automatic transmission CHRYSLER VOYAGER 2001 Service Manual

STANDARD PROCEDURE - FLUID DRAIN AND
FILL
NOTE: For proper fluid change intervals, (Refer to
LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
The fluid required in this transaxle is Mopart
ATF+4 (Automatic Transmission FluidÐType 9602).
Use of substitute fluids may result in improper
transaxle operation and/or failure.
FLUID DRAIN
(1) Raise vehicle on hoist.
(2) Remove transaxle drain plug (Fig. 135) and
drain fluid into suitable container.
(3) Install drain plug and torque to 14 N´m (120
in. lbs.).
FLUID FILL
(1) Remove transaxle fill plug (Fig. 136).
(2) Add 2.4-2.7L (2.5-2.9 qts.) of MopartATF+4
(Automatic Transmission FluidÐType 9602) until
fluid is within 1/8º below fill hole.
(3) Install fill plug, ensuring it is properly seated.
(4) Lower vehicle.
GEARSHIFT BOOT
REMOVAL
(1) Remove gearshift knob by pushing down and
rotating ò-turn clockwise (Fig. 137).(2) Remove gearshift boot from center console by
disengaging three (3) retaining clips (Fig. 138).
INSTALLATION
(1) Install gearshift boot to console and secure
with three (3) retaining clips (Fig. 138).
(2) Install gearshift knob (Fig. 137). Orient shift
pattern ò-turn clockwise, press down, and rotate
ò-turn counter-clockwise.
(3) Secure gearshift boot to base of knob.
Fig. 135 Transaxle Drain Plug
1 - TRANSAXLE DRAIN PLUG
2 - DIFFERENTIAL COVER
Fig. 136 Transaxle Fill Plug
1 - TRANSAXLE FILL PLUG
2 - END COVER
Fig. 137 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
RGT850 MANUAL TRANSAXLE21a-53
FLUID (Continued)

put component, it can verify that the command was
carried out by monitoring specific input signals for
expected changes. For example, when the PCM com-
mands the Idle Air Control (IAC) Motor to a specific
position under certain operating conditions, it expects
to see a specific (target) idle speed (RPM). If it does
not, it stores a DTC.
PCM outputs monitored for functionality include:
²Fuel Injectors
²Ignition Coils
²Torque Converter Clutch Solenoid
²Idle Air Control
²Purge Solenoid
²EGR Solenoid
²LDP Solenoid
²Radiator Fan Control
²Trans Controls
OXYGEN SENSOR (O2S) MONITOR
DESCRIPTIONÐEffective control of exhaust
emissions is achieved by an oxygen feedback system.
The most important element of the feedback system
is the O2S. The O2S is located in the exhaust path.
Once it reaches operating temperature 300É to 350ÉC
(572É to 662ÉF), the sensor generates a voltage that
is inversely proportional to the amount of oxygen in
the exhaust. When there is a large amount of oxygen
in the exhaust caused by a lean condition, the sensor
produces a low voltage, below 450 mV. When the oxy-
gen content is lower, caused by a rich condition, the
sensor produces a higher voltage, above 450mV.
The information obtained by the sensor is used to
calculate the fuel injector pulse width. The PCM is
programmed to maintain the optimum air/fuel ratio.
At this mixture ratio, the catalyst works best to
remove hydrocarbons (HC), carbon monoxide (CO)
and nitrous oxide (NOx) from the exhaust.
The O2S is also the main sensing element for the
EGR, Catalyst and Fuel Monitors.
The O2S may fail in any or all of the following
manners:
²Slow response rate (Big Slope)
²Reduced output voltage (Half Cycle)
²Heater Performance
Slow Response Rate (Big Slope)ÐResponse rate
is the time required for the sensor to switch from
lean to rich signal output once it is exposed to a
richer than optimum A/F mixture or vice versa. As
the PCM adjusts the air/fuel ratio, the sensor must
be able to rapidly detect the change. As the sensor
ages, it could take longer to detect the changes in the
oxygen content of the exhaust gas. The rate of
change that an oxygen sensor experiences is called
'Big Slope'. The PCM checks the oxygen sensor volt-
age in increments of a few milliseconds.Reduced Output Voltage (Half Cycle)ÐThe
output voltage of the O2S ranges from 0 to 1 volt. A
good sensor can easily generate any output voltage in
this range as it is exposed to different concentrations
of oxygen. To detect a shift in the A/F mixture (lean
or rich), the output voltage has to change beyond a
threshold value. A malfunctioning sensor could have
difficulty changing beyond the threshold value. Each
time the voltage signal surpasses the threshold, a
counter is incremented by one. This is called the Half
Cycle Counter.
Heater PerformanceÐThe heater is tested by a
separate monitor. Refer to the Oxygen Sensor Heater
Monitor.
OPERATIONÐAs the Oxygen Sensor signal
switches, the PCM monitors the half cycle and big
slope signals from the oxygen sensor. If during the
test neither counter reaches a predetermined value, a
malfunction is entered and a Freeze Frame is stored.
Only one counter reaching its predetermined value is
needed for the monitor to pass.
The Oxygen Sensor Monitor is a two trip monitor
that is tested only once per trip. When the Oxygen
Sensor fails the test in two consecutive trips, the
MIL is illuminated and a DTC is set. The MIL is
extinguished when the Oxygen Sensor monitor
passes in three consecutive trips. The DTC is erased
from memory after 40 consecutive warm-up cycles
without test failure.
Enabling ConditionsÐThe following conditions
must typically be met for the PCM to run the oxygen
sensor monitor:
²Battery voltage
²Engine temperature
²Engine run time
²Engine run time at a predetermined speed
²Engine run time at a predetermined speed and
throttle opening
²Transmission in gear (automatic only)
²Fuel system in Closed Loop
²Long Term Adaptive (within parameters)
²Power Steering Switch in low PSI (no load)
²Engine at idle
²Fuel level above 15%
²Ambient air temperature
²Barometric pressure
²Engine RPM within acceptable range of desired
idle
²Closed throttle speed
Pending ConditionsÐThe Task Manager typi-
cally does not run the Oxygen Sensor Monitor if over-
lapping monitors are running or the MIL is
illuminated for any of the following:
²Misfire Monitor
²Front Oxygen Sensor and Heater Monitor
²MAP Sensor
25 - 2 EMISSIONS CONTROLRS
EMISSIONS CONTROL (Continued)

TABLE OF CONTENTS - Continued
AMBIENT TEMPERATURE SENSOR - BLACK 2 WAY........................291
AMBIENT TEMPERATURE SENSOR (SENSOR SIDE)-2WAY................292
BRAKE LAMP SWITCH - BLACK 6 WAY...................................292
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - BLACK 2 WAY.......292
CAMSHAFT POSITION SENSOR - BLACK 3 WAY...........................292
CLOCKSPRING C1 - WHITE 6 WAY.......................................292
CRANKSHAFT POSITION SENSOR - BLACK 3 WAY.........................293
DATA LINK CONNECTOR - WHITE 16 WAY................................293
DIAGNOSTIC JUNCTION PORT - BLACK 16 WAY...........................293
EGR SOLENOID - GRAY 2 WAY..........................................294
ENGINE COOLANT TEMPERATURE SENSOR - BLACK 2 WAY................294
ENGINE OIL PRESSURE SWITCH - LT. GREEN 2 WAY......................294
EVAP/PURGE SOLENOID - BLACK 2 WAY.................................294
FUEL INJECTOR NO. 1 - BLACK 2 WAY...................................295
FUEL INJECTOR NO. 2 - BLACK 2 WAY...................................295
FUEL INJECTOR NO. 3 - BLACK 2 WAY...................................295
FUEL INJECTOR NO. 4 - BLACK 2 WAY...................................295
FUEL INJECTOR NO. 5 (3.3L/3.8L) - BLACK 2 WAY..........................296
FUEL INJECTOR NO. 6 (3.3L/3.8L) - BLACK 2 WAY..........................296
FUEL TANK MODULE - LT. GRAY 4 WAY...................................296
GENERATOR - BLACK 2 WAY...........................................296
GENERATOR (GENERATOR SIDE).......................................297
MANIFOLD ABSOLUTE PRESSURE SENSOR - BLACK 3 WAY................297
OXYGEN SENSOR 1/1 UPSTREAM - BLACK 4 WAY.........................297
OXYGEN SENSOR 1/2 DOWNSTREAM - BLACK 4 WAY.....................297
FUSES (IPM)..........................................................299
A/C COMPRESSOR CLUTCH RELAY......................................299
ACCESSORY RELAY...................................................299
AUTOMATIC SHUTDOWN RELAY........................................300
ENGINE STARTER MOTOR RELAY.......................................300
FUEL PUMP RELAY....................................................300
POSITIVE TEMPERATURE COEFFICIENTS................................300
TRANSMISSION SAFETY SHUTDOWN RELAY.............................300
POWERTRAIN CONTROL MODULE C1 - GRAY/BLACK 40 WAY...............301
POWERTRAIN CONTROL MODULE C2 - GRAY/GRAY 40 WAY................302
10.0 SCHEMATIC DIAGRAMS................................................303
10.12001 RG 2.4L....................................................303
10.22001 RG 3.3L/3.8L................................................304
11.0 CHARTS AND GRAPHS................................................305
11.1SPECIFICATION..................................................305
v

Symptom:
P1698-NO BUS MESSAGE FROM TRANS CONTROL MODULE
When Monitored and Set Condition:
P1698-NO BUS MESSAGE FROM TRANS CONTROL MODULE
When Monitored: Equipped with automatic transmission. The ignition on. Battery
voltage greater than 10 volts.
Set Condition: No bus messages from the TCM for 20 seconds, two trips required.
POSSIBLE CAUSES
INTERMITTENT CONDITION
COMMUNICATE WITH TCM
PCM
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, erase DTCs.
Cycle the ignition key on and off several times.
With the DRBIIIt, read DTC's.
Does the DTC reset?All
Ye s®Go To 2
No®Go To 3
2 Turn the ignition on.
With the DRBIIIt, attempt to communicate with the TCM.
Can communication be established with the TCM?All
Ye s®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Refer to the Communication Category and perform the appropri-
ate symptom related to no communication with TCM.
Perform POWERTRAIN VERIFICATION TEST VER-1.
32
COMMUNICATION

Symptom:
P1294-TARGET IDLE NOT REACHED (2.4L)
When Monitored and Set Condition:
P1294-TARGET IDLE NOT REACHED (2.4L)
When Monitored: With the engine idling and the transmission in drive, if automatic.
There must not be a MAP sensor trouble code or a Throttle Position Sensor trouble code.
Set Condition: The engine idle is not within 200 rpm above or 100 rpm below the target
idle for 11 seconds. One trip fault.
POSSIBLE CAUSES
IAC MOTOR OPERATION INTERMITTENT
INTERMITTENT CONDITION
IAC MOTOR OPERATION INTERMITTENT
IAC MOTOR
IAC DRIVER CIRCUIT OPEN
VACUUM LEAKS
AIR INDUCTION SYSTEM
THROTTLE BODY AND THROTTLE LINKAGE
PCM IAC MOTOR
PCM
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, read DTC's.
Is the Good Trip displayed and equal to zero?2.4L 4 CYL DOHC
16V MPI
Ye s®Go To 2
No®Go To 10
2 Start the engine.
Allow the engine idle to stabilize for 60 seconds.
Using the DRBIIIt, perform the IAC wiggle test.
NOTE: The engine idle should raise and lower with the display.
Does the RPM raise and lower correctly?2.4L 4 CYL DOHC
16V MPI
Ye s®Go To 3
No®Go To 6
184
DRIVEABILITY - GAS

Symptom:
P1294-TARGET IDLE NOT REACHED (3.3L/3.8L)
When Monitored and Set Condition:
P1294-TARGET IDLE NOT REACHED (3.3L/3.8L)
When Monitored: With the engine idling and the transmission in drive, if automatic.
There must not be a MAP sensor trouble code or a Throttle Position Sensor trouble code.
Set Condition: The engine idle is not within 200 rpm above or 100 rpm below the target
idle for 11 seconds. One trip fault.
POSSIBLE CAUSES
INTERMITTENT CONDITION
IAC MOTOR PASSAGES
VACUUM LEAKS
AIR INDUCTION SYSTEM
THROTTLE BODY AND THROTTLE LINKAGE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, read DTC's.
Is the Good Trip displayed and equal to zero?3.3L V6 GAS (SFI)
CMC and/or 3.3L
V6 FFV and/or
3.8L V-6 (SFI) GAS
Ye s®Go To 2
No®Go To 6
2 Turn the ignition off.
Remove the IAC Motor.
Inspect the IAC Motor and passages way for any obstructions or damage to motor.
Were any problems found?3.3L V6 GAS (SFI)
CMC and/or 3.3L
V6 FFV and/or
3.8L V-6 (SFI) GAS
Ye s®Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 3
3 Start the engine.
Inspect the vehicle for external vacuum leaks.
Inspect the engine for internal leaks.
Were any vacuum leaks found?3.3L V6 GAS (SFI)
CMC and/or 3.3L
V6 FFV and/or
3.8L V-6 (SFI) GAS
Ye s®Repair the vacuum leak as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 4
187
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
4 Turn ignition off.
Remove the Starter Relay from PDC.
WARNING: The Parking Brake must be on and the Transmission must be in
park for a vehicle equipped with an automatic transmission.
Warning: The engine may be cranked in the next step. Keep away from
moving engine parts.
Briefly connect a jumper wire between Starter Relay B+ circuit and the Starter Relay
Output Circuits.
Did the Starter Motor crank the engine?All
Ye s®Go To 5
No®Go To 8
5 Turn the ignition off.
Remove the Starter Relay from the PDC.
Turn the ignition on.
Using a 12-volt test light, probe the Ignition Switch Output circuit in the Starter
Relay connector.
While observing 12-volt test light, hold ignition key in the start position.
Does the test light illuminate brightly?All
Ye s®Go To 6
No®Repair the Ignition Switch Output circuit for an open or high
resistance.
Perform POWERTRAIN VERIFICATION TEST VER-1.
6 Turn the ignition off.
Remove the Starter Relay from the PDC.
Disconnect the PCM harness connector.
Measure the Starter Relay Control circuit between the Relay terminal and the PCM
harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 7
No®Repair the Starter Relay Control circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER-1.
7 Turn the ignition off.
Install a substitute a Relay in the of the Starter Motor Relay.
Attempt to start the vehicle.
Does the engine crank over?All
Ye s®Replace the Starter Motor Relay.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER-1.
259
STARTING
*NO CRANK CONDITION ÐContinued

AUTOMATIC SHUTDOWN RELAYCAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 K51 18BR/WT AUTOMATIC SHUTDOWN RELAY CONTROL
86 INTERNAL FUSED B(+)
87 K342 16BR/WT AUTOMATIC SHUTDOWN RELAY OUTPUT
87A --
ENGINE STARTER MOTOR RELAYCAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 T752 18DG/OR ENGINE STARTER MOTOR RELAY CONTROL
86 INTERNAL IGNITION SWITCH OUTPUT (START)
87 T750 12YL/GY ENGINE STARTER MOTOR RELAY OUTPUT
87A --
FUEL PUMP RELAYCAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 K31 18BR FUEL PUMP RELAY CONTROL
86 INTERNAL FUSED IGNITION SWITCH OUTPUT (RUN-START)
87 N1 16DB/OR FUEL PUMP RELAY OUTPUT
87A --
POSITIVE TEMPERATURE COEFFICIENTSCAV CIRCUIT FUNCTION
4 C16 20DB/GY FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
7 A105 18DB/RD FUSED B(+)
TRANSMISSION SAFETY SHUTDOWN RELAYCAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 Z115 20BK/OR GROUND
86 T15 18YL/BR TRANSMISSION CONTROL RELAY CONTROL
87 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
87A --
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
300
CONNECTOR PINOUTS

1.0 INTRODUCTION
The procedures contained in this manual include
all of the specifications, instructions, and graphics
needed to diagnose 41TE/AE Electronic Automatic
Transaxle (EATX) problems. The diagnostics in this
manual are based on the failure condition or symp-
tom being present at the time of diagnosis.
When repairs are required, refer to the appropri-
ate volume of the service manual for the proper
removal and repair procedure.
Diagnostic procedures change every year. New
diagnostic systems may be added and/or carryover
systems may be enhanced. READ THIS MANUAL
BEFORE TRYING TO DIAGNOSE A VEHICLE
TROUBLE CODE. It is recommended that you
review the entire manual to become familiar with
all new and changed diagnostic procedures.
This book reflects many suggested changes from
readers of past issues. After using this book, if you
have any comments or recommendations, please fill
out the form at the back of the book and mail it back
to us.
1.1 SYSTEM COVERAGE
This diagnostic procedures manual covers all
2001 RG equipped with a 41TE/AE transaxle.
1.2 SIX -STEP TROUBLESHOOTING
PROCEDURE
Diagnosis of the 41TE/AE electronic transaxle is
done in six basic steps:
verification of complaint
verification of any related symptoms
symptom analysis
problem isolation
repair of isolated problem
verification of proper operation
2.0 IDENTIFICATION OF
SYSTEM
RG series vehicles equipped with a 4 speed trans-
mission.
3.0 SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
3.1 GENERAL DESCRIPTION
The 41TE/AE electronic transaxle is a conven-
tional transaxle in that it uses hydraulically ap-
plied clutches to shift a planetary gear train. How-
ever, the electronic control system replaces many of
the mechanical and hydraulic components used in
conventional transmission valve bodies.
3.2 FUNCTIONAL OPERATION
The 41TE/AE electronic transaxle has a fully
adaptive control system. The system performs it's
functions based on continuous real-time sensor
feedback information. The control system automat-
ically adapts to changes in engine performance and
friction element variations to provide consistent
shift quality. The control system ensures that clutch
operation during upshifting and downshifting is
more responsive without increased harshness.
The Transmission Control Module (TCM) contin-
uously checks for electrical problems, mechanical
problems, and some hydraulic problems. When a
problem is sensed, the TCM stores a diagnostic
trouble code. Some of these codes cause the tran-
saxle to go into limp-in or default mode.
While in this mode, electrical power is taken
away from the transaxle via the TCM, de-
energizing the transmission control relay, and tak-
ing power from the solenoid pack. When this hap-
pens, the only transaxle mechanical functions are:
Park and Neutral
Reverse
Second Gear
No upshifts or downshifts are possible. The posi-
tion of the manual valve alone allows the three
ranges that are available. Although vehicle perfor-
mance is seriously degraded while in this mode, it
allows the owner to drive the vehicle in for service.
Once the DRBIIItis in the EATX portion of the
diagnostic program, it constantly monitors the
TCM to see if the system is in limp-in mode. If the
transaxle is in limp-in mode, the DRBIIIž will flash
the red LED.
3.2.1 AUTOSTICK FEATURE
This feature allows the driver to manually shift
the transaxle when the shift lever is pulled back
into the AutoStick position. When in AutoStick
mode, the instrument cluster displays the current
gear.
1
GENERAL INFORMATION

> Transmission Simulator (Miller # 8333)
> Transmission Simulator (Miller # 8333-1)
Adapter harness kit and panel overlay for FWD
vehicles.
> Jumper wires
> Test Light (minimum of 25 ohms of resistance)
> Ohmmeter
> Voltmeter
> Pressure gauge (0-300 PSI)
6.0 GLOSSARY OF TERMS
6.1 ACRONYMS
BCMBody Control Module
CKTCircuit
CVIClutch Volume Index
DLCData Link Connector
DRBIIItDiagnostic Readout Box
DTCDiagnostic Trouble Code
EATXElectronic Automatic Transaxle
EMCCElectronically Modulated Converter
Clutch
FCMFront Control Module (part of the
IPM system)
IODIgnition off-draw
IPMIntelligent Power Module
IRTIntelligent Recovery Timer
ISSInput Speed Sensor
LEDLight Emitting Diode
LRLow/reverse Clutch or Pressure
Switch
LULockupMICMechanical Instrument Cluster
MILMalfunction Indicator Lamp
OBDIIOn Board Diagnostics
ODOverdrive Clutch or Pressure
Switch
OSSOutput Speed Sensor
PCMPowertrain Control Module
PEMCCPartial Electronically Modulated
Converter Clutch
PLUPartial Lockup
REVReverse Clutch
SLPKSolenoid Pack
SSVSolenoid Switch Valve
SWSwitch
TCCTorque Converter Clutch
TCMTransmission Control Module
TPThrottle Position
TRDTorque Reduction
TRSTransmission Range Sensor
UDUnderdrive Clutch
2-42nd and 4th gear Clutch or Pres-
sure Switch
6.2 DEFINITIONS
OBDII (EURO STAGE III OBD) Trip - A vehicle
start and drive cycle such that all once per trip
diagnostic monitors have run.
Key Start - A vehicle start and run cycle of at least
20 seconds.
Warm-up Cycle - A vehicle start and run cycle
such that the engine coolant must rise to at least
71C (160ÉF) and must rise by at least 4.4C (40ÉF)
from initial start up. To count as a warm-up cycle,
no DTC may occur during the cycle.
21
GENERAL INFORMATION