sensor DODGE TOWN AND COUNTRY 2001 Service Manual

Since there are four switches, there are 16 possible
combinations of open and closed switches (codes).
Seven of these codes are related to gear position and
three are recognized as ªbetween gearº codes. This
results in six codes which should never occur. These
are called ªinvalidº codes. An invalid code will result
in a DTC, and the TCM will then determine the shift
lever position based on pressure switch data. This
allows reasonably normal transmission operation
with a TRS failure.
TRS SWITCH STATES
SLP T42 T41 T3 T1
PCL CL CL OP
RCL OP OP OP
NCL CL OP CL
ODOP OP OP CL
3OP OP CL OP
LCL OP CL CL
TRANSMISSION TEMPERATURE SENSOR
The TRS has an integrated thermistor (Fig. 342)
that the TCM uses to monitor the transmission's
sump temperature. Since fluid temperature can
affect transmission shift quality and convertor lock
up, the TCM requires this information to determine
which shift schedule to operate in. The PCM also
monitors this temperature data so it can energize the
vehicle cooling fan(s) when a transmission ªoverheatº
condition exists. If the thermistor circuit fails, the
TCM will revert to calculated oil temperature usage.
CALCULATED TEMPERATURE
A failure in the temperature sensor or circuit will
result in calculated temperature being substituted for
actual temperature. Calculated temperature is a pre-
dicted fluid temperature which is calculated from a
combination of inputs:
²Battery (ambient) temperature
²Engine coolant temperature
²In-gear run time since start-up
REMOVAL
(1) Remove valve body assembly from transaxle.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/VALVE BODY - REMOVAL)
(2) Remove transmission range sensor retaining
screw and remove sensor from valve body (Fig. 343).
(3) Remove TRS from manual shaft.
INSTALLATION
(1) Install transmission range sensor (TRS) to the
valve body and torque retaining screw (Fig. 343) to 5
N´m (45 in. lbs.).
(2) Install valve body to transaxle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
41TE/VALVE BODY - INSTALLATION)
Fig. 342 Transmission Temperature Sensor
1 - TRANSMISSION RANGE SENSOR
2 - TEMPERATURE SENSOR
Fig. 343 Remove Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
21 - 288 AUTOMATIC - 41TERS
TRANSMISSION RANGE SENSOR (Continued)
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DISASSEMBLY
NOTE: If valve body assembly is being recondi-
tioned, the TCM Quick Learn Procedure must be
performed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Remove manual shaft seal (Fig. 351).(2) Remove Transmission Range Sensor retaining
screw (Fig. 352).
(3) Remove Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 353).
Fig. 350 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 351 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 352 Remove Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
Fig. 353 Manual Shaft/Rooster Comb and
Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
21 - 292 AUTOMATIC - 41TERS
VALVE BODY (Continued)
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(14) Install Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 379).
(15) Make sure Manual Valve control pin is con-
tained within the rooster comb slot (Fig. 380). Install
Transmission Range Sensor retaining screw (Fig.
380) and torque to 5 N´m (45 in. lbs.).(16) Install manual shaft seal (Fig. 381).
INSTALLATION
NOTE: If valve body assembly is being replaced or
reconditioned, it is necessary to perform the TCM
Quick Learn Procedure. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install valve body assembly to transaxle (Fig.
382). Install and torque valve body-to-transaxle case
bolts (Fig. 383) to 12 N´m (105 in. lbs.).
Fig. 379 Install Manual Shaft/Rooster Comb and
Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
Fig. 380 Install Transmission Range Sensor
Retaining Screw
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
Fig. 381 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 382 Valve Body Removal/Installation
1 - VALVE BODY
RSAUTOMATIC - 41TE21 - 301
VALVE BODY (Continued)
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(2) Install transaxle oil filter (Fig. 384). Inspect
the o-ring and replace if necessary.
(3) Ensure the transaxle oil pan and transaxle
case sealing surfaces are clean and dry. Install an
1/8º bead of MopartSilicone Rubber Adhesive Seal-ant to the oil pan and install (Fig. 385). Torque oil
pan-to-transaxle case bolts (Fig. 386) to 19 N´m (165
in. lbs.).
(4) Lower vehicle.
(5) Connect transmission range sensor connector.
(6) Install manual valve lever to manual shaft.
(7) Install gearshift cable to manual valve lever.
(8) Connect battery negative cable.
(9) Fill transaxle with MopartATF +4 Transmis-
sion fluid. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
Fig. 383 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 384 Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 385 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 386 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
21 - 302 AUTOMATIC - 41TERS
VALVE BODY (Continued)
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T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page
T850 MANUAL TRANSAXLE.................1
T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
T850 MANUAL TRANSAXLE
DESCRIPTION............................2
OPERATION.............................4
DIAGNOSIS AND TESTING.................11
DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES.....................11
REMOVAL..............................11
DISASSEMBLY...........................17
ASSEMBLY.............................22
INSTALLATION...........................31
SPECIFICATIONS........................37
SPECIAL TOOLS.........................39
AXLE SEALS
REMOVAL..............................42
INSTALLATION...........................42
BACK-UP LAMP SWITCH
REMOVAL..............................43
INSTALLATION...........................43
DIFFERENTIAL
DESCRIPTION...........................43
OPERATION.............................43
DISASSEMBLY...........................44
ASSEMBLY.............................47
ADJUSTMENTS..........................50
FLUID
STANDARD PROCEDURE..................52
STANDARD PROCEDURE - FLUID LEVEL
CHECK...............................52
STANDARD PROCEDURE - FLUID DRAIN
AND FILL.............................53
GEARSHIFT BOOT
REMOVAL..............................53
INSTALLATION...........................53
GEARSHIFT CABLE - CROSSOVER
REMOVAL..............................54INSTALLATION...........................56
ADJUSTMENTS..........................60
GEARSHIFT CABLE - SELECTOR
REMOVAL..............................61
INSTALLATION...........................64
GEARSHIFT KNOB
REMOVAL..............................67
INSTALLATION...........................67
GEARSHIFT MECHANISM
REMOVAL..............................68
INSTALLATION...........................70
INPUT SHAFT
DESCRIPTION...........................73
DISASSEMBLY...........................74
ASSEMBLY.............................77
INTERMEDIATE SHAFT
DESCRIPTION...........................81
DISASSEMBLY...........................81
ASSEMBLY.............................88
SHIFT COVER
DESCRIPTION...........................94
SHIFT FORK AND SHAFT
DESCRIPTION...........................95
SYNCHRONIZER
DESCRIPTION...........................95
DISASSEMBLY...........................95
CLEANING..............................95
INSPECTION............................95
ASSEMBLY.............................95
VEHICLE SPEED SENSOR
REMOVAL..............................96
INSTALLATION...........................96
RGT850 MANUAL TRANSAXLE21a-1
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(5) Remove battery tray (Fig. 18). Disconnect bat-
tery temperature sensor.
(6) Remove coolant recovery bottle from bracket.
(7) Remove coolant recovery bottle mounting
bracket (Fig. 19).
(8) Disconnect gearshift cables from shift levers/
cover assembly (Fig. 20).
(9) Remove gearshift cable retaining clips from
mounting bracket (Fig. 20). Remove cables and
secure out of way.(10) Remove three (3) right engine mount bracket-
to-transaxle bolts (Fig. 21).
Fig. 18 Battery Tray
1 - BATTERY TRAY
Fig. 19 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 20 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 21 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
21a - 14 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
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(16) Connect gearshift cables to shift levers/cover
assembly (Fig. 95). Install cables into position at
mount bracket and secure with retaining clips.
(17) Install coolant recovery bottle bracket (Fig.
96).(18) Install coolant recovery bottle to bracket.
(19) Connect battery temperature sensor and
install battery tray (Fig. 97).
(20) Install battery, hold-down clamp and nut (Fig.
98).
Fig. 95 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 96 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 97 Battery Tray
1 - BATTERY TRAY
Fig. 98 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
21a - 36 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
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(7) Remove center console support bracket (Fig.
143).
(8) Remove crossover cable retainer clip (Fig. 144).
(9) Remove crossover cable from gearshift mecha-
nism (Fig. 145).(10)2.4L Gas equipped models goto Step 15.
2.5L TD models:Remove battery thermal shield
(Fig. 146).
(11) Remove battery hold down nut, clamp, and
battery (Fig. 147).
(12) Remove battery tray (Fig. 148). Disconnect
battery temperature sensor.
(13) Remove coolant recovery bottle from bracket.
(14) Remove coolant recovery bottle mounting
bracket (Fig. 149).
(15) Disconnect crossover cable from transaxle
crossover lever (Fig. 150).
Fig. 142 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 143 Center Console Support Bracket
1 - BRACKET
2 - SCREW
3 - GEARSHIFT MECHANISM
Fig. 144 Crossover Cable Retainer Clip
1 - RETAINER CLIP
2 - CROSSOVER CABLE
Fig. 145 Crossover Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - CROSSOVER CABLE
RGT850 MANUAL TRANSAXLE21a-55
GEARSHIFT CABLE - CROSSOVER (Continued)
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(5)2.4L Gas models goto Step 10. 2.5L TD
Models:Install coolant recovery bottle bracket (Fig.
152).
(6) Install coolant recovery bottle to bracket.(7) Connect battery temperature sensor to battery
tray. Install battery tray into position (Fig. 153).
Fig. 150 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 151 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 152 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 153 Battery Tray
1 - BATTERY TRAY
RGT850 MANUAL TRANSAXLE21a-57
GEARSHIFT CABLE - CROSSOVER (Continued)
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(8) Remove selector cable retainer clip (Fig. 173).
(9) Remove selector cable from gearshift mecha-
nism (Fig. 174).
(10)2.4L Gas models goto Step 15. 2.5L TD
Models:Remove battery thermal shield (Fig. 175).
(11) Remove battery hold down nut, clamp, and
battery (Fig. 176).
(12) Remove battery tray (Fig. 177). Disconnect
battery temperature sensor.
(13) Remove coolant recovery bottle from bracket.
(14) Remove coolant recovery bottle mounting
bracket (Fig. 178).(15) Disconnect crossover cable from transaxle
crossover lever (Fig. 179).
(16) Remove crossover cable retainer clip and dis-
engage cable from mount bracket (Fig. 179).
(17) Raise vehicle on hoist.
(18) Remove selector cable from engine compart-
ment, then remove cable from passenger compart-
ment through opening in floor pan.
Fig. 173 Selector Cable Retainer Clip
1 - RETAINER CLIP
Fig. 174 Selector Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - SELECTOR CABLE
Fig. 175 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 176 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
RGT850 MANUAL TRANSAXLE21a-63
GEARSHIFT CABLE - SELECTOR (Continued)
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