Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual — part 572
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.
(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.
JR
40TE AUTOMATIC TRANSAXLE
21 - 49
40TE AUTOMATIC TRANSAXLE (Continued)
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
*
REVERSE
0-2
0-7
165-235
50-100
0-2
165-235
0 mph
NEUTRAL
*
NEUTRAL
0-2
0-5
0-2
60-110
0-2
115-145
0 mph
L
#
FIRST
110-145
0-5
0-2
60-110
0-2
115-145
20 mph
3
#
SECOND
110-145
0-5
0-2
60-110
115-145
0-2
30 mph
3
#
DIRECT
75-95
75-95
0-2
60-90
0-2
0-2
45 mph
OD
#
OVERDRIVE
0-2
75-95
0-2
60-90
75-95
0-2
30 mph
OD
#
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.
Fig. 5 Air Pressure Test Plate
1 - TOOL 6056
2 - ACCUMULATORS
21 - 50
40TE AUTOMATIC TRANSAXLE
JR
40TE AUTOMATIC TRANSAXLE (Continued)
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.
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. 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
JR
40TE AUTOMATIC TRANSAXLE
21 - 51
40TE 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 cable.
(2) Remove air cleaner assembly.
(3) Remove dipstick tube. Plug hole to prevent
debris from entering transaxle.
(4) Using Tool 8875A, disconnect the transmission
cooler line quick-connect fittings. (Refer to 7 - COOL-
ING/TRANSMISSION - STANDARD PROCEDURE)
(5) Disconnect Solenoid/Pressure Switch Assy. con-
nector.
(6) Disconnect Transmission Range Sensor connec-
tor.
(7) Disconnect Input Speed Sensor connector.
(8) Disconnect Output Speed Sensor connector.
(9) Disconnect shift cable from manual valve lever
and bracket.
(10) Disconnect Crankshaft Position Sensor.
(11) Remove throttle body support bracket.
(12) Disconnect Oxygen Sensor harness retainer
from transaxle case.
(13) Remove rear mount bracket-to-transaxle case
bolts.
(14) Remove starter upper bracket-to-block bolt.
(15) Raise vehicle.
(16) Remove halfshafts. Refer to Differential and
Driveline.
(17) Remove rear mount bracket lower bolt.
(18) Remove rear mount thru-bolt.
(19) Remove rear mount-to-cross member bolts.
(20) Remove rear mount and bracket.
(21) Remove front mount thru-bolt.
(22) Remove front mount to radiator lower cross-
member bolts.
(23) Remove front mount bracket to block and
transaxle.
(24) Remove front mount bracket and mount.
(25) Remove starter lower bolt and starter motor
assembly.
(26) Remove converter dust shield.
(27) Remove torque converter bolts.
(28) Support engine/transaxle with screw jack and
wood block on engine oil pan.
(29) Remove left mount bracket-to-transaxle bolts.
(30) Carefully lower engine/transaxle assembly to
gain access to and remove transaxle-to-engine bolts.
(31) With aid of helper or transmission jack,
remove transaxle assembly from vehicle.
Fig. 8 Converter Leak Points - Typical
1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG
21 - 52
40TE AUTOMATIC TRANSAXLE
JR
40TE AUTOMATIC TRANSAXLE (Continued)
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