tow CHRYSLER VOYAGER 2001 Service Manual

OPERATION
The Brake/Transmission Shift Interlock (BTSI)
Solenoid prevents the transmission shift lever from
being moved out of PARK (P) unless the brake pedal
is applied. The BTSI solenoid is hardwired to and
controlled by the Intelligent Power Module (IPM).
Battery voltage is applied to one side of the solenoid
with the ignition key is in either the ON/RUN or
START positions (Fig. 306). The ground side of the
solenoid is controlled by a driver within the IPM. It
relies on voltage supplied from the stop lamp switch
to the stop lamp sense circuit within the IPM to tell
when the brake pedal is depressed. When the brake
pedal is depressed, the ground circuit opens, de-ener-
gizing the solenoid. When the brake pedal is
released, the ground circuit is closed, energizing the
solenoid.
When the ignition key is in either the ON/RUN or
START positions, the BTSI solenoid is energized, and
the solenoid plunger hook pulls the shift lever pawl
into position, prohibiting the shift lever from moving
out of PARK (P) (Fig. 307). When the brake pedal is
depressed, the ground circuit opens, de-energizing
the solenoid. This moves the gearshift lever pawl out
of the way (Fig. 308), allowing the shift lever to be
moved into any gear position.
A conventional mechanical interlock system is also
used. This system manually prohibits shifter move-
ment when the ignition switch is in the LOCK or
ACC positions. Solenoid operation is not required in
these key positions. When the ignition key is in the
OFF position, the gearshift lever is unrestricted, and
able to move into any gear position (during towing,
dead battery, etc.).
Fig. 306 Ignition Key/Switch Positions
1 - ACC
2 - LOCK
3 - OFF
4 - ON/RUN
5-START
Fig. 307 Pawl Engaged to Shift Lever
1 - GEAR SHIFT LEVER
2 - GEAR SHIFT LEVER PAWL
Fig. 308 Pawl Disengaged From Shift Lever
1 - GEAR SHIFT LEVER
2 - GEAR SHIFT LEVER PAWL
RSAUTOMATIC - 41TE21 - 273
SHIFT INTERLOCK SOLENOID (Continued)

OPERATION
The converter impeller (Fig. 337) (driving member),
which is integral to the converter housing and bolted
to the engine drive plate, rotates at engine speed.
The converter turbine (driven member), which reacts
from fluid pressure generated by the impeller, rotates
and turns the transmission input shaft.
TURBINE
As the fluid that was put into motion by the impel-
ler blades strikes the blades of the turbine, some of
the energy and rotational force is transferred into the
turbine and the input shaft. This causes both of them
(turbine and input shaft) to rotate in a clockwise
direction following the impeller. As the fluid is leav-
ing the trailing edges of the turbine's blades it con-
tinues in a ªhinderingº direction back toward the
impeller. If the fluid is not redirected before it strikes
the impeller, it will strike the impeller in such a
direction that it would tend to slow it down.
Fig. 334 Stator Components
1 - CAM (OUTER RACE)
2 - ROLLER
3 - SPRING
4 - INNER RACE
Fig. 335 Stator Location
1-STATOR
2 - IMPELLER
3 - FLUID FLOW
4 - TURBINE
Fig. 336 Torque Converter Clutch (TCC)
1 - IMPELLER FRONT COVER
2 - THRUST WASHER ASSEMBLY
3 - IMPELLER
4-STATOR
5 - TURBINE
6 - PISTON
7 - FRICTION DISC
21 - 284 AUTOMATIC - 41TERS
TORQUE CONVERTER (Continued)

1ST GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft first gear is integral to the input shaft,
and is in constant mesh with the intermediate shaft
first speed gear. Because of this constant mesh, the
intermediate shaft first speed gear freewheels untilfirst gear is selected. As the gearshift lever is moved
to the first gear position, the 1-2 fork moves the 1-2
synchronizer sleeve towards first gear on the inter-
mediate shaft. The synchronizer sleeve engages the
first gear clutch teeth, fixing the gear to the interme-
diate shaft, and allowing power to transmit through
the intermediate shaft to the differential (Fig. 4).
Fig. 4 1st Gear Operation
RGT850 MANUAL TRANSAXLE21a-5
T850 MANUAL TRANSAXLE (Continued)

2ND GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft second gear is integral to the input shaft,
and is in constant mesh with the intermediate shaft
second speed gear. Because of this constant mesh,
the intermediate shaft second speed gear freewheels
until second gear is selected. As the gearshift lever ismoved to the second gear position, the 1-2 fork moves
the 1-2 synchronizer sleeve towards second gear on
the intermediate shaft. The synchronizer sleeve
engages the second gear clutch teeth, fixing the gear
to the intermediate shaft, and allowing power to
transmit through the intermediate shaft to the differ-
ential (Fig. 5).
Fig. 5 2nd Gear Operation
21a - 6 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)

3RD GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft third speed gear is in constant mesh with
the intermediate shaft 3-4 cluster gear, which is fixed
to the intermediate shaft. Because of this constant
mesh, the input shaft third speed gear freewheelsuntil third gear is selected. As the gearshift lever is
moved to the third gear position, the 3-4 fork moves
the 3-4 synchronizer sleeve towards third gear on the
input shaft. The synchronizer sleeve engages the
third gear clutch teeth, fixing the gear to the input
shaft, and allowing power to transmit through the
intermediate shaft to the differential (Fig. 6).
Fig. 6 3rd Gear Operation
RGT850 MANUAL TRANSAXLE21a-7
T850 MANUAL TRANSAXLE (Continued)

4TH GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft fourth speed gear is in constant mesh
with the intermediate shaft 3-4 cluster gear, which is
fixed to the intermediate shaft. Because of this con-
stant mesh, the input shaft fourth speed gear free-
wheels until fourth gear is selected. As the gearshiftlever is moved to the fourth gear position, the 3-4
fork moves the 3-4 synchronizer sleeve towards
fourth gear on the input shaft. The synchronizer
sleeve engages the fourth gear clutch teeth, fixing
the gear to the input shaft, and allowing power to
transmit through the intermediate shaft to the differ-
ential (Fig. 7).
Fig. 7 4th Gear Operation
21a - 8 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)

5TH GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft fifth gear is pressed on to the input shaft,
and is in constant mesh with the intermediate shaft
fifth speed gear. Because of this constant mesh, the
intermediate shaft fifth speed gear freewheels untilfifth gear is selected. As the gearshift lever is moved
to the fifth gear position, the 5-R fork moves the 5-R
synchronizer sleeve towards the intermediate shaft
fifth speed gear. The synchronizer sleeve engages the
fifth gear clutch teeth, fixing the gear to the input
shaft, and allowing power to transmit through the
intermediate shaft to the differential (Fig. 8).
Fig. 8 5th Gear Operation
RGT850 MANUAL TRANSAXLE21a-9
T850 MANUAL TRANSAXLE (Continued)

REVERSE GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft reverse gear is integral to the input
shaft, and is in constant mesh with the reverse idler
gear. The reverse idler gear, which reverses the rota-
tion of the intermediate shaft, is in constant mesh
with the intermediate shaft reverse gear. Because of
this constant mesh, the intermediate shaft reversegear freewheels until reverse gear is selected. As the
gearshift lever is moved to the reverse gear position,
the 5-R fork moves the 5-R synchronizer sleeve
towards the intermediate shaft reverse gear. The
synchronizer sleeve engages the reverse gear clutch
teeth, fixing the gear to the intermediate shaft, and
allowing power to transmit through the intermediate
shaft to the differential (in reverse) (Fig. 9).
Fig. 9 Reverse Gear Operation
21a - 10 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)

DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES
The majority of transaxle malfunctions are a result
of:
²Insufficient lubrication
²Incorrect lubricant
²Misassembled or damaged internal components
²Improper operation
HARD SHIFTING
Hard shifting may be caused by a misadjusted
crossover cable. If hard shifting is accompanied by
gear clash, synchronizer clutch and stop rings or gear
teeth may be worn or damaged.
Hard shifting may also be caused by a binding or
broken shift cover mechanism. Remove shift cover
and verify smooth operation. Replace as necessary.
Misassembled synchronizer components also cause
shifting problems. Incorrectly installed synchronizer
sleeves, keys, balls, or springs can cause shift prob-
lems.
NOISY OPERATION
Transaxle noise is most often a result of worn or
damaged components. Chipped, broken gear or syn-
chronizer teeth, and brinnelled, spalled bearings all
cause noise.
Abnormal wear and damage to the internal compo-
nents is frequently the end result of insufficient
lubricant.
SLIPS OUT OF GEAR
Transaxle disengagement may be caused by mis-
aligned or damaged shift components, or worn teeth
on the drive gears or synchronizer components. Incor-
rect assembly also causes gear disengagement. Check
for missing snap rings.
LOW LUBRICANT LEVEL
Insufficient transaxle lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method. Leakage is evident by the presence of oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill.
If air±powered lubrication equipment is used to fill
a transaxle, be sure the equipment is properly cali-
brated. Equipment out of calibration can lead to an
underfill condition.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash, and noise.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
REMOVAL
REMOVAL - 2.4L GAS
(1) Raise hood.
(2) Disconnect gearshift cables from shift levers/
cover assembly (Fig. 10).
(3) Remove gearshift cable retaining clips from
mounting bracket (Fig. 10). Remove cables and
secure out of way.
(4) Remove three (3) right engine mount bracket-
to-transaxle bolts (Fig. 11).
(5) Raise vehicle on hoist.
(6) Remove front wheel/tires and halfshafts.
(7) Drain transaxle fluid into suitable container.
(8) Remove cradle plate.
(9) Remove front harness retainer and secure har-
ness out of way.
(10) Remove clutch release access cover.
(11)RHD Models:Using Tool 6638A, disconnect
clutch hydraulic circuit quick connect (located on
slave cylinder tube). Remove clutch slave cylinder by
depressing towards case and rotating counter-clock-
wise 60É, while lifting anti-rotation tab out of case
slot with screwdriver (Fig. 12).LHD Models:
Remove clutch release cable by pulling outward on
cable housing, then forward to allow cable core to
pass through case slot (Fig. 13). Disengage T-end
from release lever and secure cable out of way.
(12) Remove engine left mount bracket.
(13) Remove starter motor (Fig. 14).
Fig. 10 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
RGT850 MANUAL TRANSAXLE21a-11
T850 MANUAL TRANSAXLE (Continued)

(11) Raise vehicle on hoist.
(12) Remove front wheel/tires and halfshafts.
(13) Remove underbody splash shield.
(14) Drain transaxle fluid into suitable container.
(15) Remove cradle plate.
(16) Remove front harness retainer and secure
harness out of way.
(17) Remove clutch release access cover.
(18)RHD Models:Using Tool 6638A, disconnect
clutch hydraulic circuit quick connect (located on
slave cylinder tube). Remove clutch slave cylinder by
depressing towards case and rotating counter-clock-
wise 60É, while lifting anti-rotation tab out of case
slot with screwdriver (Fig. 22).LHD Models:
Remove clutch release cable by pulling outward on
cable housing, then forward to allow cable core to
pass through case slot (Fig. 23). Disengage T-end
from release lever and secure cable out of way.
(19) Remove engine left mount bracket (Fig. 24).
(20) Remove starter motor (Fig. 25).
(21) Disconnect back-up lamp switch connector.
(22) Position screw jack and wood block to engine
oil pan.
(23) Remove transmission upper mount through-
bolt from left frame rail.
(24) Lower engine/transaxle assembly on screw
jack.(25) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 26).
(26) Obtain helper and transmission jack. Secure
transaxle to transmission jack and remove transaxle-
to-engine bolts.
(27) Remove transaxle from engine (Fig. 27).
(28) Inspect clutch, clutch release components, and
flywheel.
Fig. 22 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 23 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
Fig. 24 Left Mount Bracket Removal/Installation
1 - BOLT (2)
2 - MOUNT BRACKET
3 - BOLT (2)
RGT850 MANUAL TRANSAXLE21a-15
T850 MANUAL TRANSAXLE (Continued)