oil type CHRYSLER VOYAGER 1996 Workshop Manual

REMOVAL AND INSTALLATION
2.4 LITER POWER STEERING PUMP
REMOVE
WARNING: POWER STEERING OIL, ENGINE COM-
PONENTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Remove the (-) negative battery cable from the
battery and isolate cable.
(4) Remove the drive belt from the power steering
pump pulley. See Cooling, Group 7 for detailed
removal procedure.
(5) Loosenbut do not removethe nut attaching
the front bracket for the power steering pump (Fig.
3) to the aluminum mounting bracket.
(6) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting, in the Lubri-
cation and Maintenance section of this service man-
ual for the required lifting procedure.
(7) Disconnect the oxygen sensor wiring harness
from the vehicle wiring harness. Access to connection
at vehicle wiring harness is through the oxygen sen-
sor wiring harness grommet in the floor pan of the
vehicle.
NOTE: The exhaust system needs to be removed
from the engine to allow for an area to remove the
power steering pump from the vehicle.(8) Remove the catalytic converter from the
exhaust manifold. Then remove all the exhaust sys-
tem hangers/isolators from the brackets on the
exhaust system.
(9) Move the exhaust system as far rearward and
to the left side of the vehicle as possible (Fig. 4).
(10) Raise the heat sleeve on the power steering
return hose to expose the hose to steel tube connec-
tion (Fig. 5). Remove the hose from the power steer-
ing fluid return line on the front suspension cradle
(Fig. 5). Allow the remaining power steering fluid to
drain from the power steering pump and reservoir
through the removed return hose.
Fig. 3 Power Steering Pump Bracket Attaching Nut
Fig. 4 Exhaust Positioned For Removing Power
Steering Pump
Fig. 5 Power Steering Return Hose At Return Line
NSSTEERING 19 - 11

(18) Remove the 3 previously loosened bolts
attaching the front bracket to the power steering
pump and separate the power steering pump from
the front bracket prior to removing the pump from
the vehicle.
(19) The power steering pump is removed from the
vehicle by pulling it out through the exhaust tunnel
area in the floor pan of the vehicle.
INSTALL
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the
exhaust tunnel are of the vehicle.
(2) Install the power steering pump on its cast
mounting bracket and loosely install nut to hold
pump in place (Fig. 9).
(3) Install the front bracket on the power steering
pump and loosely install the 3 mounting bolts (Fig.
10). Then install the nut and bolt attaching the front
bracket to the cast bracket (Fig. 10).
(4) Tighten the 3 power steering pump mounting
bolts (Fig. 10) to a torque of 54 N´m (40 ft. lbs.).
NOTE: Before installing power steering fluid pres-
sure hose on power steering pump, inspect the
O-ring on the pressure hose for damage and
replace if necessary.
(5) Install the power steering fluid pressure line
onto the output fitting of the power steering pump
(Fig. 8). Tighten the pressure line to pump fitting
tube nut to a torque of 31 N´m (275 in. lbs.).
(6) Install the power steering fluid, low pressure
return hose on the power steering pump low pressure
fitting (Fig. 8).Be sure hose clamps are properly
reinstalled.
(7) Install the power steering fluid supply hose
from the power steering fluid reservoir, on the power
steering pump fluid fitting (Fig. 7).Be sure hose is
clear of accessory drive belts all hose clamps
are properly reinstalled.
(8) Install the power steering pump drive belt on
pulley. See Cooling, Group 7 for detailed installation
procedure.
(9) Install the accessory drive splash shield (Fig.
6).
(10) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig. 5).
(11) Install a screw type hose clamp on the power
steering hose to steel tube connection.Be sure hose
clamps are properly reinstalled.Tighten the screw
clamp to a torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 5). This is requiredto prevent the overheating of the power steering
hoses.
(12) When used, properly position the protective
heat sleeves on the power steering hoses (Fig. 5).
Then, tie strap the heat sleeves to the power steering
hoses to keep them in their proper position.
(13) Install the exhaust pipe on the exhaust man-
ifold. Install all exhaust system hangers/isolators on
the exhaust system brackets.
(14) Connect the oxygen sensor wiring harness to
the vehicle wiring harness. Install wiring harness
grommet in the floor pan of the vehicle.
(15) Lower vehicle.
(16) Adjust the power steering pump drive belt.
See Cooling, Group 7 for detailed adjustment proce-
dure.
(17) Tighten the top nut and bottom bolt on the
power steering pump front mounting bracket (Fig. 3)
to a torque of 54 N´m (40 ft. lbs.).
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use MoparT, Power
Steering Fluid, or equivalent.
(18) Fill the remote power steering pump fluid res-
ervoir to correct fluid level.
(19) Install cap on power steering fluid reservoir.
(20) Connect the negative battery cable on the
negative battery post.
(21) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
3.0 LITER POWER STEERING PUMP
REMOVE
WARNING: POWER STEERING OIL, ENGINE COM-
PONENTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove cap from power steering fluid reser-
voir.
(3) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
NSSTEERING 19 - 13
REMOVAL AND INSTALLATION (Continued)

(15) Fill the remote power steering pump fluid res-
ervoir to correct fluid level.
(16) Install cap on power steering fluid reservoir.
(17) Connect the negative battery cable on the
negative battery post.
(18) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
3.3/3.8 LITER POWER STEERING PUMP
REMOVE
WARNING: POWER STEERING OIL, ENGINE COM-
PONENTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove cap from power steering fluid reser-
voir.
(3) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(4) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting, in the Lubri-
cation and Maintenance section of this service man-
ual for the required lifting procedure.
(5) Disconnect the oxygen sensor wiring harness
from the vehicle wiring harness. Access to connection
at vehicle wiring harness is through the oxygen sen-
sor wiring harness grommet in the floor pan of the
vehicle.
NOTE: The exhaust system needs to be removed
from the engine to allow for an area to remove the
power steering pump from the vehicle.
(6) Remove the catalytic converter from the
exhaust manifold. Then remove all the exhaust sys-
tem hangers/isolators from the brackets on the
exhaust system.
(7) Move the exhaust system as far rearward and
to the left side of the vehicle as possible (Fig. 17).
(8) Raise the heat sleeve on the power steering
hoses to expose the hose to steel tube connection.
Remove the hose from the power steering fluid
return line on the front suspension cradle (Fig. 18).
Allow the remaining power steering fluid to drain
from the pump and fluid reservoir through the
removed return hose.
(9) Remove the accessory drive splash shield (Fig.
19).
Fig. 17 Exhaust Position For Removing Power
Steering Pump
Fig. 18 Power Steering Return Hose At Return Line
Fig. 19 Accessory Drive Splash Shield
19 - 16 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(5) Remove at power steering pump, the power
steering fluid hose coming from the power steering
fluid reservoir. Let the power steering fluid drain out
of the reservoir and hose.
(6) Lower vehicle.
(7) Remove hose clamp attaching the power steer-
ing fluid supply hose to the power steering fluid res-
ervoir (Fig. 24).
(8) Remove the power steering fluid supply hose
from the vehicle. Hose is removed from the top of the
engine compartment.
INSTALL
CAUTION: On V-6 engine applications, the power
steering fluid reservoir to power steering hose must
be routed tightly against the strut tower and parallel
to the dash panel. It must also be routed under the
wiring harness and below the drip tube. This rout-
ing will prevent the power steering fluid supply
hose from coming in contact with the accessory
drive belt.
(1) Install and correctly route the power steering
fluid supply hose from remote fluid reservoir down to
power steering pump.
(2) Install the fluid supply hose onto the power
steering fluid reservoir (Fig. 24). Install the hose
clamp on the fluid supply hose.Be sure hose clamp
is installed past bead on fluid reservoir fitting.
(3) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(4) Install power steering fluid supply hose on
power steering pump. Install the hose clamp on the
fluid supply hose.Be sure hose clamp is installed
past bead on pump fitting.
(5) Lower vehicle.
(6) Install routing clip on power steering fluid sup-
ply hose. Be sure routing clip is installed in a posi-
tion to correctly align with stud in strut tower.
(7) Install routing clip for power steering fluid sup-
ply hose on stud in strut tower (Fig. 25).
(8) Fill the remote fluid reservoir to the proper
level and let the fluid settle for at least two (2) min-
utes.
(9) Start the engine and let run for a few seconds.
Then turn the engine off.
(10) Add fluid if necessary. Repeat the above pro-
cedure until the fluid level remains constant after
running the engine.
(11) Raise the front wheels off the ground.(12) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(13) Add power steering fluid if necessary.
(14) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(15) Stop the engine. Check the fluid level and
refill as required.
(16) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
POWER STEERING FLUID PRESSURE HOSE
Service all power steering hoses with vehicle raised
on hoist. Cap all open ends of hoses, power steering
pump fittings and steering gear ports to prevent
entry of foreign material into the components.
WARNING: POWER STEERING OIL, ENGINE
PARTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
For part reference and part location for the vehicle
that is being serviced, refer to the following figure
numbers. These show the hose bracket locations,
hose routings and fitting locations by the engine
application of the vehicle. Use these figure numbers
when referring to the removal or installation proce-
dures for the power steering hoses listed below.
REMOVE
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Raise vehicle See Hoisting, Group 0. Put oil
drain pan under vehicle to catch power steering fluid.
(4) Raise the heat sleeve on the power steering
fluid return hose (Fig. 26) to expose the return hose
to steel tube connection. Remove the hose clamp from
the power steering fluid return hose (Fig. 26).
Remove power steering fluid return hose from steel
tube and allow power steering fluid to drain from
pump.
NSSTEERING 19 - 19
REMOVAL AND INSTALLATION (Continued)

(6) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig.
26).
(7) Install a screw type hose clamp on the power
steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat sleeves must cover
the entire rubber hose and hose to tube connection
portion of both the power steering fluid pressure
and return hoses (Fig. 26).
(8) When used, properly position the protective
heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses to
keep them in their proper position.
(9) After hoses are installed and power steering
system is filled with fluid and cap is installed on res-
ervoir. Start the engine and check for leaks. (See
Pump Installation).
POWER STEERING FLUID RETURN HOSE
Service all power steering hoses with vehicle raised
on hoist. Cap all open ends of hoses, power steering
pump fittings and steering gear ports to prevent
entry of foreign material into the components.
WARNING: POWER STEERING OIL, ENGINE
PARTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
For part reference and part location for the vehicle
that is being serviced, refer to the following figure
numbers. These show the hose bracket locations,
hose routings and fitting locations by the engine
application of the vehicle. Use these figure numbers
when referring to the removal or installation proce-
dures for the power steering hoses listed below.
REMOVE
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Raise vehicle See Hoisting, Group 0. Put oil
drain pan under vehicle to catch power steering fluid.
(4) Raise the insulating heat sleeve on the power
steering hoses to expose the hose to steel tube con-
nection. Remove hose clamp where rubber portion of
power steering fluid return hose attaches to steel
tube on suspension cradle (Fig. 30). Remove rubber
hose from steel tube and allow power steering fluid
to drain from pump.(5) Remove the power steering fluid return hose
from the power steering pump return hose fitting.
INSTALL
(1) Using a lint free towel, wipe clean the open
power steering hose ends and power steering pump
fitting.
(2) Attach the power steering return hose to the
fitting on the power steering pump. Route hose
smoothly avoiding tight bends or kinking. Hose must
remain away from the exhaust system and not come
in contact with any unfriendly surfaces of the vehi-
cle.
(3) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig.
30).
(4) Install a screw type hose clamp on the power
steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 30). This is to pre-
vent overheating of the power steering fluid hoses.
(5) When used, position the protective heat sleeves
on the power steering hoses so they cover the connec-
tion to the power steering pump. Then, tie strap the
heat sleeves to the power steering hoses to keep
them in their proper position.
(6) After hoses are installed and power steering
system is filled with fluid and cap is installed on res-
ervoir. Start the engine and check for leaks. (See
Pump Installation).
Fig. 30 Power Steering Return Hose At Steel Tube
NSSTEERING 19 - 21
REMOVAL AND INSTALLATION (Continued)

POWER STEERING GEAR
INDEX
page page
DESCRIPTION AND OPERATION
STEERING GEAR OPERATION DESCRIPTION . 26
DIAGNOSIS AND TESTING
POWER STEERING GEAR................. 27
REMOVAL AND INSTALLATION
STEERING GEAR....................... 27
DISASSEMBLY AND ASSEMBLY
OUTER TIE ROD END................... 33STEERING GEAR INNER TIE ROD BOOT..... 31
SPECIFICATIONS
STEERING GEAR FASTENER TORQUE
SPECIFICATIONS...................... 34
SPECIAL TOOLS
POWER STEERING GEAR................. 35
DESCRIPTION AND OPERATION
STEERING GEAR OPERATION DESCRIPTION
NOTE: The power steering gear (Fig. 1) should NOT
be serviced or adjusted. If a malfunction or oil leak
occurs, the complete steering gear should be
replaced.
If a steering gear boot needs to be replaced due to
damage, refer to the power steering gear service sec-
tion in this manual for proper procedure.
The power steering system consists of these four
major components. Power Steering Gear, Power
Steering Pump, Pressure Hose, and Return Line.Turning of the steering wheel is converted into linear
travel through the meshing of the helical pinion
teeth with the rack teeth. Power assist steering is
provided by an open center, rotary type control valve
which directs oil from the pump to either side of the
integral rack piston.
Road feel is controlled by the diameter of a torsion
bar which initially steers the vehicle. As required
steering effort increases, as in a turn, the torsion bar
twists, causing relative rotary motion between the
rotary valve body and the valve spool. This move-
ment directs oil behind the integral rack piston,
which, in turn, builds up hydraulic pressure and
assists in the turning effort.
Fig. 1 Power Steering Gear Assembly
19 - 26 STEERINGNS

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

If there is any doubt about its condition, drain out a
sample for a double check.
SELECTION OF LUBRICANT
It is important that the proper lubricant be used in
these transmissions. Mopar ATF PLUS 3 (Automatic
Transmission Fluid- type 7176) should be used to aid
in ensuring optimum transmission performance. It is
important that the transmission fluid be maintained
at the prescribed level using the recommended fluids.
SPECIAL ADDITIVES
Chrysler Corporation does not recommend the
addition of any fluids to the transmission, other than
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
TORQUE CONVERTER CLUTCH
A torque converter clutch is standard on all vehi-
cles. The torque converter clutch is activated only in
direct drive and is controlled by the engine electron-
ics. A solenoid on the valve body, is powered by the
powertrain control module to activate torque con-
verter clutch.
HYDRAULIC CONTROL SYSTEM
The hydraulic control system makes the transaxle
fully automatic, and has four important functions to
perform. The components of any automatic control
system may be grouped into the following basic
groups:
The pressure supply system, the pressure regulat-
ing valves, the flow control valves, the clutches, and
band servos.
Taking each of these basic groups or systems in
turn, the control system may be described as follows:
PRESSURE SUPPLY SYSTEM
The pressure supply system consists of an oil pump
driven by the engine through the torque converter.
The single pump furnishes pressure for all the
hydraulic and lubrication requirements.Oil pump
housing assemblies are available with prese-
lected pump gears.
PRESSURE REGULATING VALVES
The pressure regulating valve controls line pres-
sure dependent on throttle opening. The governor
valve transmits regulated pressure to the valve body
(in conjunction with vehicle speed) to control upshift
and downshift.The throttle valve transmits regulated pressure to
the transaxle (dependent on throttle position) to con-
trol upshift and downshift.
FLOW CONTROL VALVES
The manual valve provides the different transaxle
drive ranges as selected by the vehicle operator.
The 1-2 shift valve automatically shifts the tran-
saxle from first to second or from second to first,
depending on the vehicle operation.
The 2-3 shift valve automatically shifts the tran-
saxle from second to third or from third to second
depending on the vehicle operation.
The kickdown valve makes possible a forced down-
shift from third to second, second to first, or third to
first (depending on vehicle speed). This can be done
by depressing the accelerator pedal past the detent
feel near wide open throttle.
The shuttle valve has two separate functions and
performs each independently of the other. The first is
providing fast release of the kickdown band, and
smooth front clutch engagement when a lift-foot
upshift from second to third is made. The second
function is to regulate the application of the kick-
down servo and band when making third to second
kickdown.
The by-pass valve provides for smooth application
of the kickdown band on 1-2 upshifts.
The torque converter clutch solenoid allows for the
electronic control of the torque converter clutch. It
also disengages the torque converter at closed throt-
tle. This is done during engine warm-up, and part-
throttle acceleration.
The switch valve directs oil to apply the torque
converter clutch in one position. The switch valve
releases the torque converter clutch in the other posi-
tion.
CLUTCHES, BAND SERVOS, AND ACCUMULATOR
The front and rear clutch pistons, and both servo
pistons are moved hydraulically to engage the
clutches and apply the bands. The pistons are
released by spring tension when hydraulic pressure
is released. On the 2-3 upshift, the kickdown servo
piston is released by spring tension and hydraulic
pressure.
The accumulator controls the hydraulic pressure
on the apply side of the kickdown servo during the
1-2 upshift; thereby, cushioning the kickdown band
application at any throttle position.
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 3
GENERAL INFORMATION (Continued)

GEARSHIFT AND PARKING LOCK CONTROLS
The transaxle is controlled by a lever type gear-
shift incorporated within the steering column. The
control has six selector lever positions: P (park), R
(reverse), N (neutral), and D (drive), 2 (second), and
1 (first). The parking lock is applied by moving the
selector lever past a gate to the P position.Do not
apply the parking lock until the vehicle has
stopped; otherwise, a severe ratchet noise will
occur.
TORQUE CONVERTER CLUTCH SOLENOID WIRING
CONNECTOR
If wiring connector is unplugged, the torque con-
verter will not engage (Fig. 1) .
GOVERNOR
The governor may be serviced by removing the
transaxle oil pan and valve body assembly. The gov-
ernor may be unbolted from the governor support
and removed from the transaxle for reconditioning or
replacement.
When cleaning or assembling the governor, make
sure the governor valves move freely in the bores of
the governor body.
DIAGNOSIS AND TESTING
THREE SPEED TRANSAXLE DIAGNOSIS AND
TESTS
Automatic transaxle malfunctions may be caused
by four general conditions:
(1) Poor engine performance
(2) Improper adjustments
(3) Hydraulic malfunctions
(4) Mechanical malfunctionsDiagnosis of these problems should always begin
by checking the easily accessible variables; fluid level
and condition, gearshift cable adjustment, and throt-
tle pressure cable adjustment. Then perform a road
test to determine if the problem has been corrected
or that more diagnosis is necessary. If the problem
exists after the preliminary tests and corrections are
completed, hydraulic pressure tests should be per-
formed
31TH HYDRAULIC TROUBLE CODE CHARTS
The following charts should be used to help diag-
nose hydraulic or mechanical faults in the transaxle .
ROAD TEST
Prior to performing a road test, check the fluid
level, and control cable adjustments.
During the road test, the transaxle should be oper-
ated in each position to check for slipping and any
variation in shifting.
If vehicle operates at high speeds, but has poor
acceleration, the converter's overrunning clutch may
be slipping. If acceleration is normal, but high throt-
tle opening is needed for high speeds, the stator
clutch may have seized.
Observe closely for slipping or engine speed flare-
up. Slipping or flare-up in any gear usually indicates
clutch, band, or overrunning clutch problems. If the
condition is far advanced, an overhaul will probably
be necessary to restore normal operation.
In most cases, the clutch or band that is slipping
can be determined by noting the transaxle operation
in all selector positions. Then comparing which inter-
nal units are applied in those positions. The Ele-
ments in Use Chart provides a basis for road test
analysis .
The rear clutch is applied in both the D first gear
and 1 first gear positions. Also the overrunning
clutch is applied in D first gear and the low/reverse
band is applied in 1 first gear position. If the tran-
saxle slips in D range first gear, but does not slip in
1 first gear, the overrunning clutch is slipping. Simi-
larly, if the transaxle slips in any two forward gears,
the rear clutch is slipping.
Using the same procedure, the rear clutch and
front clutch are applied in D third gear. If the tran-
saxle slips in third gear, either the front clutch or the
rear clutch is slipping. By selecting another gear
which does not use one of those units, the unit which
is slipping can be determined. If the transaxle also
slips in reverse, the front clutch is slipping. If the
transaxle does not slip in reverse, the rear clutch is
slipping.
The process of eliminating can be used to detect
any unit which slips and to confirm proper operation
of good units. Road testing can usually diagnose slip-
ping units. Although the actual cause of the problem
Fig. 1 Torque Converter Clutch Solenoid Wiring
Connector
21 - 4 TRANSAXLE AND POWER TRANSFER UNITNS
DESCRIPTION AND OPERATION (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)