manual transmission CHRYSLER CARAVAN 2005 Owner's Guide
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Page 572 of 2339
DESCRIPTION - CONNECTOR, GROUND AND
SPLICE INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as
follows:
²In-line connectors located in the engine compart-
ment are C100 series numbers
²In-line connectors located in the Instrument
Panel area are C200 series numbers.
²In-line connectors located in the body are C300
series numbers.
²Jumper harness connectors are C400 series
numbers.
²Grounds and ground connectors are identified
with a ªGº and follow the same series numbering as
the in-line connectors.
²Splices are identified with an ªSº and follow the
same series numbering as the in-line connectors.
²Component connectors are identified by the com-
ponent name instead of a number. Multiple connec-
tors on a component use a C1, C2, etc. identifier.
LOCATIONS
Section 8W-91 contains connector/ground/splice
location illustrations. The illustrations contain the
connector name (or number)/ground number/splice
number and component identification. Connector/
ground/splice location charts in section 8W-91 refer-
ence the figure numbers of the illustrations.
The abbreviation T/O is used in the component
location section to indicate a point in which the wir-
ing harness branches out to a component. The abbre-
viation N/S means Not Shown in the illustrations
WARNING
WARNINGS - GENERAL
WARNINGSprovide information to prevent per-
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY AND AVOID LOOSE
CLOTHING.
DIAGNOSIS AND TESTING - WIRING HARNESS
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit
there are several common tools necessary. These tools
are listed and explained below.
²Jumper Wire - This is a test wire used to con-
nect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
²Voltmeter - Used to check for voltage on a cir-
cuit. Always connect the black lead to a known good
ground and the red lead to the positive side of the
circuit.
CAUTION: Most of the electrical components used
in today's vehicles are Solid State. When checking
voltages in these circuits, use a meter with a 10 -
megohm or greater impedance rating.
RS8W-01 WIRING DIAGRAM INFORMATION8W-01-7
WIRING DIAGRAM INFORMATION (Continued)
Page 974 of 2339
Component Page
Rear Blower Front Control Switch (3 Zone
MTC)......................... 8W-80-124
Rear Blower Motor Power Module C1 (3 Zone
ATC) .......................... 8W-80-125
Rear Blower Motor Power Module C2 (3 Zone
ATC) .......................... 8W-80-125
Rear Blower Rear Control Switch C1 (3 Zone
MTC)......................... 8W-80-125
Rear Blower Rear Control Switch C2 (3 Zone
MTC)......................... 8W-80-125
Rear Dome Lamp (Except Luxury)..... 8W-80-126
Rear Intrusion Sensor (United
Kingdom)...................... 8W-80-126
Rear Mode Motor (3 Zone ATC)....... 8W-80-126
Rear Power Outlet................. 8W-80-126
Rear Temperature Motor (3 Zone ATC) . . 8W-80-127
Rear View Mirror C1 (Luxury)........ 8W-80-127
Rear View Mirror C2 (Hands Free)..... 8W-80-127
Rear Wiper Motor.................. 8W-80-128
Recirculation Door Actuator.......... 8W-80-128
Right B-Pillar Switch (Power Sliding
Door).......................... 8W-80-128
Right Cinch/Release Motor (Power Sliding
Door).......................... 8W-80-128
Right Curtain Airbag Squib.......... 8W-80-129
Right Cylinder Lock Switch (Export) . . . 8W-80-129
Right Door Speaker................ 8W-80-129
Right Fog Lamp................... 8W-80-129
Right Front Door Ajar Switch (Base) . . . 8W-80-130
Right Front Door Lock Motor/Ajar Switch (Except
Base).......................... 8W-80-130
Right Front Impact Sensor........... 8W-80-130
Right Front Park/Turn Signal Lamp.... 8W-80-130
Right Front Wheel Speed Sensor...... 8W-80-131
Right Full Open Switch (Power Sliding
Door).......................... 8W-80-131
Right Headlamp (Caravan/Voyager Except
Export)........................ 8W-80-131
Right Headlamp (Town And Country) . . . 8W-80-131
Right Headlamp Leveling Motor
(Export)....................... 8W-80-132
Right High Beam Lamp (Export)...... 8W-80-132
Right Instrument Panel Speaker...... 8W-80-132
Right Liftgate Flood Lamp........... 8W-80-132
Right Low Beam Lamp (Export)....... 8W-80-133
Right Mid Reading Lamp (Premium/
Luxury)........................ 8W-80-133
Right Park Lamp (Export)........... 8W-80-133
Right Power Mirror................ 8W-80-133
Right Rear Lamp Assembly.......... 8W-80-134
Right Rear Pillar Speaker (Highline
Audio)......................... 8W-80-134Component Page
Right Rear Reading Lamp (Luxury).... 8W-80-134
Right Rear Speaker................ 8W-80-134
Right Rear Vent Motor.............. 8W-80-135
Right Rear Wheel Speed Sensor....... 8W-80-135
Right Remote Radio Switch.......... 8W-80-135
Right Repeater Lamp (Export)........ 8W-80-135
Right Side Impact Sensor 1 (Export) . . . 8W-80-135
Right Side Impact Sensor 1 (Except
Export)........................ 8W-80-136
Right Side Impact Sensor 2.......... 8W-80-136
Right Side Impact Sensor 3.......... 8W-80-136
Right Sliding Door Control Module C1 (Power
Sliding Door)................... 8W-80-136
Right Sliding Door Control Module C2 (Power
Sliding Door)................... 8W-80-137
Right Sliding Door Latch Sensing Switch (Power
Sliding Door)................... 8W-80-137
Right Sliding Door Lock Motor (Power Sliding
Door).......................... 8W-80-137
Right Sliding Door Lock Motor/Ajar Switch (Manual
Sliding Door)................... 8W-80-138
Right Sliding Door Motor (Power Sliding
Door).......................... 8W-80-138
Right Speed Control Switch.......... 8W-80-138
Right Turn Signal Lamp (Export)...... 8W-80-138
Right Visor/Vanity Lamp (Except Base/
Export)........................ 8W-80-139
Sentry Key Remote Entry Module
(SKREEM)..................... 8W-80-139
Siren (United Kingdom)............. 8W-80-139
Speed Control Servo (Gas)........... 8W-80-139
Sunroof Module (Except Export)....... 8W-80-140
Sunroof Switch (Except Export)....... 8W-80-140
Thatcham Alarm Module (United
Kingdom)...................... 8W-80-140
Throttle Position Sensor (Gas)........ 8W-80-141
Traction Control Switch............. 8W-80-141
Trailer Tow Connector (Except Export) . . 8W-80-141
Transmission Control Module (Diesel) . . 8W-80-141
Transmission Control Relay (Diesel).... 8W-80-143
Transmission Range Sensor.......... 8W-80-143
Transmission Solenoid/Pressure Switch
Assembly...................... 8W-80-143
Vehicle Speed Sensor (MTX).......... 8W-80-144
Washer Fluid Level Switch........... 8W-80-144
Washer Pump Motor................ 8W-80-144
Water In Fuel Sensor (Diesel)......... 8W-80-144
Wiper Module..................... 8W-80-144
RS8W-80 CONNECTOR PIN-OUTS8W-80-5
Page 1121 of 2339
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Liftgate Ajar Switch (Manual
Release)BK At Latch 49
Liftgate Ajar Switch (Power
Release)BK Lower Liftgate 49
Liftgate Cinch/Release Motor
(Power Liftgate)BL Liftgate 49
Liftgate Left Pinch Sensor (Power
Liftgate)BK Left Side of Liftgate 49
Liftgate Right Pinch Sensor
(Power Liftgate)BK Right Side of Liftgate 49
Manifold Absolute Pressure
Sensor (Gas)BK On Intake N/S
Mass Air Flow Sensor (Diesel) OR Top of Engine 15, 16
Memory Seat/Mirror/Adjustable
Pedals Module C1GY Under Driver Seat N/S
Memory Seat/Mirror/ Adjustable
Pedals Module C2GY Under Driver Seat N/S
Memory Seat/Mirror/ Adjustable
Pedals Module C3WT Under Driver Seat N/S
Memory Seat/Mirror/ Adjustable
Pedals Module C4GY Under Driver Seat N/S
Memory Set Switch BK At Switch Driver Door 43
Message Center (Highline) WT Rear of Message Center 20, 21, 28
Mode Door Actuator GY Left Side of HVAC N/S
Multi Function Switch BK At Steering Column 20, 21, 22, 23, 31
Natural Vacuum Leak Detection
Assembly (Except Export)LTGY Top of Engine 12
Occupant Classification Module BK Passenger Seat N/S
Occupant Restraint Controller C1 YL Right Side Instrument Panel
Occupant Restraint Controller C2 YL Right Side Instrument Panel 20, 24, 25
Output Speed Sensor GY Front of Transmission 14, 19
Overhead Console (Except Base) BK Front of Console N/S
Oxygen Sensor 1/1 Upstream
(Gas)Rear of Engine 11, 12, 18
Oxygen Sensor 1/2 Downstream
(Gas)Rear of Engine 11, 12,18
Park Brake Switck Bottoom Left Side of Instrument
Panel20, 21
Park Sensor No.1 (Parktronics) Rear Fascia N/S
Park Sensor No.2 (Parktronics) Rear Fascia N/S
Park Sensor No.3 (Parktronics) Rear Fascia N/S
Park Sensor No.4 (Parktronics) Rear Fascia N/S
Passenger Airbag YL Passenger Side of Instrument Panel 20, 23, 24, 29
Passenger Airbag On/Off
Indicator LampRight Center of Instrument Panel 20, 23, 25
Passenger Blend Door Actuator GY On HVAC N/S
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1368 of 2339
(6) Open fuel fill door and remove screws mount-
ing fuel filler tube assembly to body. Do not discon-
nect rubber fuel fill or vent hoses from tank at this
time.
(7) Place a transmission jack under center of fuel
tank. Apply a slight amount of pressure to fuel tank
with transmission jack.
(8) Remove fuel tank mounting straps.
(9)Lower the tank just enough so that the
filler tube fitting is the highest point of the fuel
tank.
(10) Remove filler tube from fuel tank. Tank will
be drained through this fitting.
NOTE: WRAP SHOP TOWELS AROUND HOSES TO
CATCH ANY GASOLINE SPILLAGE.
(11) Drain fuel tank into holding tank or a prop-
erly labeledGasolinesafety container.
WARNING: GASOLINE OR GASOLINE VAPORS ARE
HIGHLY FLAMMABLE. A FIRE COULD OCCUR IF AN
IGNITION SOURCE IS PRESENT. NEVER DRAIN OR
STORE GASOLINE OR DIESEL FUEL IN AN OPEN
CONTAINER, DUE TO THE POSSIBILITY OF FIRE
OR EXPLOSION. THIS MAY RESULT IN PERSONAL
INJURY OR DEATH.
(12) If fuel pump module removal is necessary,
refer to Fuel Pump Module Removal/Installation in
this section.
STANDARD PROCEDURE - FUEL PRESSURE
GAUGE
This gauge package (special tool #8974) (Fig. 1)is
designed to check the injectors or fuel pump for leak
down conditions and fuel system pressures. Refer to
the Powertrain Diagnostic Manual for more informa-
tion on the operation of this tool.
(1) Preform the fuel pressure release procedure,
refer to the Fuel Pressure release procedure in this
section.(2) Find a fuel line quick connect fitting that is
accessible and install special tool #8974.
(3) Refer to the Powertrain Diagnostic Manual for
the proper operation of this gauge package.
(4) Preform the fuel pressure release procedure,
refer to the Fuel Pressure release procedure in this
section.
(5) Remove gauge from fuel system and reconnect
fuel lines.
(6) Use the DRBIIItto pressurize the fuel system
to check for leaks
Fig. 1 FUEL SYSTEM PRESSURE TESTER #8978
1 - GAUGES
2 - HANGER
3 - RELEASE TOOL
4 - DRAIN HOSE
5 - DRAIN HOSE VALVE
6 - SHUT-OFF VALVE
RSFUEL DELIVERY14-3
FUEL DELIVERY (Continued)
Page 1395 of 2339
The PCM uses crankshaft position reference to
determine injector sequence, ignition timing and the
presence of misfire. Once the PCM determines crank-
shaft position, it begins energizing the injectors in
sequence.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support.
(3) Disconnect the electrical connector (Fig. 8).
(4) Remove crankshaft sensor bolt (Fig. 9).
(5) Remove the crankshaft sensor.
INSTALLATION - 2.4L
(1) Install the crankshaft sensor.
(2) Install crankshaft sensor bolt and tighten.
(3) Connect the electrical connector (Fig. 8).
(4) Lower vehicle.
(5) Connect the negative battery cable.
ENGINE SPEED SENSOR
DESCRIPTION
The PCM receives a signal from the TCM to indi-
cate vehicle speed on automatic transmission cars.
On 4 cylinder Manual transmission cars (if equipped)
vehicle, a dedicated vehicle speed sensor is connected
to the PCM.On V-6 Manual transmission cars (if
equipped) vehicle, the ABS module provides the sig-
nal to the PCM for vehicle speed.
OPERATION
The Transmission Control Module (TCM) supplies
the road speed and distance traveled inputs to the
PCM. From these inputs and the throttle position
sensor input, the PCM determines when a decelera-
tion condition occurs.
FUEL INJECTOR
DESCRIPTION
The injectors are positioned in the intake manifold
or cylinder head with the nozzle ends directly above
the intake valve port (Fig. 10).Fig. 8 CRANKSHAFT SENSOR 2.4L
Fig. 9 CRANKSHAFT POSITION SENSOR LOCATION
2.4L
Fig. 10 Fuel Injector Location - Typical
1 - FUEL RAIL
2 - INTAKE MANIFOLD
3 - FUEL INJECTORS
14 - 30 FUEL INJECTIONRS
CRANKSHAFT POSITION SENSOR (Continued)
Page 1466 of 2339
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
trouble 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.
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 may
have 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.
RS40TE AUTOMATIC TRANSAXLE21-5
40TE AUTOMATIC TRANSAXLE (Continued)
Page 1471 of 2339
(3) Remove coolant recovery bottle (Fig. 10).
(4) Remove fluid level indicator/tube assembly.
Plug opening to prevent debris from entering trans-
axle.
(5) Disconnect transaxle oil cooler lines using Tool
8875A. (Refer to 7 - COOLING/TRANSMISSION -
STANDARD PROCEDURE). Install plugs to prevent
debris intrusion.
(6) Disconnect input and output shaft speed sensor
connectors (Fig. 11).
(7) Disconnect transmission range sensor (TRS)
connector (Fig. 11).
(8) Disconnect solenoid/pressure switch assembly
connector (Fig. 11).
(9) Disconnect gear shift cable from manual valve
lever and upper mount bracket (Fig. 12).
(10) Disconnect crankshaft position sensor (if
equipped). Remove sensor from bellhousing.
(11) Reposition leak detection pump harness and
hoses.
Fig. 10 Coolant Recovery Bottle
1 - COOLANT RECOVERY CONTAINER
2 - HOSE
3 - BOLT
4 - SUB FRAME RAIL
Fig. 11 Component Connector LocationÐTypical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 12 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 10 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)
Page 1512 of 2339
(69) Install and tighten solenoid/pressure switch
assembly-to-transaxle case bolts to 12 N´m (110 in.
lbs.) (Fig. 158).
(70) Install and torque input and output speed
sensors to case to 27 N´m (20 ft. lbs.).
INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perfrom the ªQuick-Learnº procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
(1) Using a transmission jack and a helper, posi-
tion transaxle assembly to engine. Install and torque
bellhousing bolts to 95 N´m (70 ft. lbs.).
(2) Install upper mount assembly to transaxle and
torque bolts to 54 N´m (40 ft. lbs.) (Fig. 159).
(3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 159).
(4) Remove transmission jack and screw jack.
(5) Secure left wheelhouse splash shield.
(6) Install torque converter-to-drive plate bolts and
torque to 88 N´m (65 ft. lbs.)
(7) Install inspection cover.
(8) Install lateral bending brace.
(9) Install starter motor.(10) Install front mount/bracket assembly.
(11) Align and install rear mount bracket-to-case
bolts by hand (Fig. 160). Torque horizontal bolt to
102 N´m (75 ft. lbs.).
(12) AWD models: Install power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - INSTALLATION)
(13) Install left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
(14) Install front wheel/tire assemblies.
(15) Lower vehicle.
(16) Torque remaining rear mount bracket-to-tran-
saxle vertical bolts (Fig. 160) to 102 N´m (75 ft. lbs.).
(17) Install transaxle upper bellhousing-to-block
bolts and torque to 95 N´m (70 ft. lbs.).
(18) Install and connect crank position sensor (if
equipped).
(19) Connect gearshift cable to upper mount
bracket and transaxle manual valve lever (Fig. 161).
(20) Connect solenoid/pressure switch assembly
(Fig. 162).
(21) Connect transmission range sensor connector
(Fig. 162).
(22) Connect input and output speed sensor con-
nectors (Fig. 162).
Fig. 158 Attaching Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
Fig. 159 Left Mount to Bracket and Transaxle
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
RS40TE AUTOMATIC TRANSAXLE21-51
40TE AUTOMATIC TRANSAXLE (Continued)
Page 1513 of 2339
Fig. 160 Rear Mount Bracket - Typical
1 - BOLT - VERTICAL 102 N´m (75 ft. lbs.)
2 - BRACKET - REAR MOUNT3 - BOLT - HORIZONTAL 102 N´m (75 ft. lbs.)
Fig. 161 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 162 Component Connector Location - Typical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
21 - 52 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)
Page 1543 of 2339
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. 187). 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. 188).
(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-
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.
Fig. 187 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
21 - 82 40TE AUTOMATIC TRANSAXLERS