Chrysler Voyager. Manual — part 443

TABLE OF CONTENTS - Continued

TRANSMISSION CONTROL MODULE (3.3L/3.8L). . . . . . . . . . . . . . . . . . . . . . . . . . . .333
TRANSMISSION RANGE SENSOR (EATX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334

10.0

SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .335

10.1 EATX–3.3/3.8L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .335
10.2 NGC–2.4L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .336

11.0

CHARTS AND GRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337

11.1 TRANSMISSION RANGE SENSOR STATES . . . . . . . . . . . . . . . . . . . . . . . . . . .337
11.2

PRESSURE SWITCH STATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

11.3 SOLENOID APPLICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338
11.4 SHIFT LEVER ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338
11.5 TRANSMISSION TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . .338

v

NOTES

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1.0

INTRODUCTION

IMPORTANT

The 2003 RS model year vehicles, will use both

the standard EATX controlled transmission with
3.3/3.8L engines and the new NGC controlled trans-
mission with 2.4L engine.

NGC CONTROLLER

New for 2003 model year, RS vehicles will inte-

grate the Transmission Control Module and Power-
train Control Module into a single control module.
This new module is the Next Generation Controller
for DaimlerChrysler and will be referred to as the
Powertrain Control Module (PCM).

Some of the changes you will see are several new

Diagnostics Trouble Codes and supporting diagnos-
tic procedures which reflect the new combined mod-
ule technology. The PCM will have four color coded
connectors, C1 through C4, (C1-BLK, C2-GRAY,
C3-WHITE, C4-GREEN), each PCM connector will
have 38 pins. Two new tools are used for probing
and repairing the new PCM connectors. Miller tool
#3638, and Miller tool #8815. Miller tool #3638 is
designed to release the pins from the PCM harness
connectors. You must use the Miller tool #3638 to
release the harness connector terminals or harness
connector or terminal damage will occur. Miller tool
#8815 was designed for probing the PCM harness
connectors. You must use Miller tool #8815 for
probing the PCM terminals or damage to the ter-
minal will occur resulting in a poor terminal to pin
connection. There are also new Verification tests
and module replacement procedures for the new
PCM.

The procedures contained in this manual include

all of the specifications, manuals, and graphics
needed to diagnose,
*41TE (EATX) Electronic Automatic Transmission
problems
*41TE (NGC) Electronic Automatic Transmission
problems

The diagnostics in this manual are based on the

failure condition or symptom 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

The diagnostic procedure manual covers all 2003

RS vehicles equipped with a 41TE transaxle.

1.2

SIX -STEP TROUBLESHOOTING
PROCEDURE

Diagnosis of the 41TE 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

The 41TE Transmission family can be identified

through a visual inspection. Confirm the presense
of a Solenoid/Pressure Switch Assembly, Transmis-
sion Range Sensor, Input Speed Sensor and Output
Speed Sensor all located on the same side of the
transmission case. Refer to the Service Information
for transmission ID tag descriptions.

3.0

SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION

3.1

GENERAL DESCRIPTION

The 41TE electronic transaxle is a conventional

transaxle in that it uses hydraulically applied
clutches to shift a planetary gear train. However,
the electronic control system replaces many of the
mechanical and hydraulic components used in con-
ventional transmission valve bodies.

3.2

FUNCTIONAL OPERATION

The 41TE electronic transaxle has a fully adap-

tive control system. The system performs its func-
tions based on continuous real-time sensor feedback
information. The control system automatically
adapts to changes in engine performance and fric-
tion element variations to provide consistent shift
quality. The control system ensures that clutch
operation during upshifting and downshifting is
more responsive without increased harshness.

1

GENERAL INFORMATION

The control module continuously checks for elec-

trical problems, mechanical problems, and some
hydraulic problems. When a problem is sensed, the
control module stores a diagnostic trouble code.
Some of these codes cause the transaxle to go into
Limp-in or?default mode. While in this mode, elec-
trical power is removed from the transaxle, de-
energizing the transmission control relay, and sole-
noid pack. When this happens, 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 DRBIII

t is in the Transmission portion

of the diagnostic program, it constantly monitors
the control module to see if the system is in Limp-in
mode. If the transaxle is in Limp-in mode, the
DRBIII

t will flash the red LED.

3.2.1

AUTOSTICK FEATURE (IF
EQUIPPED)

This feature allows the driver to manually shift

the transaxle when the shift lever is moved to the
AutoStick position. When in AutoStick mode, the
instrument cluster displays the current gear.

3.2.2

TRANSMISSION OPERATION AND
SHIFT SCHEDULING AT VARIOUS
OIL TEMPERATURES.

The transmission covered in this manual has

unique shift schedules depending on the tempera-
ture of the transmission oil. The shift schedule is
modified to extend the life of the transmission while
operating under extreme conditions.

The oil temperature is measured with a Temper-

ature Sensor on the 41TE transmission. The Tem-
perature Sensor is an integral component of the
Transmission Range Sensor (TRS). If the Tempera-
ture Sensor is faulty, the transmission will default
to a calculated oil temperature. Oil temperature
will then be calculated through a complex heat
transfer equation using engine coolant tempera-
ture, battery/ambient temperature, and engine off
time. These inputs are received from the PCI bus
periodically and used to initialize the oil tempera-
ture at start up. Once the engine is started, the
control module updates the transmission oil tem-
perature based on torque converter slip speed, ve-
hicle speed, gear, and engine coolant temperature to
determine an estimated oil temperature during
vehicle operation. Vehicles using calculated oil tem-

perature, are reasonably accurate, during normal
operation. However, if a transmission is overfilled, a
transmission oil cooler becomes restricted, or if a
customer drives aggressively in low gear, the calcu-
lated oil temperature will be inaccurate. Conse-
quently the shift schedule selected may be inappro-
priate for the current conditions.

3.3

DIAGNOSTIC TROUBLE CODES

Diagnostic trouble codes (DTC’s) are codes stored

by the PCM (NGC) or TCM (EATX) depending on
application and help diagnose Transmission prob-
lems. They are viewed using the DRBIII

t scan tool.

Always begin by performing a visual inspection of

the wiring, connectors, cooler lines and the trans-
mission. Any obvious wiring problems or leaks
should be repaired prior to performing any diagnos-
tic test procedures. Some engine driveability prob-
lems can be misinterpreted as a transmission prob-
lem. Ensure that the engine is running properly
and no engine DTC’s are present that could cause a
transmission complaint.

If there is a bus communication problem, trouble

codes will not be accessible until the bus problem is
fixed. The DRBIII

t will display an appropriate

message.

Each diagnostic trouble code is diagnosed by

following a specific testing sequence. The diagnostic
test procedures contain step-by-step manuals
for determining the cause of a transmission diag-
nostic trouble code. Possible sources of the code are
checked and eliminated one by one. It is not neces-
sary to perform all of the tests in this book to
diagnose an individual code. These tests are based
on the problem being present at the time that the
test is run.

All testing should be done with a fully charged
battery.

If the control module records a DTC that will

adversely affect vehicle emissions, it will request
(via the communication bus) that the PCM illumi-
nate the Malfunction Indicator Lamp (MIL). Al-
though these DTC’s will be stored immediately as a
1 trip failure, it may take up to five minutes of
accumulated trouble confirmation set the DTC and
illuminate the MIL. Three consecutive successful
OBDII (EURO STAGE III OBD) trips or clearing
the DTC’s with a diagnostic tool (DRBIII

t or equiv-

alent) is required to extinguish the MIL. When the
Transmission Control system requests that the
PCM illuminate the MIL, the PCM sets a DTC
P0700 ($89) to alert the technician that there are
DTC’s in the Transmission Control System. You
must also erase the DTC P0700 in the PCM, in
order to extinguish the MIL.

2

GENERAL INFORMATION