fig. 204). The turning torque
should be between 5-18 inch-pounds.
NOTE: If turning torque is too high install a 0.05mm
(0.002 inch) thicker shim. If the turning torque is too
low, install a 0.05mm (0.002 inch) thinner shim.
Repeat until 5-18 inch-pounds of turning torque is
obtained.
FLUID
STANDARD PROCEDURE
FLUID LEVEL AND CONDITION CHECK
NOTE: Only transmission fluid of the type labeled
Mopar ATF+4 (Automatic Transmission Fluid)
should be used in this transaxle.
FLUID LEVEL CHECK
The transmission sump has a fluid level indicator
(dipstick) to check oil similar to most automatic
transmissions. It is located on the left side of the
engine. Be sure to wipe all dirt from dipstick handle
before removing.
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.At normal operating temperature 82É C
(180É F), the fluid level is correct if it is in the HOT
region on the oil level indicator (Fig. 205). The fluid
level should be within the COLD region of the dip-
stick at 27É C (80É F) fluid temperature.
FLUID LEVEL CHECK USING DRB
NOTE: Engine and Transaxle should be at normal
operating temperature before performing this proce-
dure.
(1) Start engine and apply parking brake.
(2) Hook up DRB scan tool and select transmis-
sion.
(3) Select sensors.
(4) Read the transmission temperature value.
(5) Compare the fluid temperature value with the
fluid temperature chart (Fig. 206).
(6) Adjust transmission fluid level shown on the
indicator according to the chart.
(7) Check transmission for leaks.
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, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transaxle vent where it may be mistaken
for a leak.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle recondition is proba-
bly required. Be sure to examine the fluid on the dip-
Fig. 205 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
21 - 230 41TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)

stick closely. If there is any doubt about its condition,
drain out a sample for a double check.
MopartATF+4 (Automatic Transmission Fluid)
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
SERVICE
NOTE: Refer to the maintenance schedules in
LUBRICATION and MAINTENANCE, or the vehicle
owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
NOTE: Only fluids of the type labeled MoparTATF+4
(Automatic Transmission Fluid) 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.
Fig. 206 Transmission Fluid Temperature Chart
1 - MAX. LEVEL2 - MIN. LEVEL
RS41TE AUTOMATIC TRANSAXLE21 - 231
FLUID (Continued)

FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Refer to LUBRICA-
TION and MAINTENANCE for proper procedures.
Place a drain container 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) Install a new filter and o-ring on bottom of the
valve body (Fig. 207).
(4) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.).
(5) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) through the dipstick opening.
(6) 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.
(7) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 208).
(8) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.). Refer
to Fluid Level and Condition Check for the proper
fluid fill procedure.
(9) 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 Fluid) 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 lowest mark on the dip-
stick (Fig. 208).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/FLUID - STANDARD PROCEDURE)
(10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
Fig. 207 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
Fig. 208 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
21 - 232 41TE AUTOMATIC TRANSAXLERS
FLUID (Continued)

ment can be obtained. The result of this engagement
is a direct 1:1 mechanical link between the engine
and the transmission.
The engagement and disengagement of the TCC
are automatic and controlled by the Powertrain Con-
trol Module (PCM). The engagement cannot be acti-
vated in the lower gears because it eliminates the
torque multiplication effect of the torque converter
necessary for acceleration. Inputs that determine
clutch engagement are: coolant temperature, vehicle
speed and throttle position. The torque converter
clutch is engaged by the clutch solenoid on the valve
body. The clutch will engage at approximately 56
km/h (35 mph) with light throttle, after the shift to
third gear.
REMOVAL
(1) Remove transmission and torque converter
from vehicle. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE - REMOVAL)
(2) Place a suitable drain pan under the converter
housing end of the transmission.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pull the torque converter forward until the cen-
ter hub clears the oil pump seal.
(4) Separate the torque converter from the trans-
mission.
INSTALLATION
Check converter hub and drive notches for sharp
edges, burrs, scratches, or nicks. Polish the hub and
notches with 320/400 grit paper or crocus cloth if nec-
essary. The hub must be smooth to avoid damaging
the pump seal at installation.
(1) Lubricate converter hub and oil pump seal lip
with transmission fluid.
(2) Place torque converter in position on transmis-
sion.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.(3) Align torque converter to oil pump seal open-
ing.
(4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 329). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter is fully seated.
(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.
(8) Install the transmission in the vehicle. (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE - INSTALLATION)
(9) Fill the transmission with the recommended
fluid. (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 41TE/FLUID - STANDARD PROCE-
DURE)
Fig. 329 Checking Torque Converter Seating
1 - SCALE
2 - STRAIGHTEDGE
21 - 280 41TE AUTOMATIC TRANSAXLERS
TORQUE CONVERTER (Continued)

TRANSMISSION CONTROL
RELAY
DESCRIPTION
The transmission control relay (Fig. 330) is located
in the Intelligent Power Module (IPM), which is
located on the left side of the engine compartment
between the battery and left fender.
OPERATION
The relay is supplied fused B+ voltage, energized by
the PCM/TCM, and is used to supply power to the sole-
noid pack when the transmission is in normal operating
mode. When the relay is ªoffº, no power is supplied to
the solenoid pack and the transmission is in ªlimp-inº
mode. After a controller reset (ignition key turned to the
ªrunº position or after cranking engine), the PCM/TCM
energizes the relay. Prior to this, the PCM/TCM verifies
that the contacts are open by checking for no voltage at
the switched battery terminals. After this is verified,
the voltage at the solenoid pack pressure switches is
checked. After the relay is energized, the PCM/TCM
monitors the terminals to verify that the voltage is
greater than 3 volts.
TRANSMISSION RANGE
SENSOR
DESCRIPTION
The Transmission Range Sensor (TRS) is mounted
to the top of the valve body inside the transaxle andcan only be serviced by removing the valve body. The
electrical connector extends through the transaxle
case (Fig. 331).
The Transmission Range Sensor (TRS) has four
switch contacts that monitor shift lever position and
send the information to the PCM/TCM.
The TRS also has an integrated temperature sen-
sor (thermistor) that communicates transaxle tem-
perature to the TCM and PCM (Fig. 332).
Fig. 330 Transmission Control Relay Location
1 - TRANSMISSION CONTROL RELAY
2 - LEFT FENDER
3 - INTELLIGENT POWER MODULE (IPM)
4 - BATTERY
Fig. 331 Transmission Range Sensor (TRS)
Location
1 - TRANSMISSION RANGE SENSOR
Fig. 332 Transmission Temperature Sensor
1 - TRANSMISSION RANGE SENSOR
2 - TEMPERATURE SENSOR
RS41TE AUTOMATIC TRANSAXLE21 - 281

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Sliding door glass nuts 3.4 Ð 30
Sliding door latch striker 28 21 Ð
Sliding door to roller arm bracket 12 9 Ð
Storage bin track guide to seat riser 3.5 Ð 31
Sunroof opening panel to lifter arm screws 5 44
Sunroof opening panel motor screws 4 35
Sunroof trough bracket to roof bolts 6 53
Sunroof trough to trough bracket bolts 6 53
Sunroof trough bracket bolts 6 53
Support cylinders to liftgate 28 21 Ð
BODY LUBRICATION
LUBRICATION REQUIREMENTS
Body mechanisms and linkages should be
inspected, cleaned, and lubricated, as required, to
maintain ease of operation and to provide protection
against rust and wear. When performing other under
hood services, the hood latch release mechanism and
safety catch should be inspected, cleaned, and lubri-
cated. During the winter season, external door lock
cylinders should be lubricated to assure proper oper-
ation when exposed to water and ice.
Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to
clean the item to be lubricated. After lubricating a
component, any excess oil or grease should be
removed.
LUBRICANT APPLICATION
DOOR LOCK CYLINDERS
(1) Apply a small amount of lubricant directly into
the lock cylinder.
(2) Apply a small amount of lubricant to the key.
(3) Insert key into lock cylinder and cycle the
mechanism from the locked to the unlocked position.
NOTE: Do not add more lubricant.
(4) Cycle the lock cylinder mechanism several
times to allow the lubricant to flow throughout the
cylinder.
(5) Wipe all lubricant from exterior of lock cylinder
and key.ALL OTHER BODY MECHANISMS
(1) Clean component as described above.
(2) Apply specified lubricant to all pivoting and
sliding contact areas of component.
LUBRICANT USAGE
ENGINE OIL
²Door Hinges ± Hinge Pin and Pivot Contact
Areas
²Hood Hinges ± Pivot Points
²Liftgate Hinges
MOPARTSPRAY WHITE LUBE OR EQUIVALENT
²Door Check Straps
²Liftgate Latches
²Liftgate Prop Pivots
²Ash Receiver
²Fuel Filler Door Remote Control Latch Mecha-
nism
²Parking Brake Mechanism
²Sliding Seat Tracks
²Liftgate Latch
MOPARTMultipurpose GREASE OR EQUIVALENT
²All Other Hood Mechanisms
MOPARTLOCK CYLINDER LUBRICANT OR
EQUIVALENT
²Door Lock Cylinders
²Liftgate Lock Cylinder
23 - 12 BODYRS
BODY (Continued)