oil dipstick CHRYSLER VOYAGER 1996 User Guide

GENERAL INFORMATION
31TH TRANSAXLE
NOTE: Safety goggles should be worn at all times
when working on these transaxles.
This transaxle combines torque converter, three
speed transmission, final drive gearing, and differen-
tial into a front wheel drive system. The identifica-
tion markings and usage of the transaxle are charted
in Diagnosis and Tests.
NOTE: Transaxle operation requirements are differ-
ent for each vehicle and engine combination. Some
internal parts will be different to provide for this.
Therefore, when replacing parts, refer to the seven
digit part number stamped on rear of the transaxle
oil pan flange.
Within this transaxle, there are three primary
areas:
(1) Main center line plus valve body.
(2) Transfer shaft center line (includes governor
and parking sprag).
(3) Differential center line.
(4) Center distances between the main rotating
parts in these three areas are held precise to main-
tain a low noise level.
(5) The torque converter, transaxle area, and dif-
ferential are housed in an integral aluminum die
casting.The differential oil sump is common
with the transaxle sump. Separate filling of the
differential is NOT necessary.
(6) The torque converter is attached to the crank-
shaft through a flexible driving plate. Cooling of the
converter is accomplished by circulating the tran-
saxle fluid through a remote cooler. There are two
types of coolers used. An oil-to-water type cooler
located in the radiator side tank and/or an oil-to air
heat exchanger. The torque converter assembly is a
sealed unit that cannot be disassembled.
(7) The transaxle fluid is filtered by an internal fil-
ter attached to the lower side of the valve body
assembly.
(8) Engine torque is transmitted to the torque con-
verter then, through the input shaft to multiple-disc
clutches in the transaxle. The power flow depends on
the application of the clutches and bands. Refer to
Elements in Use Chart in Diagnosis and Tests sec-
tion.
(9) The transaxle consists of:
²Two multiple-disc clutches
²An overrunning clutch
²Two servos
²A hydraulic accumulator
²Two bands²Two planetary gear sets
This provides three forward ratios and a reverse
ratio. The common sun gear of the planetary gear
sets is connected to the front clutch by a driving
shell. The drive shell is splined to the sun gear and
front clutch retainer. The hydraulic system consists
of an oil pump, and a single valve body which con-
tains all of the valves except the governor valves.
The transaxle sump and differential sump are both
vented through the dipstick. Output torque from the
main center line is delivered through helical gears to
the transfer shaft. This gear set is a factor of the
final drive (axle) ratio. The shaft also carries the gov-
ernor and parking sprag. An integral helical gear on
the transfer shaft drives the differential ring gear.
The final drive gearing is completed with one of two
gear ratios of 2.98 or 3.19 depending on model and
application.
FLUID LEVEL AND CONDITION
NOTE: The transmission and differential sump have
a common oil sump with a communicating opening
between the two.
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 dipstick.
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 the
transaxle dipstick where it may be mistaken for a
leak.
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 overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
21 - 2 TRANSAXLE AND POWER TRANSFER UNITNS

(4) Low pressure in R and 1 but correct pressure
in 2 indicates rear servo circuit leakage.
(5) Low line pressure in all positions indicates a
defective pump, a clogged filter, or a stuck pressure
regulator valve.
GOVERNOR PRESSURE
Test only if transaxle shifts at wrong vehicle
speeds when throttle cable is correctly adjusted.
(1) Connect a 0-150 psi pressure gauge to governor
pressure take-off point. It is located at lower right
side of case, below differential cover.
(2) Operate transaxle in third gear to read pres-
sures. The governor pressure should respond
smoothly to changes in mph and should return to 0
to 3 psi when vehicle is stopped. High pressure at
standstill (above 3 psi) will prevent the transaxle
from downshifting.
THROTTLE PRESSURE
No gauge port is provided for throttle pressure.
Incorrect throttle pressure should be suspected if
part throttle upshift speeds are either delayed or
occur too early in relation to vehicle speeds. Engine
runaway on shifts can also be an indicator of low
throttle pressure setting, or misadjusted throttle
cable.
In no case should throttle pressure be adjusted
until the transaxle throttle cable adjustment has
been verified to be correct.
CLUTCH AND SERVO AIR PRESSURE TESTS
A no drive condition might exist even with correct
fluid pressure, because of inoperative clutches or
bands. The inoperative units, clutches, bands, and
servos can be located through a series of tests. This
is done by substituting air pressure for fluid pressure
(Fig. 4) .
The front and rear clutches, kickdown servo, and
low-reverse servo may be tested by applying air pres-
sure to their respective passages. To make air pres-
sure tests, proceed as follows:
NOTE: Compressed air supply must be free of all
dirt or moisture. Use a pressure of 30 psi.
Remove oil pan and valve body. Refer to Valve
Body for removal procedure.
FRONT CLUTCH
Apply air pressure to front clutch apply passage
and listen for a dull thud which indicates that front
clutch is operating. Hold air pressure on for a few
seconds and inspect system for excessive oil leaks.
REAR CLUTCH
Apply air pressure to rear clutch apply passage
and listen for a dull thud which indicates that rear
clutch is operating. Also inspect for excessive oil
leaks. If a dull thud cannot be heard in the clutches,
place finger tips on clutch housing and again apply
air pressure. Movement of piston can be felt as the
clutch is applied.
KICKDOWN SERVO (FRONT)
Direct air pressure into KICKDOWN SERVO ON
passage. Operation of servo is indicated by a tighten-
ing of front band. Spring tension on servo piston
should release the band.
LOW AND REVERSE SERVO (REAR)
Direct air pressure into LOW-REVERSE SERVO
APPLY passage. Operation of servo is indicated by a
tightening of rear band. Spring tension on servo pis-
ton should release the band.
If clutches and servos operate properly, no upshift
indicates that a malfunction exists in the valve body.
FLUID LEAKAGE-TRANSAXLE TORQUE
CONVERTER HOUSING AREA
(1) Check for source of leakage.
(2) Since fluid leakage near the torque converter
area may be from an engine oil leak, the area should
be checked closely. Factory fill fluid is dyed red and,
therefore, can be distinguished from engine oil.
(3) Prior to removing the transaxle, perform the
following checks:
(4) When leakage is determined to originate from
the transaxle, check fluid level prior to removal of
the transaxle and torque converter.
(5) High oil level can result in oil leakage out the
vent in the dipstick. If the fluid level is high, adjust
to proper level.
(6) After performing this operation, inspect for
leakage. If a leak persists, perform the following
operation on the vehicle. This will determine if the
torque converter or transaxle is leaking.
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
²Torque converter weld leaks at the outside diam-
eter (peripheral) weld.
²Torque converter hub weld.
²Torque converter impeller shell cracked adjacent
to hub.
²At drive lug welds.
NOTE: Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter.
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 15
DIAGNOSIS AND TESTING (Continued)

SERVICE PROCEDURES
FLUID AND FILTER CHANGE
When the factory fill fluid is changed, only fluids
labeled MOPARtATF PLUS 3 (Automatic Transmis-
sion fluid) Type 7176 should be used.
If the transaxle is disassembled for any reason, the
fluid and filter should be changed.
30,000 MILE TRANSAXLE OIL CHANGE
When a vehicle attains 30,000 miles on its odome-
ter it is recommended that the transaxle oil be
changed. To change the oil, use the procedure that
follows:
It is recommended that a transaxle fluid exchanger
(ATF 2000+ or equivalent) be used to replace the
used fluid in the transaxle. If a fluid exchanger is not
available use a fluid suction pump (Vaculayor equiv-
alent) to draw the fluid out of the dipstick tube. If a
fluid suction pump is not available remove the oil
pan and drain the fluid.
CAUTION: Chrysler Corporation does not recom-
mend using any fluid exchanger that introduces
additives into the transaxle.TRANSAXLE FLUID EXCHANGER METHOD
(1) To perform the transaxle fluid exchange, the
transaxle must be at operating temperature. Drive
the vehicle till it reaches full operating temperature.
(2) Verify that the fill tank on the transaxle fluid
exchanger (ATF 2000+ or equivalent) is clean and
dry.
(3) Fill the tank to the recommended fill capacity
with Mopar ATF Plus 3 Type 7176.
(4) Hookup the vehicle to the machine following
the manufacturers instructions. Perform the
exchange procedure following the instructions pro-
vided with the machine.
(5) Once machine has completed the fluid
exchange. Check the fluid level and condition and fill
to proper level with Mopar ATF Plus 3 Type 7176.
NOTE: Verify that the transaxle cooler lines are
tightened to proper specifications. Cooler line
torque specification is 2 N²m (18 in. lbs.).
DIPSTICK TUBE FLUID SUCTION METHOD
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
Fig. 4 Air Pressure Tests
21 - 16 TRANSAXLE AND POWER TRANSFER UNITNS
SERVICE PROCEDURES (Continued)

(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (Vaculay
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) Add 4 Quarts of Mopar ATF Plus 3 Type 7176
transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be in
the HOT range.
TRANSAXLE OIL PAN DROP METHOD
This procedure involves removing the transaxle oil
pan to drain the transaxle fluid.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N²m (165 in. lbs.).
(6) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be inthe HOT range. Drive the vehicle a minimum of 10
miles.
(10) Raise the vehicle on the hoist.
(11) Check for leaks around the transaxle oil pan
sealing surfaces.
(12) Recheck the fluid level. The level should be in
the HOT range.
SEVERE USAGE SERVICE
If the vehicle exhibits any of the following symp-
toms, it is recommended that the transaxle oil and
filter be replaced.
²Transaxle oil discolored
²Transaxle oil has high mileage
²Oil feels grimy when rubbed between fingertips
²Poor shift quality
²Delayed gear engagement
²Vehicle shudder between shifts
TRANSAXLE OIL AND FILTER REPLACEMENT
This procedure involves changing the transaxle
fluid and filter, driving the vehicle for 10 miles and
changing the transaxle fluid a second time.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Separate the filter and O-ring from the valve
body. Inspect the O-ring for cuts or improper instal-
lation. This could lead to delayed garage shifts.
(6) Install a new filter. Replace the O-ring as nec-
essary.
(7) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N²m (165 in. lbs.).
(8) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(9) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(10) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(11) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range. Drive the vehicle a minimum of
10 miles.
(12) Raise the vehicle on the hoist.
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 17
SERVICE PROCEDURES (Continued)

(13) Remove the pan and clean all sealant from
the pan and transaxle mating surfaces. Clean the
magnet and the inside of the pan.
(14) Separate the filter from the valve body to
allow additional fluid to drain from the transaxle.
Inspect the filter O-ring for any damage and replace
as necessary.
(15) After the transaxle has stopped draining,
reinstall the filter and O-ring.
(16) Apply a 1/8 inch bead of Mopar RTV Sealant
to the mounting flange of the transaxle oil pan.
Apply RTV Sealant to the underside of the attaching
bolts. Attach the oil pan to the transaxle. Tighten the
bolts to 19 N²m (165 in. lbs.).
(17) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(18) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(19) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(20) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range.
FLUID DRAIN AND REFILL
(1) Raise vehicle on a hoist (See Group 0, Lubrica-
tion). 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 gasket on bottom of the
valve body and tighten retaining screws to 5 N´m (40
inch-pounds).
(4) Clean the oil pan and magnet. Reinstall pan
using new sealant. Tighten oil pan bolts to 19 N´m
(165 in. lbs.).
(5) Pour four quarts of Mopar ATF PLUS 3 (Auto-
matic Transmission Fluid) Type 7176 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) Add sufficient fluid to bring level to 1/8 inch
below the ADD mark.
(8) Recheck fluid level after transaxle is at normal
operating temperature. The level should be in the
HOT region.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum transaxle
case and valve body can be repaired by the use of Heli-
Coils, or equivalent. This repair consists of drilling out
the worn-out damaged threads. Then tapping the hole
with a Heli-Coil tap, or equivalent, and installing a
Heli-Coil insert, or equivalent, into the hole. This
brings the hole back to its original thread size.
Heli-Coil, or equivalent, tools and inserts are readily
available from most automotive parts suppliers.
FLUSHING COOLERS AND TUBES
When a transaxle failure has contaminated the
fluid, the oil cooler(s) must be flushed. The cooler
bypass valve in the transaxle must be replaced also.
The torque converter must also be replaced with an
exchange unit. This will ensure that metal particles
or sludged oil are not later transferred back into the
reconditioned (or replaced) transaxle.
The recommended procedure for flushing the cool-
ers and tubes is to use Tool 6906A Cooler Flusher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover plate filler plug on Tool 6906A.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906A.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
21 - 18 TRANSAXLE AND POWER TRANSFER UNITNS
SERVICE PROCEDURES (Continued)

(5) Continuity should exist only with transaxle in
Reverse position.
(6) No continuity should exist from either pin to
the case.
TRANSAXLE AND TORQUE CONVERTER REMOVAL
NOTE: Transaxle removal does NOT require engine
removal.
The transaxle and torque converter must be
removed as an assembly; otherwise, the torque con-
verter drive plate, pump bushing, or oil seal may be
damaged. The drive plate will not support a load;
therefore, none of the weight of the transaxle should
be allowed to rest on the plate during removal.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner and hoses.
(3) Disconnect throttle linkage and shift linkage
from transaxle.
(4) Unplug torque converter clutch connector,
located near the dipstick. Unplug the gear position
switch.
(5) Remove transaxle dipstick tube.
(6) Remove the transaxle cooler lines and plug.
(7) Install engine support fixture (Fig. 5) .
(8) Remove bell housing upper bolts.
(9) Raise vehicle. Remove front wheels. Refer to
Group 2, Suspension to remove or install wheel hub
nut and both drive shafts.
CAUTION: The exhaust flex joint must be discon-
nected from the exhaust manifold anytime the
engine is lowered. If the engine is lowered while the
flex pipe is attached, damage will occur.(10) Remove bolts securing exhaust flex joint to
exhaust manifold. Disconnect exhaust pipe from
manifold.
(11) Remove torque converter dust cover. Mark
torque converter and drive plate with chalk, for reas-
sembly. Rotate engine clockwise and remove torque
converter mounting bolts.
(12) Remove engine mount bracket from front
crossmember.
(13) Remove front mount insulator through-bolt
and bellhousing bolts.
(14) Position transaxle jack (Fig. 6) .
(15) Remove rear engine mount shield.
(16) Remove rear engine mount bracket bolts and
bracket.
(17) Remove left engine mount thru-bolt.
(18) Remove left engine mount from transaxle.
(19) Remove starter. Remove lower bell housing
bolts.
(20) Carefully work transaxle and torque converter
assembly rearward off engine block dowels and dis-
engage converter hub from end of crankshaft.Attach
a small C clamp to edge of bell housing. This
will hold torque converter in place during tran-
saxle removal.Lower transaxle and remove assem-
bly from under the vehicle.
(21) To remove torque converter assembly, remove
C±clamp from edge of bellhousing and slide converter
out of transaxle.
INSTALLATION
(1) When installing transaxle, reverse the above
procedure.
(2) If torque converter was removed from transaxle
be sure to align pump inner gear pilot flats with
torque converter impeller hub flats.
(3) Adjust gearshift and throttle cables.
(4) Refill transaxle with Mopar ATF PLUS 3
(Automatic Transmission Fluid) Type 7176.
Fig. 5 Engine Support Fixture
Fig. 6 Transaxle Jack
21 - 20 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)

OPERATION
The gear ratios for the 41TE transaxle are as fol-
lows:
²1stÐ2.84
²2ndÐ1.57
²3rdÐ1.00
²ODÐ0.69
²ReverseÐ2.21
Final Drive Ratio is dependent on which engine
option is selected.
²2.4 Liter: 3.91 FDR
²3.3 Liter: 3.62 FDR
²3.8 Liter: 3.45 FDR
The torque converter clutch is available in 2nd,
direct, or overdrive gear;. The shift lever is conven-
tional with six positions: P, R, N, OD, 3, and L avail-
able. When OD is selected the transaxle shifts
through all four speeds with torque converter clutch
available in overdrive. This position is recommended
for most driving. The 3 position is tailored for use in
hilly or mountainous driving. When 3 is selected, the
transmission uses only 1st, 2nd, and direct gears
with 2nd-direct shift delayed to 40 mph or greater.
When operating in 3 or L positions torque converter
clutch application occurs in direct gear. This
improves transmission cooling under heavy loads. If
high engine coolant temperature occurs, the torque
converter clutch will also engage in 2nd gear. The L
position provides maximum engine braking for
descending steep grades. Unlike most current tran-
saxles, upshifts are provided to 2nd or direct gear at
peak engine speeds if the accelerator is depressed.
This provides engine over-speed protection and max-
imum performance.
FLUID LEVEL AND CONDITION
NOTE: The transmission and differential sump have
a common oil sump with an opening between the
two.
The torque converter fills in both the (P) Park and
(N) Neutral positions. Place the selector lever in (P)
Park to check the fluid level.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 stabilization between
differential and transmission.The fluid should be
at normal operating temperature (approximately 82
C. or 180 F.). The fluid level is correct if it is in the
HOTregion (cross-hatched area) on the oil level indi-
cator.
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 accumulator
operation. Foaming can also result in fluid escaping
from the transaxle vent where it may be mistaken
for a leak.
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 overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
If there is any doubt about its condition, drain out a
sample for a double check.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
SELECTION OF LUBRICANT
It is important that the proper lubricant be used in
the 41TE transaxle. MOPARtATF PLUS 3 (Auto-
matic Transmission FluidÐtype 7176) should be used
to aid in assuring optimum transmission perfor-
mance. Fluids of the type labeled DEXRON II Auto-
matic Transmission Fluid arenot recommended.It
is important that the transmission fluid be main-
tained at the prescribed level using the recommended
fluids.
SPECIAL ADDITIVES
Chrysler Corporation does not recommend the
addition of any fluids to the transaxle, other than the
fluid listed above. An exception to this policy is the
use of special dyes to aid in detecting fluid leaks. The
use of transmission sealers should be avoided, since
they may adversely affect seals.
DESCRIPTION AND OPERATION
CLUTCH AND GEAR
The transaxle consists of:
²Three multiple disc input clutches
²Two multiple disc grounded clutches
²Four hydraulic accumulators
²Two planetary gear sets
This provides four forward ratios and a reverse
ratio. The input clutch-apply pistons were designed
with centrifugally balanced oil cavities so that quick
response and good control can be achieved at any
speed. A push/pull piston is incorporated for two of
the three input clutches.
21 - 72 TRANSAXLE AND POWER TRANSFER UNITNS
GENERAL INFORMATION (Continued)

If a problem arises with the shifter position indica-
tor, consult the following chart for diagnostic infor-
mation. If the malfunction cannot be corrected using
the chart, consult the proper diagnostic manual.
To replace the shifter position indicator, refer to
Group 8E, Instrument Panel And Gauges.SERVICE PROCEDURES
FLUID AND FILTER CHANGE
When the factory fill fluid is changed, only fluids
labeled MOPARtATF PLUS 3 (Automatic Transmis-
sion fluid) Type 7176 should be used.
If the transaxle is disassembled for any reason, the
fluid and filter should be changed.
30,000 MILE TRANSAXLE OIL CHANGE
When a vehicle attains 30,000 miles on its odome-
ter it is recommended that the transaxle oil be
changed. To change the oil, use the procedure that
follows:
It is recommended that a transaxle fluid exchanger
(ATF 2000+ or equivalent) be used to replace the
used fluid in the transaxle. If a fluid exchanger is not
available use a fluid suction pump (Vaculayor equiv-
alent) to draw the fluid out of the dipstick tube. If a
fluid suction pump is not available remove the oil
pan and drain the fluid.
CAUTION: Chrysler Corporation does not recom-
mend using any fluid exchanger that introduces
additives into the transaxle.
TRANSAXLE FLUID EXCHANGER METHOD
(1) To perform the transaxle fluid exchange, the
transaxle must be at operating temperature. Drive
the vehicle till it reaches full operating temperature.
(2) Verify that the fill tank on the transaxle fluid
exchanger (ATF 2000+ or equivalent) is clean and
dry.
(3) Fill the tank to the recommended fill capacity
with Mopar ATF Plus 3 Type 7176.
(4) Hookup the vehicle to the machine following
the manufacturers instructions. Perform the
exchange procedure following the instructions pro-
vided with the machine.
(5) Once machine has completed the fluid
exchange. Check the fluid level and condition and fill
to proper level with Mopar ATF Plus 3 Type 7176.
NOTE: Verify that the transaxle cooler lines are
tightened to proper specifications. Cooler line
torque specification is 2 N´m (18 in. lbs.).
CONDITION POSSIBLE CAUSE
ALL PRND3L DISPLAY
LIGHTS9ON9IN P&N
GEAR POSITIONS1.Check wiring and
connectors
2. Faulty trans. range
sensor
3. Faulty manual lever
ALL DISPLAY LIGHTS
9ON9IN ALL GEAR
POSITIONS1. Check wiring &
connectors
2. Faulty trans. range
sensor
3. Faulty manual lever
4. CCD communication
malfunction
5. Check oil level
ALL DISPLAY LIGHTS
9OFF91. Normal transient
condition between P&R
and R&N gear positions
2. Check shift lever
linkage
3. Body controller
malfunction
4. Check wiring and
connectors
5. Faulty cluster
ALL DISPLAY LIGHTS
9OFF9ACCOMPANIED
BY A9NO BUS9
MESSAGE1. CCD communication
malfunction
DISPLAY LIGHTS OUT
OF SEQUENCE WITH
SHIFT LEVER1. Check wiring and
connectors
2. Faulty trans. range
sensor
3. Faulty manual lever
4. CCD communication
malfunction
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 79
DIAGNOSIS AND TESTING (Continued)

DIPSTICK TUBE FLUID SUCTION METHOD
(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 (Vaculay
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) Add 4 Quarts of Mopar ATF Plus 3 Type 7176
transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be in
the HOT range.
TRANSAXLE OIL PAN DROP METHOD
This procedure involves removing the transaxle oil
pan to drain the transaxle fluid.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N²m (165 in. lbs.).
(6) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid levelto 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be in
the HOT range. Drive the vehicle a minimum of 10
miles.
(10) Raise the vehicle on the hoist.
(11) Check for leaks around the transaxle oil pan
sealing surfaces.
(12) Recheck the fluid level. The level should be in
the HOT range.
SEVERE USAGE SERVICE
If the vehicle exhibits any of the following symp-
toms, it is recommended that the transaxle oil and
filter be replaced.
²Transaxle oil discolored
²Transaxle oil has high mileage
²Oil feels grimy when rubbed between fingertips
²Poor shift quality
²Delayed gear engagement
²Vehicle shudder between shifts
TRANSAXLE OIL AND FILTER REPLACEMENT
This procedure involves changing the transaxle
fluid and filter, driving the vehicle for 10 miles and
changing the transaxle fluid a second time.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Separate the filter and O-ring from the valve
body. Inspect the O-ring for cuts or improper instal-
lation. This could lead to delayed garage shifts.
(6) Install a new filter. Replace the O-ring as nec-
essary.
(7) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N´m (165 in. lbs.).
(8) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(9) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(10) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
21 - 80 TRANSAXLE AND POWER TRANSFER UNITNS
SERVICE PROCEDURES (Continued)

(11) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range. Drive the vehicle a minimum of
10 miles.
(12) Raise the vehicle on the hoist.
(13) Remove the pan and clean all sealant from
the pan and transaxle mating surfaces. Clean the
magnet and the inside of the pan.
(14) Separate the filter from the valve body to
allow additional fluid to drain from the transaxle.
Inspect the filter O-ring for any damage and replace
as necessary.
(15) After the transaxle has stopped draining,
reinstall the filter and O-ring.
(16) Apply a 1/8 inch bead of Mopar RTV Sealant
to the mounting flange of the transaxle oil pan.
Apply RTV Sealant to the underside of the attaching
bolts. Attach the oil pan to the transaxle. Tighten the
bolts to 19 N´m (165 in. lbs.).
(17) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(18) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(19) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(20) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range.
FLUID DRAIN AND REFILL
(1) Raise vehicle on a hoist (See Group 0, Lubrica-
tion). 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.
(4) Clean the oil pan and magnet. Reinstall pan
using new MOPARtRTV sealant. Tighten oil pan
bolts to 19 N´m (165 in. lbs.).
(5) Pour four quarts of MOPARtATF PLUS 3
(Automatic Transmission Fluid) Type 7176 through
the fill tube.
(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) Add sufficient fluid to bring level to 1/8 inch
below the ADD mark.
CAUTION: Do not overfill transaxle. Do not add oil
if level is between: Lower holes for warm oil
(100ÉF). Upper holes for hot oil (180ÉF).
(8) Recheck fluid level after transaxle is at normal
operating temperature. The level should be in the
HOT region (Fig. 5).
(9) To prevent dirt from entering transaxle, make
certain that dipstick is seated into the dipstick fill
tube.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum tran-
saxle case and valve body can be repaired by the use
of Heli-Coils, or equivalent. This repair consists of
drilling out the worn-out damaged threads. Then tap
the hole with a special Heli-Coil tap, or equivalent,
and installing a Heli-Coil insert, or equivalent, into
the hole. This brings the hole back to its original
thread size.
Heli-Coil, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
FLUSHING COOLERS AND TUBES
When a transaxle failure has contaminated the
fluid, the oil cooler(s) must be flushed. The cooler
bypass valve in the transaxle must be replaced also.
The torque converter must also be replaced with an
exchange unit. This will insure that metal particles
or sludged oil are not later transferred back into the
reconditioned (or replaced) transaxle.
The recommended procedure for flushing the tran-
saxle cooler is to use Tool 6906A Cooler Flusher.
Fig. 5 Oil Level Indicator
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 81
SERVICE PROCEDURES (Continued)