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Chrysler Town, Dodge Caravan. Manual - part 393

(3) Clutch circuit leaks are indicated if pressures

do not fall within the specified pressure range.

(4) If the overdrive clutch pressure is greater than 5

psi in Step 4 of Test Three, a worn reaction shaft seal
ring or a defective solenoid assembly is indicated.

(5) If the underdrive clutch pressure is greater

than 5 psi in Step 4 of Test Two A, a defective sole-
noid assembly or PCM/TCM is the cause.

PRESSURE CHECK SPECIFICATIONS

Gear Selector

Position

Actual Gear

Pressure Taps

Underdrive

Clutch

Overdrive

Clutch

Reverse

Clutch

Torque

Converter

Clutch

Off

2/4

Clutch

Low/

Reverse

Clutch

Park

PARK

0-2

0-5

0-2

60-110

0-2

115-145

0 mph

REVERSE

0-2

0-7

165-235

50-100

0-2

165-235

0 mph

NEUTRAL

0-2

0-5

0-2

60-110

0-2

115-145

0 mph

FIRST

110-145

0-5

0-2

60-110

0-2

115-145

20 mph

SECOND

110-145

0-5

0-2

60-110

115-145

0-2

30 mph

DIRECT

75-95

0-2

60-90

0-2

45 mph

OVERDRIVE

0-2

75-95

0-2

60-90

75-95

0-2

30 mph

OVERDRIVE

WITH TCC

0-2

75-95

0-2

0-5

75-95

0-2

50 mph

* Engine speed at 1500 rpm

# CAUTION: Both front wheels must be turning at the same speed.

DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS

Inoperative clutches can be located using a series

of tests by substituting air pressure for fluid pressure
(Fig. 5) (Fig. 6). The clutches may be tested by apply-
ing air pressure to their respective passages. The
valve body must be removed and Tool 6056 installed.
To make air pressure tests, proceed as follows:

NOTE: The compressed air supply must be free of
all dirt and moisture. Use a pressure of 30 psi.

Remove oil pan and valve body. See Valve body

removal.

OVERDRIVE CLUTCH

Apply air pressure to the overdrive clutch apply

passage and watch for the push/pull piston to move

forward. The piston should return to its starting
position when the air pressure is removed.

REVERSE CLUTCH

Apply air pressure to the reverse clutch apply pas-

sage and watch for the push/pull piston to move rear-
ward. The piston should return to its starting
position when the air pressure is removed.

2/4 CLUTCH

Apply air pressure to the feed hole located on the

2/4 clutch retainer. Look in the area where the 2/4
piston contacts the first separator plate and watch
carefully for the 2/4 piston to move rearward. The
piston should return to its original position after the
air pressure is removed.

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41TE AUTOMATIC TRANSAXLE

41TE AUTOMATIC TRANSAXLE (Continued)

LOW/REVERSE CLUTCH

Apply air pressure to the low/reverse clutch feed

hole (rear of case, between 2 bolt holes). Then, look
in the area where the low/reverse piston contacts the
first separator plate. Watch carefully for the piston to
move forward. The piston should return to its origi-
nal position after the air pressure is removed.

UNDERDRIVE CLUTCH

Because this clutch piston cannot be seen, its oper-

ation is checked by function. Air pressure is applied
to the low/reverse and the 2/4 clutches. This locks the
output shaft. Use a piece of rubber hose wrapped
around the input shaft and a pair of clamp-on pliers
to turn the input shaft. Next apply air pressure to
the underdrive clutch. The input shaft should not

rotate with hand torque. Release the air pressure
and confirm that the input shaft will rotate.

DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE

When diagnosing converter housing fluid leaks,

three actions must be taken before repair:

(1) Verify proper transmission fluid level.
(2) Verify that the leak originates from the con-

verter housing area and is transmission fluid.

(3) Determine the true source of the leak.
Fluid leakage at or around the torque converter

area may originate from an engine oil leak (Fig. 7).
The area should be examined closely. Factory fill
fluid is red and, therefore, can be distinguished from
engine oil.

Some suspected converter housing fluid leaks may

not be leaks at all. They may only be the result of
residual fluid in the converter housing, or excess
fluid spilled during factory fill, or fill after repair.
Converter

housing

leaks

have

several

potential

sources. Through careful observation, a leak source
can be identified before removing the transmission
for repair.

Pump seal leaks tend to move along the drive hub

and onto the rear of the converter (Fig. 7). Pump
o-ring or pump body leaks follow the same path as a
seal leak. Pump attaching bolt leaks are generally
deposited on the inside of the converter housing and
not on the converter itself. Pump seal or gasket leaks
usually travel down the inside of the converter hous-
ing (Fig. 7).

Fig. 5 Air Pressure Test Plate

1 - TOOL 6056
2 - ACCUMULATORS

Fig. 6 Testing Reverse Clutch

1 - TOOL 6056
2 - AIR NOZZLE

Fig. 7 Converter Housing Leak Paths

1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK

41TE AUTOMATIC TRANSAXLE

21 - 123

41TE AUTOMATIC TRANSAXLE (Continued)

TORQUE CONVERTER LEAKAGE

Possible sources of torque converter leakage are:
• Torque converter weld leaks at the outside diam-

eter weld (Fig. 8).

• Torque converter hub weld (Fig. 8).

REMOVAL

NOTE: If transaxle assembly is being replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perform the TCM Quick Learn Proce-
dure. (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL

MODULES/TRANSMISSION

CONTROL

MODULE - STANDARD PROCEDURE)

(1) Disconnect battery cables.
(2) Remove battery shield (Fig. 9).
(3) Remove coolant recovery bottle (Fig. 10).
(4) Remove fluid level indicator/tube assembly.

Plug opening to prevent debris from entering trans-
axle.

(5) Using a blade or suitable hose cutter, cut trans-

axle oil cooler lines off flush with fittings. Plug lines
and fittings to prevent debris from entering transaxle
or cooler circuit. A service splice kit will be installed
upon reassembly.

(6) Disconnect input and output shaft speed sensor

connectors (Fig. 11).

(7) Disconnect transmission range sensor (TRS)

connector (Fig. 11).

(8) Disconnect solenoid/pressure switch assembly

connector (Fig. 11).

Fig. 8 Converter Leak Points - Typical

1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG

Fig. 9 Battery Thermal Guard

1 - BATTERY THERMOWRAP (IF EQUIPPED)
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE

Fig. 10 Coolant Recovery Bottle

1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL

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41TE AUTOMATIC TRANSAXLE

41TE AUTOMATIC TRANSAXLE (Continued)

(9) Disconnect gear shift cable from manual valve

lever and upper mount bracket (Fig. 12).

(10) Disconnect

crankshaft

position

sensor

(if

equipped). Remove sensor from bellhousing.

(11) Reposition leak detection pump harness and

hoses.

(12) Remove rear mount bracket-to-transaxle case

bolts (Fig. 13).

(13) Remove transaxle upper bellhousing-to-block

bolts.

(14) Raise vehicle on hoist.
(15) Remove transaxle oil pan and drain fluid into

suitable container.

(16) Remove front wheel/tire assemblies.
(17) Remove left and right halfshaft assemblies.

(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - REMOVAL)

(18) AWD models: Remove power transfer unit.

(Refer

TRANSMISSION/TRANSAXLE/

POWER TRANSFER UNIT - REMOVAL)

(19) Remove rear mount bracket-to-transaxle case

lower (horizontal) bolt (Fig. 13).

(20) Remove front mount/bracket assembly.
(21) Remove starter motor.
(22) Remove lateral bending brace.
(23) Remove inspection cover.
(24) Remove torque converter-to-drive plate bolts.
(25) Support engine/transaxle assembly at engine

oil pan with screw jack and wood block.

(26) Partially remove left wheelhouse splash shield

to gain access to and remove upper mount thru-bolt
(Fig. 14).

(27) Lower engine/transaxle assembly with screw

jack.

(28) Obtain

helper

and/or

transmission

jack.

Secure transmission jack to transaxle assembly.

(29) Remove upper mount bracket from transaxle

(Fig. 14).

(30) Remove remaining transaxle bellhousing-to-

engine bolts.

(31) Remove transaxle assembly from vehicle.

DISASSEMBLY

NOTE: If transaxle is being overhauled (clutch
and/or seal replacement) or replaced, it is neces-
sary to perform the PCM/TCM Quick Learn Proce-
dure.

(Refer

ELECTRICAL/ELECTRONIC

CONTROL

MODULES/POWERTRAIN/TRANSMIS-

SION CONTROL MODULE - STANDARD PROCE-
DURE)

NOTE: This procedure does not include final drive
(differential) disassembly.

(1) Remove input and output speed sensors.
(2) Remove

three

(3)

solenoid/pressure

switch

assembly-to-case bolts.

(3) Remove solenoid/pressure switch assembly and

gasket (Fig. 15).

Fig. 11 Component Connector Location—Typical

1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR

Fig. 12 Gearshift Cable at Transaxle - Typical

1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET

41TE AUTOMATIC TRANSAXLE

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41TE AUTOMATIC TRANSAXLE (Continued)

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