clutch CHRYSLER VOYAGER 1996 Manual Online

may not be detected. Practically any condition can be
caused by leaking hydraulic circuits or sticking
valves.
Therefore, unless the condition is obvious, the tran-
saxle should never be disassembled until hydraulic
pressure tests have been performed.
HYDRAULIC PRESSURE TESTS
Pressure testing is a very important step in the
diagnostic procedure. These tests usually reveal the
cause of most transaxle problems.
Before performing pressure tests, be certain that
fluid level and condition, and control cable adjust-
ments have been checked and approved. Fluid must
be at operating temperature (150 to 200 degrees F.).
Install an engine tachometer, raise vehicle on hoist
which allows front wheels to turn, and position
tachometer so it can be read.
Disconnect throttle cable and shift cable from tran-
saxle levers so they can be controlled from outside
the vehicle.
Attach 150 psi gauges to ports required for test
being conducted. A 300 psi gauge (C-3293) is required
for reverse pressure test at rear servo.
Test port locations are shown in (Fig. 2) .
TEST ONE (SELECTOR IN 1)
(1) Attach gauges to line and low-reverse ports.
(2) Operate engine at 1000 rpm for test.
(3) Move selector lever on transaxle all the way
rearward (1 position).
(4) Read pressures on both gauges as throttle lever
on transaxle is moved from full clockwise position to
full counterclockwise position.
(5) Line pressure should read 52 to 58 psi with
throttle lever clockwise. Pressure should gradually
increase, as lever is moved counterclockwise, to 80 to
88 psi.(6) Low-reverse pressure should read the same as
line pressure within 3 psi.
(7) This tests pump output, pressure regulation,
and condition of rear clutch and rear servo hydraulic
circuits.
TEST TWO (SELECTOR IN 2)
(1) Attach one gauge to line pressure port and tee
another gauge into lower cooler line fitting. This will
allow lubrication pressure readings to be taken..
(2) Operate engine at 1000 rpm for test.
(3) Move selector lever on transaxle one detent for-
ward from full rearward position. This is selector 2
position.
(4) Read pressures on both gauges as throttle lever
on transaxle is moved from full clockwise position to
full counterclockwise position.
(5) Line pressure should read 52 to 58 psi with
throttle lever clockwise. Pressure should gradually
increase, as lever is moved counterclockwise, to 80 to
88 psi.
(6) Lubrication pressure should be 10 to 25 psi
with lever clockwise and 10 to 35 psi with lever full
counterclockwise.
(7) This tests pump output, pressure regulation,
and condition of rear clutch and lubrication hydraulic
circuits.
TEST THREE (SELECTOR IN D)
(1) Attach gauges to line and kickdown release
ports.
(2) Operate engine at 1600 rpm for test.
(3) Move selector lever on transaxle two detents
forward from full rearward position. This is selector
D position.
(4) Read pressures on both gauges as throttle lever
on transaxle is moved from full clockwise position to
full counterclockwise position.
(5) Line pressure should read 52 to 58 psi with
throttle lever clockwise. Pressure should gradually
ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 13
DIAGNOSIS AND TESTING (Continued)

increase, as lever is moved counterclockwise to 80 to
88 psi.
(6) Kickdown release is pressurized only in direct
drive and should be same as line pressure within 3
psi, up to kickdown point.
(7) This tests pump output, pressure regulation,
and condition of rear clutch, front clutch, and
hydraulic circuits.
TEST FOUR (SELECTOR IN REVERSE)
(1) Attach 300 psi gauge to low-reverse port.
(2) Operate engine at 1600 rpm for test.
(3) Move selector lever on transaxle four detents
forward from full rearward position. This is selector
R position.
(4) Low-reverse pressure should read 180 to 220
psi with throttle lever clockwise. Pressure should
gradually increase, as lever is moved counterclock-
wise to 260 to 300 psi.
(5) This tests pump output, pressure regulation,
and condition of front clutch and rear servo hydraulic
circuits.
(6) Move selector lever on transaxle to D position
to check that low-reverse pressure drops to zero.
(7) This tests for leakage into rear servo, due to
case porosity, which can cause reverse band burn out.
TEST RESULT INDICATIONS
(1) If proper line pressure, minimum to maximum,
is found in any one test, the pump and pressure reg-
ulator are working properly.
(2) Low pressure in D, 1, and 2 but correct pres-
sure in R indicates rear clutch circuit leakage.
(3) Low pressure in D and R but correct pressure
in 1 indicates front clutch circuit leakage.
Fig. 2 Test Port Locations
Fig. 3 Governor Pressure Tap
21 - 14 TRANSAXLE AND POWER TRANSFER UNITNS
DIAGNOSIS AND TESTING (Continued)

(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)

(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)

Fig. 22 Oil Pump Gasket
Fig. 23 Loosen Kickdown Band Adjusting Screw
Fig. 24 Kickdown Band and Strut
Fig. 25 Front Clutch Assembly
Fig. 26 No. 2 Thrust Washer and Rear Clutch
Fig. 27 No. 3 Thrust Washer
21 - 24 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 34 No. 10 Thrust Washer
Fig. 35 Overrunning Clutch Cam Assembly
Fig. 36 Overrunning Clutch Rollers and Spring
Fig. 37 Loosen or Adjust Low/Reverse Band
Fig. 38 Low/Reverse Band and Strut
Fig. 39 No. 11 Thrust Washer
21 - 26 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
When rebuilding, reverse the above procedure.
VALVE BODY RECONDITION
NOTE: Tighten all valve body screws to 5 N´m (40
in. lbs.).
Do not clamp any portion of valve body or transfer
plate in a vise. Any slight distortion of the aluminum
body or transfer plate will result in sticking valves,
excessive leakage or both.When removing or
installing valves or plugs, slide them in or out
carefully. Do not use force.
NOTE: TAG ALL SPRINGS AS THEY ARE
REMOVED FOR REASSEMBLY IDENTIFICATION.
Fig. 40 Install Overrunning Clutch Rollers and
Springs
Fig. 41 Detent Spring Attaching Screw and Spring
Fig. 42 Using Tool L-4553 on Valve Body Screw
Fig. 43 Remove or Install Valve Body Screws
Fig. 44 Transfer Plate and Separator Plate
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 27
DISASSEMBLY AND ASSEMBLY (Continued)

FRONT CLUTCH-RECONDITION
INSPECTION
Inspect plates and discs for flatness. They must not
be warped or cone shaped.
Inspect facing material on all driving discs.
Replace discs that are charred, glazed or heavily pit-
ted. Discs should also be replaced if they show evi-
dence of material flaking off or if facing material can
be scraped off easily. Inspect driving disc splines for
wear or other damage. Inspect steel plate surfaces for
burning, scoring, or damaged driving lugs. Replace if
necessary.
Inspect steel plate lug grooves in clutch retainer
for smooth surfaces, plates must travel freely in
grooves. Inspect band contacting surface on clutchretainer for scores, the contact surface should be
protected from damage during disassembly and han-
dling. Note ball check in clutch retainer, make sure
ball moves freely. Inspect piston seal surfaces in
clutch retainer for nicks or deep scratches, light
scratches will not interfere with sealing of seals.
Inspect clutch retainer inner bore surface for wear
from reaction shaft support seal rings. Inspect
clutch retainer bushing for wear or scores.
Inspect inside bore of piston for score marks, if
light, remove with crocus cloth. Inspect seal grooves
for nicks and burrs. Inspect seals for deterioration,
wear, and hardness. Inspect piston spring, retainer
and snap ring for distortion.
DISASSEMBLY
Fig. 58 Inner and Outer Pump Gears
Fig. 59 Measuring Pump Clearance (Gear to Pocket)
Fig. 60 Front Clutch Waved Snap Ring
Fig. 61 Thick Steel Plate and Waved Snap Ring
21 - 32 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
To reassemble, reverse the above procedure.MEASURING PLATE CLEARANCE
REAR CLUTCH-RECONDITION
INSPECTION
Inspect facing material on all driving discs.
Replace discs that are charred, glazed or heavily pit-
ted. Discs should also be replaced if they show evi-
dence of material flaking off or if facing material can
be scraped off easily. Inspect driving disc splines for
wear or other damage. Inspect steel plate and pres-
sure plate surface for burning, scoring or damaged
driving lugs. Re place if necessary. Inspect plates and
discs for flatness, they must not be warped or cone-
shaped.
Inspect steel plate lug grooves in clutch retainer
for smooth surfaces, plates must travel freely in the
grooves. Note ball check in piston; make sure ball
moves freely. Inspect seal rings surfaces in clutch
retainer for nicks or deep scratches; light scratches
will not interfere with sealing of the seals. Inspect
neoprene seal rings for deterioration, wear and hard-
ness. Inspect piston spring and waved snap ring for
distortion or breakage.
Inspect teflon and/or cast iron seal rings on input
shaft for wear. Do not remove rings unless conditions
warrant. Inspect rear clutch to front clutch No. 2
thrust washer for wear. Washer thickness should be
.061 to .063 inch, replace if necessary.
DISASSEMBLY
Press out input shaft, if required.
ASSEMBLY
To reassemble, reverse the above procedure.
Fig. 62 Front Clutch (4-Disc Shown)
Fig. 63 Front Clutch Return Spring Snap Ring
Fig. 64 Front Clutch Return Spring and Piston
Fig. 65 Measuring Front Clutch Plate Clearance
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 33
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 66 Rear Clutch Outer Snap Ring
Fig. 67 Rear Clutch (4-Disc Shown)
Fig. 68 Piston Spring Waved Snap Ring
Fig. 69 Rear Clutch Piston and Piston Spring
Fig. 70 Remove or Install Input Shaft Snap Ring
Fig. 71 Input Shaft Snap Ring
21 - 34 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)