Dodge Neon / Neon SRT-4. Manual - part 338

TRANSAXLE IDENTIFICATION

The 40TE transaxle is identified by a barcode label

that is fixed to the transaxle case as shown in (Fig.
2).

The label contains a series of digits that can be

translated into useful information such as transaxle
part number, date of manufacture, manufacturing
origin, plant shift number, build sequence number,
etc. Refer to (Fig. 3) for identification label break-
down.

If the tag is not legible or missing, the “PK” num-

ber, which is stamped into the transaxle case behind
the transfer gear cover, can be referred to for identi-
fication. This number differs slightly in that it con-
tains the entire transaxle part number, rather than
the last three digits.

OPERATION

Transmission output is directed to an integral dif-

ferential by a transfer gear system in the following
input-to-output ratios:

First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.84 : 1
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57 : 1
Third . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 : 1
Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.69 : 1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 : 1

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - 4XTE TRANSAXLE
GENERAL DIAGNOSIS

NOTE: Before attempting any repair on a 4XTE four-
speed automatic transaxle, check for diagnostic
trouble codes (DTC’s) using the DRB scan tool.
Refer to the Transmission Diagnostic Procedures
Manual.

Transaxle malfunctions may be caused by these

general conditions:

• Poor engine performance

• Improper adjustments

• Hydraulic malfunctions

• Mechanical malfunctions

• Electronic malfunctions
Diagnosis of these problems should always begin

by checking the easily accessible variables: fluid level
and condition, gearshift cable adjustment. Then per-
form a road test to determine if the problem has been
corrected or that more diagnosis is necessary. If the
problem persists after the preliminary tests and cor-

Fig. 2 Transaxle Identification Label

1 - IDENTIFICATION LABEL

Fig. 3 Identification Label Breakdown

1 - T=TRACEABILITY
2 - SUPPLIER CODE (PK=KOKOMO)
3 - COMPONENT CODE (TK=KOKOMO TRANSMISSION)
4 - BUILD DAY (344=DEC. 9)
5 - BUILD YEAR (9=1999)
6 - LINE/SHIFT CODE (3=3RD SHIFT)
7 - BUILD SEQUENCE NUMBER
8 - LAST THREE OF P/N
9 - ALPHA
10 - TRANSAXLE PART NUMBER
11 - P=PART NUMBER

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40TE AUTOMATIC TRANSAXLE

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40TE AUTOMATIC TRANSAXLE (Continued)

rections are completed, hydraulic pressure checks
should be performed.

DIAGNOSIS AND TESTING - ROAD TEST

Prior to performing a road test, verify that the

fluid level, fluid condition, and linkage adjustment
have been approved.

During the road test, the transaxle should be oper-

ated in each position to check for slipping and any
variation in shifting.

If the vehicle operates properly at highway speeds,

but has poor acceleration, the converter stator over-
running clutch may be slipping. If acceleration is nor-

mal, but high throttle opening is needed to maintain
highway speeds, the converter stator clutch may
have seized. Both of these stator defects require
replacement of the torque converter and thorough
transaxle cleaning.

Slipping clutches can be isolated by comparing the

“Elements in Use” chart with clutch operation
encountered on a road test. This chart identifies
which clutches are applied at each position of the
selector lever.

A slipping clutch may also set a DTC and can be

determined by operating the transaxle in all selector
positions.

ELEMENTS IN USE AT EACH POSITION OF SELECTOR LEVER

Shift Lever

Position

INPUT CLUTCHES

HOLDING CLUTCHES

Underdrive

Overdrive

Reverse

2/4

Low/Reverse

P - PARK

R - REVERSE

N - NEUTRAL

OD -

OVERDRIVE

First

Second

Direct

Overdrive

D - DRIVE*

First

Second

Direct

L - LOW*

First

Second

Direct

* Vehicle upshift and downshift speeds are increased when in these selector positions.

The process of elimination can be used to detect

any unit which slips and to confirm proper operation
of good units. Road test analysis can diagnose slip-
ping units, but the cause of the malfunction cannot
be determined. Practically any condition can be
caused by leaking hydraulic circuits or sticking
valves.

DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS

Pressure testing is a very important step in the

diagnostic procedure. These tests usually reveal the
cause of most hydraulic transaxle problems.

Before performing pressure tests, be certain that

fluid level and condition, and shift cable adjustments
have been checked and approved. Fluid must be at
operating temperature (150 to 200 degrees F.).

Install an engine tachometer, raise vehicle on hoist

which allows front wheels to turn, and position
tachometer so it can be read.

PL/SRT-4

40TE AUTOMATIC TRANSAXLE

21 - 137

40TE AUTOMATIC TRANSAXLE (Continued)

Attach

300

psi

gauge

(C-3293SP)

port(s)

required for test(s) being conducted. Use adapter set
L-4559 to adapt gauge(s) to transaxle.

Test port locations are shown in (Fig. 4).

TEST ONE-SELECTOR IN LOW (1st GEAR)

(1) Attach pressure gauge to the low/reverse clutch

tap.

(2) Move selector lever to the (L) position.
(3) Allow vehicle wheels to turn and increase

throttle opening to achieve an indicated vehicle speed
to 20 mph.

(4) Low/reverse clutch pressure should read 115 to

145 psi.

(5) This test checks pump output, pressure regula-

tion and condition of the low/reverse clutch hydraulic
circuit and shift schedule.

TEST TWO-SELECTOR IN DRIVE (2nd GEAR)

NOTE: This test checks the underdrive clutch
hydraulic circuit as well as the shift schedule.

(1) Attach gauge to the underdrive clutch tap.
(2) Move selector lever to the 3 position.
(3) Allow vehicle wheels to turn and increase

throttle opening to achieve an indicated vehicle speed
of 30 mph.

(4) In second gear the underdrive clutch pressure

should read 110 to 145 psi.

TEST TWO A–SELECTOR IN OD (4th Gear)

NOTE: This test checks the underdrive clutch
hydraulic circuit as well as the shift schedule.

(1) Attach gauge to the underdrive clutch tap.
(2) Move selector lever to the (OD) position.
(3) Allow wheels to rotate freely and increase

throttle opening to achieve an indicated speed of 40
mph.

(4) Underdrive clutch pressure should read below

5 psi. If not, then either the solenoid assembly or
PCM/TCM is at fault.

TEST THREE-OVERDRIVE CLUTCH CHECK (3rd and
2nd Gear)

(1) Attach gauge to the overdrive clutch tap.
(2) Move selector lever to the (OD) position.
(3) Allow vehicle wheels to turn and increase

throttle opening to achieve an indicated vehicle speed
of 20 mph. Vehicle should be in 3rd gear.

(4) Overdrive clutch pressure should read 74 to 95

psi.

(5) Move selector lever to the (3) position and

increase indicated vehicle speed to 30 mph.

(6) The vehicle should be in second gear and over-

drive clutch pressure should be less than 5 psi.

(7) This test checks the overdrive clutch hydraulic

circuit as well as the shift schedule.

TEST FOUR-SELECTOR IN OVERDRIVE (4th Gear)

(1) Attach gauge to the 2/4 clutch tap.
(2) Move selector lever to the (OD) position.
(3) Allow vehicle front wheels to turn and increase

throttle opening to achieve an indicated vehicle speed
of 30 mph. Vehicle should be in 4th gear.

(4) The 2/4 clutch pressure should read 75 to 95

psi.

(5) This test checks the 2/4 clutch hydraulic cir-

cuit.

TEST FIVE-SELECTOR IN OVERDRIVE (4th Gear-CC
on)

(1) Attach gauge to the torque converter clutch off

pressure tap.

(2) Move selector lever to the (OD) position.
(3) Allow vehicle wheels to turn and increase

throttle opening to achieve an indicated vehicle speed
of 50 mph. Vehicle should be in 4th gear, CC on.

CAUTION: Both wheels must turn at the same
speed.

(4) Torque converter clutch off pressure should be

less than 5 psi.

(5) This test checks the torque converter clutch

hydraulic circuit.

TEST SIX-SELECTOR IN REVERSE

(1) Attach gauges to the reverse and LR clutch

tap.

Fig. 4 Pressure Taps

1 - OVERDRIVE CLUTCH
2 - TORQUE CONVERTER OFF
3 - LOW/REVERSE CLUTCH
4 - 2/4 CLUTCH
5 - REVERSE CLUTCH
6 - UNDERDRIVE CLUTCH

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40TE AUTOMATIC TRANSAXLE

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40TE AUTOMATIC TRANSAXLE (Continued)

(2) Move selector lever to the (R) position.
(3) Read reverse clutch pressure with output sta-

tionary (foot on brake) and throttle opened to achieve
1500 rpm.

(4) Reverse and LR clutch pressure should read

165 to 235 psi.

(5) This test checks the reverse clutch hydraulic

circuit.

TEST RESULT INDICATIONS

(1) If proper line pressure is found in any one test,

the pump and pressure regulator are working prop-
erly.

(2) Low pressure in all positions indicates a defec-

tive pump, a clogged filter, or a stuck pressure regu-
lator valve.

(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 indi-
cated.

(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

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40TE AUTOMATIC TRANSAXLE

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40TE AUTOMATIC TRANSAXLE (Continued)

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