brake sensor CHRYSLER VOYAGER 2001 Service Manual

INSPECTION
Check manifold for:
²Damage and cracks.
²Mounting surface distortion by using a straight-
edge and thickness gauge.
INSTALLATION - 3.8L
(1) If the following components were removed from
manifold, install and tighten to specifications:
²MAP sensor - 3.4 N´m (30 in. lbs.)
²Throttle cable bracket - 12 N´m (105 in. lbs.)
(2) Remove covering on lower intake manifold and
clean surfaces.
(3) Position the new intake manifold gasket on
lower manifold.
(4) Position upper manifold on lower manifold (Fig.
133). Install and tighten bolts to 12 N´m (105 in. lbs.)
following torque sequence in (Fig. 134).
(5) Connect the MAP sensor electrical connector.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
MAP SENSOR - COMPONENT LOCATION)
(6) Connect the brake booster and LDP vacuum
hose to intake manifold (Fig. 132).
(7) Connect the PCV hose (Fig. 130).
(8) Install the power steering reservoir (Fig. 131)
and torque fasteners to 12 N´m (105 in. lbs.).
(9) Connect the EGR transducer vacuum hose.
(10) Using new gaskets, install the EGR tube (Fig.
129) and torque bolts to 12 N´m (105 in. lbs.).
Fig. 132 BRAKE BOOSTER & LDP VACUUM HOSES
1 - LDP & SPEED CONTROL VACUUM HOSE
2 - BRAKE BOOSTER VACUUM HOSE
3 - MAP SENSOR
Fig. 133 INTAKE MANIFOLD - UPPER 3.8L
1 - BRACKET - THROTTLE CABLE
2 - BOLT
3 - SCREW
4 - MAP SENSOR
5 - MANIFOLD - UPPER
6 - WIRE HARNESS
7 - GASKET (1 PER CYL. BANK)
8 - BOLT
Fig. 134 UPPER MANIFOLD TIGHTENING
SEQUENCE
RSENGINE 3.3/3.8L9 - 147
INTAKE MANIFOLD - UPPER 3.8L (Continued)

(10) Disconnect high pressure line at pump (Fig.
5).
(11) Disconnect power steering pump return hose
clamp (Fig. 5).
(12) Remove power steering return line retaining
clamp (Fig. 5).
(13) Remove power steering line clamps from oil
pan (Fig. 5).
(14) Remove power steering pump reservoir and
bracket (Fig. 5).
(15) Drain coolant system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(16) Remove coolant pressure tank (Fig. 6).
(17) Remove battery shield.
(18) Remove charge air cooler outlet hose.
(19) Remove charge air cooler inlet hose (Fig. 7).
(20) Disconnect upper radiator hose at engine (Fig.
8).
(21) Disconnect lower radiator hose at engine (Fig.
8).
(22) Disconnet brake booster vacuum supply hose.
(23) Disconnect heater core return hose at engine.
Fig. 4 MASS AIR FLOW (MAF) SENSOR LOCATION
1 - MAF SENSOR ELECTRICAL CONNECTOR
2 - RETAINING CLAMPS
3 - MASS AIR FLOW (MAF) SENSOR
4 - AIR CLEANER HOUSING
Fig. 5 RESERVOIR AND HOSES - 2.5L DIESEL
1 - RESERVOIR
2 - RESERVOIR BRACKET
3 - SUPPLY HOSE BRACKET
4 - RETURN HOSE FROM GEAR
5 - ROUTING CLIP
6 - PRESSURE HOSE TO GEAR
7 - SUPPLY HOSE (PUMP END)
8 - PRESSURE HOSE (PUMP END)
9 - SUPPLY HOSE
10 - RETURN HOSE
Fig. 6 COOLANT RECOVERY PRESSURE
CONTAINER LOCATION
1 - PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - BATTERY
4 - BATTERY SHIELD
5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING
CLIP
6 - ENGINE COVER
7 - COOLANT RECOVERY PRESSURE CONTAINER
9a - 4 ENGINE 2.5L TURBO DIESELRG
ENGINE 2.5L TURBO DIESEL (Continued)

(24) Disconnect egr solenoid vacuum line at brake
booster check valve.
(25) Disconnect fuel injector, cam sensor, boost
pressure/intake air temp sensor, fuel rail high pres-
sure, and egr solenoid connectors (Fig. 9).
(26) Disconnect generator electrical connectors.
(27) Disconnect coolant temp sensor and glow plug
electrical connectors.
(28) Disconnect injection pump and A/C compres-
sor electrical connectors.
(29) Disconnect starter electrical connectors.
(30) Disconnect ground wires at engine block.
(31) Raise vehicle on hoist.
(32) Disconnect oil temp sensor, oil pressure sen-
sor, engine speed sensor, and vehicle speed sensor
electrical connector (Fig. 10).
(33) Remove front wheels.
(34) Remove the suspension cradle assembly (Refer
to 13 - FRAME & BUMPERS/FRAME/ENGINE
CRADLE CROSSMEMBER - REMOVAL).
(35) Remove both axle shaft assemblies (Refer to 3
- DIFFERENTIAL & DRIVELINE/HALF SHAFT -
REMOVAL).(36) Disconnect the clutch slave cylinder quick dis-
connect line (RHD only)(Refer to 6 - CLUTCH/SLAVE
CYLINDER - REMOVAL).
(37) Disconnect reverse lamp connector.
(38) Disconnect shifter cables at the tranmission
(Refer to 21 - TRANSMISSION/TRANSAXLE/MAN-
UAL/GEAR SHIFT CABLE - REMOVAL).
(39) Disconnect exhaust pipe from the turbo-
charger downpipe and reposition to right side of vehi-
cle.
(40) Disconnect cabin heater coolant line (Refer to
24 - HEATING & AIR CONDITIONING/CABIN
HEATER/HEATER UNIT - REMOVAL).
(41) Remove front engine mount bracket retaining
bolts from lower radiator support
(42) Lower vehicle. Evacuate the A/C system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT - STANDARD PROCE-
DURE).
(43) Disconnect the A/C lines at the A/C compres-
sor.
(44) Disconnect the fuel supply and return lines.
(45) Position engine cradle under engine and lower
vehicle over cradle.
(46) Remove right engine mount bolts.
Fig. 7 CHARGE AIR COOLER HOSES
1 - COOLING MODULE
2 - BYPASS HOSE
3 - UPPER RADIATOR HOSE
4 - CHARGE AIR COOLER OULET HOSE
5 - CHARGE AIR COOLER INLET HOSE
6 - LOWER RADIATOR HOSE
7 - CHARGE AIR COOLER
Fig. 8 UPPER AND LOWER RADIATOR HOSES
1 - COOLANT BYPASS HOSE
2 - RADIATOR ASSEMBLY
3 - UPPER RADIATOR HOSE
4 - COOLING FAN
5 - LOWER RADIATOR HOSE
6 - CHARGE AIR COOLER
7 - RADIATOR BRACKET
RGENGINE 2.5L TURBO DIESEL9a-5
ENGINE 2.5L TURBO DIESEL (Continued)

(7) Attach front engine mount bracket to lower
radiator support. Torque to 54N´m (40 ft. lbs.)
(8) Connect cabin heater coolant hose.
(9) Connect exhaust pipe to the turbocharger
downpipe flange. Torque to 28 N´m (250 in. lbs.)
(10) Connect reverse lamp electrical connector at
transmission.
(11) Connect both shifter cables (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/GEAR
SHIFT CABLE - INSTALLATION).
(12) Connect the clutch slave cylinder quick dis-
connect connector (RHD only)(Refer to 6 - CLUTCH/
SLAVE CYLINDER - INSTALLATION).
(13) Install engine harness into bracket on trans-
mission.
(14) Lower vehicle.
(15) Connect fuel supply and return lines.
(16) Connect A/C lines to A/C compressor. Torque
to 23N´m (17 ft. lbs.)
(17) Route engine wiring harnes to proper location.
(18) Connect engine harness ground cables to
engine block
(19) Connect starter solenoid electrical connector
and battery feed wire to starter. Torque to 10N´m (90
in. lbs.)
(20) Connect A/C compressor, injection pump, glow
plugs, and coolant temperature sensor electrical con-
nectors.
(21) Connect generator electrical connector. Torque
to 9N´m (75 in. lbs.)
(22) Connect the fuel injector, fuel pressure sensor,
boost pressure/intake air temp sensor, cam sensor,
and egr solenoid electrical connectors (Fig. 9).
(23) Connect egr solenoid vacuum supply line to
brake boost vacuum supply line.
(24) Connect brake booster vacuum supply line.
(25) Connect heater core return hose to coolant
pipe.
(26) Connect lower radiator hose to engine (Fig. 8).
(27) Install charger air cooler inlet hose (Fig. 7).
(28) Install charge air cooler outlet hose (Fig. 7).
(29) Connect upper radiator hose to engine (Fig.
8).
(30) Install battery shield.
(31) Install coolant reserve pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - INSTALLATION).
(32) Install power steering reservoir and bracket
(Fig. 5).
(33) Raise vehicle
(34) Connect oil pressure sensor, oil temperature
sensor, engine speed sensor, and vehicle speed sensor
electrical connector (Fig. 10).(35) Install suspension cradle in vehicle (Refer to
13 - FRAME & BUMPERS/FRAME/ENGINE CRA-
DLE CROSSMEMBER - INSTALLATION).
(36) Install both axle shaft assemblies (Refer to 3 -
DIFFERENTIAL & DRIVELINE/HALF SHAFT -
INSTALLATION).
(37) Connect the power steering supply, pressure,
and return lines to power steering pump (Fig. 5).
(38) Install the power steering line brackets on oil
pan (Fig. 5).
(39) Install lower splash shield and side panels.
(40) Install both front wheel and tire assemblies.
(41) Lower vehicle.
(42) Install air cleaner housing, MAF sensor, and
air intake tube assembly (Fig. 4).
(43) Refill transmission to proper level (Refer to 21
- TRANSMISSION/TRANSAXLE/MANUAL/FLUID -
STANDARD PROCEDURE).
(44) Refill engine coolant (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(45) Recharge A/C system (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/REFRIGER-
ANT - STANDARD PROCEDURE) .
(46) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION) (Fig. 3).
(47) Connect negative battery cable.
INSTALLATION - ENGINE COVER
(1) Install engine cover on engine.
(2) Install the engine cover mounting bolts (Fig.
11).
SPECIFICATIONS
SPECIFICATIONS - 2.5L COMMON RAIL
DIESEL ENGINE
ENGINE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Type R2516C
Number of Cylinders 4
Bore 92 mm
Stroke 94 mm
Displacement 2499.5cc
Injection Order 1-3-4-2
Compression Ratio 17.5:1 (  0.5)
Maximum Power 103kW (140 HP) @ 4000
RPM
Peak Torque 340Nm (34.6 kgm) @
1800 RPM
RGENGINE 2.5L TURBO DIESEL9a-7
ENGINE 2.5L TURBO DIESEL (Continued)

DIAGNOSIS AND TESTING - EXHAUST SYSTEM
CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE EXHAUST NOISE
(UNDER HOOD)1. Exhaust manifold cracked or
broken.1. Replace manifold.
2. Manifold to cylinder head leak. 2. Tighten manifold and/or replace
gasket.
3. EGR Valve to manifold gasket
leakage.3. Tighten fasteners or replace
gasket.
4. EGR Valve to EGR tube gasket
leakage.4. Tighten fasteners or replace
gasket.
5. EGR tube to manifold tube
leakage.5. Tighten tube nut.
6. Exhaust flex-joint to manifold
leak.6. Tighten joint fasteners and/or
replace gasket.
7. Exhaust flex-joint. 7. Replace catalytic converter
assembly.
8. Pipe and shell noise from front
exhaust pipe.8. Characteristic of single wall pipe.
EXCESSIVE EXHAUST NOISE 1. Leak at exhaust pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or rusted out muffler
assembly or exhaust pipe.2. Replace muffler resonator tailpipe
assembly or exhaust pipe with
catalytic converter assembly.
3. Burned or rusted out resonator. 3. Replace muffler resonator tailpipe
assembly.
4. Restriction in exhaust system. 4. Perform exhaust restriction test.
replace component as necessary.
5. Converter material in muffler. 5. Replace muffler and converter
assemblies. Check fuel injection and
ignition systems for proper
operation.
DIAGNOSIS AND TESTING - EXHAUST SYSTEM
RESTRICTION
Exhaust system restriction can be checked by mea-
suring back pressure using the DRB IIItand PEP
module pressure tester.
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
(1) Disconnect and remove the upstream (before
catalytic converter) oxygen sensor. (Refer to 14 -FUEL SYSTEM/FUEL INJECTION/O2 SENSOR -
REMOVAL)
(2) Install the Exhaust Back Pressure Fitting
Adaptor CH8519.
(3) Connect the Low Pressure Sensor (15 psi)
CH7063 to the back pressure fitting.
(4) Following the PEP module instruction manual,
connect all required cables to the DRB IIItand PEP
module. Select the available menu options on the
DRBIIItdisplay screen for using the digital pressure
gauge function.
(5) Apply the park brake and start the engine.
(6) With transmission in Park or Neutral, raise
engine speed to 2000 RPM. Monitor the pressure
readings on the DRBIIIt. Back pressure should not
exceed specified limit. Refer to specification in table
below EXHAUST BACK PRESSURE LIMITS .
11 - 2 EXHAUST SYSTEMRS
EXHAUST SYSTEM (Continued)

²Needle Nose Pliers ± For Removal Of Thread
Insert Driving Tang
REMOVAL
The front cradle crossmember must be installed in
the design location to achieve proper front end sus-
pension alignment. If the cradle crossmember is
removed without applying reference marks on the
frame rails, align the cradle crossmember according
to the dimensions provided in this group.
NOTE: If the caged nuts in the frame rails become
damaged and cannot be reused, a replacement nut
can be obtained through MoparT.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove steering column lower cover from
instrument panel. Refer to Group 8E, Instrument
Panel and Systems.
(3) Remove knee blocker reinforcement. Refer to
Group 8E, Instrument Panel and Systems.
(4) Position steering so front wheels are straight
ahead.
CAUTION: Do not rotate steering wheel after disen-
gaging lower coupling from steering gear, damage
to air bag clock spring can result.
(5) Remove clinch bolt attaching steering column
coupling to steering gear shaft (Fig. 10).
(6) Remove steering column coupling from tele-
scoping steering gear shaft.
(7) Hoist vehicle and support on safety stands.
(8) Position a drain pan under power steering
pump and oil return hose coupling.
(9) Using a hose pinch-off pliers (C-4390), pinch
power steering oil return hose off between the cross-
member coupling and the pump.
(10) Loosen hose clamp at the cradle crossmember
coupling.
(11) Disconnect return hose from metal tube.
(12) While holding pressure relief valve nut on
back of power steering pump, Remove flare nut hold-
ing high pressure hose to back of pump.
(13) Remove high pressure hose from pump.
(14) Allow power steering fluid to drain into pan.
(15) Remove bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(16) Position anti-lock brake leads out of the way.
(17) Disconnect stabilizer bar links from ends of
stabilizer bar. Refer to Group 2, Suspension.
(18) Disconnect lower ball joints from lower steer-
ing knuckles. Refer to Group 2, Suspension.
(19) Remove the rear engine mount heat shield
(Fig. 11).(20) Remove through bolt attaching rear engine
mount to cradle crossmember (Fig. 12).
(21) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails to aid installation.
(22) Support cradle crossmember on suitable lift-
ing device (Fig. 14).
(23) Remove bolts attaching crossmember to front
frame rails (Fig. 13).
(24) Remove cradle crossmember from vehicle (Fig.
14).
Fig. 10 STEERING COUPLING
1 - STEERING SHAFT BOOT
2 - STEERING SHAFT
3 - CROSSMEMBER
4 - STEERING GEAR
5 - MOUNT
6 - TRANSAXLE
Fig. 11 REAR MOUNT HEAT SHIELD
1 - BOLT
2 - HEAT SHIELD
3 - CLIP
4 - REAR ENGINE MOUNT
13 - 10 FRAMES & BUMPERSRS
FRONT CRADLE CROSSMEMBER (Continued)

INSTALLATION
NOTE: If cradle crossmember requires replacement.
Refer to Group 2, Suspension, to transfer suspen-
sion components and Group 19, Steering, to trans-
fer steering components.
(1) Support crossmember on suitable lifting device
(Fig. 14).
(2) Position crossmember to vehicle.(3) Loosely install bolts attaching cradle cross-
member to front frame rails.
(4) Align crossmember to previously made marks
on frame rails.
(5) Tighten bolts attaching cradle crossmember to
frame rails.
(6) Install through bolt attaching rear engine
mount to cradle crossmember (Fig. 12) and tighten to
68 N´m (50 ft. lbs.) .
(7) Install the rear mount heat shield (Fig. 11).
(8) Connect lower ball joints to steering knuckles.
Refer to Group 2, Suspension.
(9) Connect stabilizer bar links to ends of stabi-
lizer bar. Refer to Group 2, Suspension.
(10) Install bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(11) Install high pressure hose to pump.
(12) Connect return hose to metal tube.
(13) Tighten hose clamp at the cradle crossmember
coupling.
(14) Remove pinch-off pliers.
(15) Position steering so front wheels are straight
ahead.
(16) Install steering column coupling to telescoping
steering gear shaft.
(17) Install clinch bolt attaching steering column
coupling to steering gear shaft.
(18) Install knee blocker reinforcement. Refer to
Group 8E, Instrument Panel and Systems.
(19) Install steering column lower cover from
instrument panel. Refer to Group 8E, Instrument
Panel and Systems.
(20) Connect battery negative cable.
FRONT CROSSMEMBER
MOUNT BUSHINGS
REMOVAL
(1) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails.
(2) Loosen bolts attaching crossmember to frame
rails.
(3) Remove bolt on bushing that requires replace-
ment.
(4) Allow cradle crossmember to drop down enough
to gain clearance for bushing removal.
(5) Remove bushing from vehicle.
INSTALLATION
(1) Apply rubber lubrication or soap to replace-
ment bushing.
(2) Insert lower half of bushing into square hole in
cradle crossmember.
Fig. 12 REAR MOUNT
1 - BOLT
2 - REAR MOUNT BRACKET
3 - THROUGH BOLT
4 - REAR MOUNT
Fig. 13 Cradle Crossmember Mount
1 - CROSSMEMBER MOUNT
2 - BRAKE HOSE MOUNT
3 - STEERING TIE ROD
4 - FRONT CROSSMEMBER
5 - FRAME RAIL
RSFRAMES & BUMPERS13-11
FRONT CRADLE CROSSMEMBER (Continued)

FUEL PUMP RELAY
DESCRIPTION
The fuel pump relay is located in the PDC. The
inside top of the PDC cover has a label showing relay
and fuse location.
OPERATION
The fuel pump relay supplies battery voltage to the
fuel pump. A buss bar in the Power Distribution Cen-
ter (PDC) supplies voltage to the solenoid side and
contact side of the relay. The fuel pump relay power
circuit contains a fuse between the buss bar in the
PDC and the relay. The fuse also protects the power
circuit for the Automatic Shutdown (ASD) relay. The
fuse is located in the PDC. Refer to the Wiring Dia-
grams for circuit information.
The PCM controls the fuel pump relay by switch-
ing the ground path for the solenoid side of the relay
on and off. The PCM turns the ground path off when
the ignition switch is in the Off position. When the
ignition switch is in the On position, the PCM ener-
gizes the fuel pump. If the crankshaft position sensor
does not detect engine rotation, the PCM de-ener-
gizes the relay after approximately one second.
IDLE AIR CONTROL MOTOR
DESCRIPTION
The idle air control motor is mounted on the throt-
tle body. The PCM operates the idle air control motor
(Fig. 11) or (Fig. 12).
OPERATION
The PCM adjusts engine idle speed through the
idle air control motor to compensate for engine load,
coolant temperature or barometric pressure changes.
The throttle body has an air bypass passage that
provides air for the engine during closed throttle idle.
The idle air control motor pintle protrudes into the
air bypass passage and regulates air flow through it.
The PCM adjusts engine idle speed by moving the
IAC motor pintle in and out of the bypass passage.
The adjustments are based on inputs the PCM
receives. The inputs are from the throttle position
sensor, crankshaft position sensor, coolant tempera-
ture sensor, MAP sensor, vehicle speed sensor and
various switch operations (brake, park/neutral, air
conditioning).
When engine rpm is above idle speed, the IAC is
used for the following functions:
²Off-idle dashpot
²Deceleration air flow control
²A/C compressor load control (also opens the pas-
sage slightly before the compressor is engaged sothat the engine rpm does not dip down when the
compressor engages)
Target Idle
Target idle is determined by the following inputs:
²Gear position
²ECT Sensor
²Battery voltage
²Ambient/Battery Temperature Sensor
²VSS
Fig. 11 TPS/IAC 2.4L
1 - IAC MOTOR
2 - TP SENSOR
3 - IAT SENSOR
Fig. 12 TPS/IAC 3.3/3.8L
1 - IDLE AIR CONTROL VALVE
2 - TP SENSOR
RSFUEL INJECTION14-27

AUTOMATIC - 41TE
TABLE OF CONTENTS
page page
AUTOMATIC - 41TE
DESCRIPTION..........................159
OPERATION............................159
DIAGNOSIS AND TESTING................159
41TE TRANSAXLE GENERAL DIAGNOSIS . . . 159
ROAD TEST..........................161
HYDRAULIC PRESSURE TESTS..........162
CLUTCH AIR PRESSURE TESTS..........164
TORQUE CONVERTER HOUSING FLUID
LEAKAGE............................164
REMOVAL.............................165
DISASSEMBLY..........................169
ASSEMBLY............................186
INSTALLATION..........................209
SCHEMATICS AND DIAGRAMS.............212
SPECIFICATIONS........................225
SPECIAL TOOLS........................227
ACCUMULATOR
DESCRIPTION..........................232
OPERATION............................233
AUTOSTICK SWITCH
DESCRIPTION..........................233
OPERATION............................233
DRIVING CLUTCHES
DESCRIPTION..........................234
OPERATION............................234
FINAL DRIVE
DESCRIPTION..........................234
OPERATION............................234
DISASSEMBLY..........................235
ASSEMBLY............................240
ADJUSTMENTS.........................243
FLUID
STANDARD PROCEDURE.................246
FLUID LEVEL AND CONDITION CHECK.....246
FLUID AND FILTER SERVICE.............246
GEAR SHIFT CABLE
REMOVAL.............................248
INSTALLATION..........................250
ADJUSTMENTS.........................251
HOLDING CLUTCHES
DESCRIPTION..........................251
OPERATION............................251
INPUT CLUTCH ASSEMBLY
DISASSEMBLY..........................252
ASSEMBLY............................259
OIL PUMP
DESCRIPTION..........................269
OPERATION............................269STANDARD PROCEDURE.................269
OIL PUMP VOLUME CHECK..............269
DISASSEMBLY..........................270
ASSEMBLY............................271
PLANETARY GEARTRAIN
DESCRIPTION..........................271
OPERATION............................271
SEAL - OIL PUMP
REMOVAL.............................271
INSTALLATION..........................272
SHIFT INTERLOCK SOLENOID
DESCRIPTION..........................272
OPERATION............................273
DIAGNOSIS AND TESTING................274
BRAKE/TRANSMISSION SHIFT INTERLOCK
SOLENOID...........................274
REMOVAL.............................274
INSTALLATION..........................275
SOLENOID/PRESSURE SWITCH ASSEMBLY
DESCRIPTION..........................276
OPERATION............................276
REMOVAL.............................277
INSTALLATION..........................277
SPEED SENSOR - INPUT
DESCRIPTION..........................278
OPERATION............................278
REMOVAL.............................279
INSTALLATION..........................279
SPEED SENSOR - OUTPUT
DESCRIPTION..........................280
OPERATION............................280
REMOVAL.............................280
INSTALLATION..........................281
TORQUE CONVERTER
DESCRIPTION..........................281
OPERATION............................284
REMOVAL.............................286
INSTALLATION..........................286
TRANSMISSION CONTROL RELAY
DESCRIPTION..........................287
OPERATION............................287
TRANSMISSION RANGE SENSOR
DESCRIPTION..........................287
OPERATION............................287
REMOVAL.............................288
INSTALLATION..........................288
TORQUE REDUCTION LINK (TRD)
DESCRIPTION..........................289
OPERATION............................289
21 - 158 AUTOMATIC - 41TERS

FLUID
STANDARD PROCEDURE - FLUID LEVEL AND
CONDITION CHECK
NOTE: Only transmission fluid of the type labeled
Mopar ATF+4 (Automatic Transmission Fluid±Type
9602) 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 (approxi-
mately 82 C. or 180 F.), the fluid level is correct if it
is in the HOT region (cross-hatched area) on the oil
level indicator (Fig. 214). The fluid level should be
within the WARM range of the dipstick at 70É 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. 215).
(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.
Moparž ATF+4 (Automatic Transmission Fluid-
Type 9602) 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. A dark brown/black fluid
accompanied with a burnt odor and/or deterioration
in shift quality may indicate fluid deterioration or
transmission component failure.
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. 214 Transaxle Fluid Level Indicator
1 - TRANSAXLE DIPSTICK
21 - 246 AUTOMATIC - 41TERS