DODGE TOWN AND COUNTRY 2001 Service Manual

INSTALLATION
The power transfer unit input shaft cover seal is
the larger of the two seals located on the inside of
the end cover. The differential bearing cup must be
removed to service this seal.
(1) Clean and inspect seal area.
(2) Use special tool No. MD998803 and install seal
(Fig. 34). When installing seal the spring side of the
seal must face toward the special tool.
(3) Reinstall the original bearing race and shim
using special tool No. 6522 (Fig. 35) and (Fig. 36).
Fig. 30 P.T.U. End Cover Bolts
1 - POWER TRANSFER UNIT
2 - FILL PLUG
3 - END COVER
4 - OUTPUT SHAFT
Fig. 31 End Cover Removal
1 - END COVER EARS
2 - HAMMER
3 - POWER TRANSFER UNIT
Fig. 32 Bearing Race Removal
1 - END COVER
2 - SPECIAL TOOL No. 6514
Fig. 33 Seal Removal
1 - END COVER
2 - SPECIAL TOOL 7794±A
3 - SLIDE HAMMER
4 - SOFT JAW VICE
21 - 14 POWER TRANSFER UNITRS
INPUT SHAFT COVER SEAL (Continued)
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CAUTION: The original shim must be installed
behind the bearing cup to maintain proper bearing
preload.
(4) Apply Moparž Gasket Maker, Loctite Gasket
Eliminator No. 518 or equivalent to sealing surfaces
of end cover.
(5) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N´m (250 in. lbs.) in thesequence shown in (Fig. 37). Retighten first bolt after
all others are tight.
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly into vehicle.
(7) Check and fill fluids as required.
Fig. 34 Seal Installation
1 - SPECIAL TOOL No. MD998803
2 - HAMMER
3 - END COVER
Fig. 35 Bearing Shim and Race
1 - SHIM
2 - BEARING RACE
3 - END COVER
Fig. 36 Installing Bearing Race
1 - HAMMER
2 - END COVER
3 - SPECIAL TOOL No. 6522
4 - HANDLE 4171
Fig. 37 Bolt Tightening Sequence
RSPOWER TRANSFER UNIT21-15
INPUT SHAFT COVER SEAL (Continued)
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INPUT SHAFT END SEAL
REMOVAL
The input shaft end seal is located on the end of
the input shaft.
(1) Remove power transfer unit from the vehicle.
(2) Remove end cover bolts (Fig. 38).
(3) Tap on end cover ears to separate end cover
from case (Fig. 39).
(4) Pry out seal with a pry bar (Fig. 40).
INSTALLATION
The input shaft end seal is located on the end of
the input shaft.
(1) Clean and inspect seal area.
(2) Remove input shaft from housing and stand on
soft block of wood. Install input shaft end seal with
seal installer 5065 and handle C-4171.
(3) Lubricate seal lip after installing seal into
input shaft.
(4) Clean sealing surfaces of the end cover and
P.T.U. case. Apply a bead of Moparž Gasket Maker,
Loctite Gasket Eliminator No. 518 or equivalent.
Fig. 38 End Cover Bolts
1 - POWER TRANSFER UNIT
2 - FILL PLUG
3 - END COVER
4 - OUTPUT SHAFT
Fig. 39 Side Cover Removal
1 - END COVER EARS
2 - HAMMER
3 - POWER TRANSFER UNIT
Fig. 40 Seal Removal
1 - POWER TRANSFER UNIT
2 - PRYBAR
3 - SEAL
21 - 16 POWER TRANSFER UNITRS
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(5) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N´m (250 in. lbs.) in the
sequence shown in (Fig. 41). Retighten first bolt after
all others are tight.
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly.
(7) Check and fill fluids as required.
INPUT SHAFT SEAL
REMOVAL
The Power Transfer Unit must be removed from
the vehicle to service this seal. Refer to Power Trans-
fer Unit Removal in this section for procedures.
(1) Remove P.T.U. end cover bolts (Fig. 42).
(2) Gently tap on end cover ears to separate cover
from case (Fig. 43).
(3) Remove ring gear oil trough (Fig. 44).
(4) Remove input shaft and ring gear from case
(Fig. 45).
(5) Use Special Tool No. 7794-A (seal puller) to
remove seal (Fig. 46).
Fig. 41 Bolt Tightening Sequence
Fig. 42 P.T.U. End Cover Bolts
1 - POWER TRANSFER UNIT
2 - FILL PLUG
3 - END COVER
4 - OUTPUT SHAFT
Fig. 43 End Cover Removal
1 - END COVER EARS
2 - HAMMER
3 - POWER TRANSFER UNIT
RSPOWER TRANSFER UNIT21-17
INPUT SHAFT END SEAL (Continued)
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INSTALLATION
The Power Transfer Unit must be removed from
the vehicle to service this seal. Refer to Power Trans-
fer Unit Removal in this section for procedures.(1) Clean and inspect seal area.
(2) Lay housing on bench and install new seal with
seal driver C-4657 and handle C-4171 (Fig. 47). The
seal must be installed with the spring side facing
towards the ring gear. Drive the seal in until it bot-
toms against the case shoulder.
(3) Install input shaft.
(4) Install oil trough.
(5) Apply Moparž Gasket Maker or equivalent to
sealing surfaces of end cover and reinstall. Tighten
bolts to 28 N´m (250 in. lbs.)
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly into vehicle.
(7) Check and fill fluids as required.
OUTER HALF SHAFT SEAL
REMOVAL
The outer half shaft seal is located on the outside
of the end cover. The P.T.U. does not have to be
removed to replace this seal.
(1) Lift vehicle on hoist.
(2) Remove right front half shaft from vehicle.
(3) Remove seal with a chisel and hammer (Fig.
48).
Fig. 44 Oil Trough
1 - OIL TROUGH
2 - POWER TRANSFER UNIT
Fig. 45 Input Shaft and Ring Gear Removal
1 - POWER TRANSFER UNIT
2 - RING GEAR
Fig. 46 Seal Removal
1 - POWER TRANSFER UNIT
2 - SPECIAL TOOL
7794±A
21 - 18 POWER TRANSFER UNITRS
INPUT SHAFT SEAL (Continued)
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INSTALLATION
The outer half shaft seal is located on the outside
of the end cover. The P.T.U. does not have to be
removed to replace this seal.
(1) Clean and inspect seal area.
(2) Install new seal with seal installer MD998334
(Fig. 49).
(3) Reinstall right front half shaft.
(4) Check and fill fluids as required.
Fig. 47 Seal Installation
1 - HAMMER
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL C-4657
4 - POWER TRANSFER UNIT
Fig. 48 Seal Removal
1 - HAMMER
2 - CHISEL
3 - SEAL
4 - POWER TRANSFER UNIT
Fig. 49 Seal Installation
1 - BEARING
2 - SNAP RING PLIERS
3 - BEARING SNAP RING
RSPOWER TRANSFER UNIT21-19
OUTER HALF SHAFT SEAL (Continued)
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REAR COVER O-RING
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove rear cover retaining bolts (Fig. 50).
(3) Index rear cover to the case for later reassem-
bly (Fig. 51).(4) Pull rear cover out of the P.T.U. case (Fig. 52).
(5) Remove rear cover O-Ring (Fig. 53).
INSTALLATION
(1) To install, reverse removal procedure.
Fig. 50 Rear Cover Bolts
1 - OUTPUT FLANGE SEAL
2 - REAR COVER
3 - OUTPUT SHAFT
Fig. 51 Mark Rear Cover
1 - REAR COVER
2 - OUTPUT SHAFT
3 - PAINT MARK
Fig. 52 Rear Cover Removal
1 - POWER TRANSFER UNIT ASSEMBLY
2 - REAR COVER
3 - O-RING
Fig. 53 O-Ring Removal
1 - REAR COVER
2 - PINION GEAR
3 - O-RING
21 - 20 POWER TRANSFER UNITRS
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AUTOMATIC - 31TH
TABLE OF CONTENTS
page page
AUTOMATIC - 31TH
DESCRIPTION...........................22
OPERATION.............................24
DIAGNOSIS AND TESTING.................24
PRELIMINARY DIAGNOSIS...............24
ROAD TEST...........................31
HYDRAULIC PRESSURE TESTS...........32
TORQUE CONVERTER HOUSING FLUID
LEAKAGE.............................34
CLUTCH AND SERVO AIR PRESSURE
TESTS...............................35
STANDARD PROCEDURE..................36
ALUMINUM THREAD REPAIR.............36
REMOVAL..............................36
DISASSEMBLY...........................39
ASSEMBLY.............................50
INSTALLATION...........................59
SCHEMATICS AND DIAGRAMS..............63
SPECIFICATIONS........................71
SPECIAL TOOLS.........................74
ACCUMULATOR
DESCRIPTION...........................78
OPERATION.............................78
BANDS
DESCRIPTION...........................79
OPERATION.............................79
ADJUSTMENTS..........................79
CLUTCH - FRONT
DESCRIPTION...........................80
OPERATION.............................81
DISASSEMBLY...........................81
ASSEMBLY.............................84
CLUTCH - REAR
DESCRIPTION...........................85
OPERATION.............................85
DISASSEMBLY...........................86
ASSEMBLY.............................89
FINAL DRIVE
DISASSEMBLY...........................90
ASSEMBLY.............................94
ADJUSTMENTS..........................96
FLUID
STANDARD PROCEDURE..................98
FLUID LEVEL AND CONDITION CHECK......98
FLUID AND FILTER CHANGE..............98
GEAR SHIFT CABLE
REMOVAL.............................100
INSTALLATION..........................101
ADJUSTMENTS.........................103GOVERNOR
DESCRIPTION..........................103
OPERATION............................103
CLEANING.............................104
INSPECTION...........................104
OIL PUMP
DESCRIPTION..........................104
OPERATION............................104
STANDARD PROCEDURE.................105
OIL PUMP VOLUME CHECK..............105
DISASSEMBLY..........................105
CLEANING.............................105
INSPECTION...........................105
ASSEMBLY............................105
PARK/NEUTRAL POSITION SWITCH
DIAGNOSIS AND TESTING................106
PARK/NEUTRAL POSITION SWITCH.......106
REMOVAL.............................106
INSTALLATION..........................107
PLANETARY GEARTRAIN
DISASSEMBLY..........................107
ASSEMBLY............................107
SEAL - OIL PUMP
REMOVAL.............................109
INSTALLATION..........................109
SERVO - KICKDOWN
DESCRIPTION..........................109
OPERATION............................109
DISASSEMBLY..........................110
CLEANING.............................111
INSPECTION...........................111
ASSEMBLY.............................112
SERVO - LOW/REVERSE
DESCRIPTION..........................112
OPERATION............................112
DISASSEMBLY..........................112
CLEANING.............................113
ASSEMBLY.............................113
SHIFT INTERLOCK SOLENOID
DESCRIPTION..........................113
OPERATION............................114
DIAGNOSIS AND TESTING................115
BRAKE/TRANSMISSION SHIFT INTERLOCK
SOLENOID...........................115
REMOVAL.............................115
INSTALLATION..........................116
SOLENOID - TCC
DESCRIPTION..........................117
OPERATION............................117
RSAUTOMATIC - 31TH21-21
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REMOVAL.............................118
INSTALLATION..........................118
THROTTLE VALVE CABLE
REMOVAL.............................118
INSTALLATION..........................118
ADJUSTMENTS.........................120
TORQUE CONVERTER
DESCRIPTION..........................120
OPERATION............................123
REMOVAL.............................125
INSTALLATION..........................125
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/
BEARING
REMOVAL.............................126
INSTALLATION..........................129
ADJUSTMENTS.........................132TRANSFER SYSTEM - TRANSFER SHAFT/
GEAR/BEARING
REMOVAL.............................134
INSTALLATION..........................137
ADJUSTMENTS.........................142
VALVE BODY
REMOVAL.............................142
DISASSEMBLY..........................145
CLEANING.............................151
INSPECTION...........................152
ASSEMBLY............................152
INSTALLATION..........................155
ADJUSTMENTS.........................157
VEHICLE SPEED SENSOR/PINION GEAR
REMOVAL.............................157
INSTALLATION..........................157
AUTOMATIC - 31TH
DESCRIPTION
This transaxle combines torque converter, three
speed transmission, final drive gearing, and differen-
tial into a front wheel drive system.
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.
Center distances between the main rotating parts
in these three areas are held precise to maintain a
low noise level.
The torque converter, transaxle area, and differen-
tial are housed in an integral aluminum die casting.
The differential oil sump is common with the
transaxle sump. Separate filling of the differen-
tial is NOT necessary.
The torque converter is attached to the crankshaft
through a flexible driving plate. Cooling of the con-
verter is accomplished by circulating the transaxle
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.
The transaxle fluid is filtered by an internal filter
attached to the lower side of the valve body assembly.Engine torque is transmitted to the torque con-
verter and 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 section.
The transaxle consists of:
²Two multiple-disc clutches
²An overrunning clutch
²Two servos
²A hydraulic accumulator
²Two bands
²Two 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 driving 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 in the
transaxle final drive (axle) ratio. The shaft also car-
ries the governor and parking sprag. An integral heli-
cal gear on the transfer shaft drives the differential
ring gear.
21 - 22 AUTOMATIC - 31THRS
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31TH Automatic Transaxle
1 - TORQUE CONVERTER CLUTCH
2 - TORQUE CONVERTER
3 - OIL PUMP
4 - FRONT CLUTCH
5 - REAR CLUTCH
6 - OVER-RUNNING CLUTCH7 - PLANETARY GEARS
8 - TRANSFER GEARS
9 - TRANSFER SHAFT
10 - GOVERNOR
11 - DIFFERENTIAL
RSAUTOMATIC - 31TH21-23
AUTOMATIC - 31TH (Continued)
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