Chrysler Town, Dodge Caravan. Manual — part 85
SHIFT SCHEDULES
As mentioned earlier, the TCM has programming
that allows it to select a variety of shift schedules.
Shift schedule selection is dependent on the follow-
ing:
• Shift lever position
• Throttle position
• Engine load
• Fluid temperature
• Software level
As driving conditions change, the TCM appropri-
ately adjusts the shift schedule. Refer to the follow-
ing chart to determine the appropriate operation
expected, depending on driving conditions.
Schedule
Condition
Expected Operation
Extreme Cold
Oil temperature at start-up below
-16° F
Park, Reverse, Neutral and 2nd
gear only (prevents shifting which
may fail a clutch with frequent
shifts)
Cold
Oil temperature at start-up above
-12° F and below 36° F
– Delayed 2-3 upshift
(approximately 22-31 mph)
– Delayed 3-4 upshift (45-53 mph)
– Early 4-3 costdown shift
(approximately 30 mph)
– Early 3-2 coastdown shift
(approximately 17 mph)
– High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
– No EMCC
Warm
Oil temperature at start-up above
36° F and below 80 degree F
– Normal operation (upshift,
kickdowns, and coastdowns)
– No EMCC
Hot
Oil temperature at start-up above
80° F
– Normal operation (upshift,
kickdowns, and coastdowns)
– Full EMCC, no PEMCC except to
engage FEMCC (except at closed
throttle at speeds above 70-83 mph)
Overheat
Oil temperature above 240° F or
engine coolant temperature above
244° F
– Delayed 2-3 upshift (25-32 mph)
– Delayed 3-4 upshift (41-48 mph)
– 3rd gear FEMCC from 30-48 mph
– 3rd gear PEMCC from 27-31 mph
Super Overheat
Oil temperature above 260° F
– All
9
Overheat
9
shift schedule
features apply
– 2nd gear PEMCC above 22 mph
– Above 22 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
8E - 22
ELECTRONIC CONTROL MODULES
RS
TRANSMISSION CONTROL MODULE (Continued)
STANDARD PROCEDURE
STANDARD PROCEDURE - PINION FACTOR
SETTING
NOTE: This procedure must be performed if the
PCM/TCM
has
been
replaced
with
a
NEW
or
replacement unit. Failure to perform this procedure
will result in an inoperative or improperly calibrated
speedometer.
The vehicle speed readings for the speedometer are
taken from the output speed sensor. The PCM/TCM
must be calibrated to the different combinations of
equipment (final drive and tires) available. Pinion
Factor allows the technician to set the Powertrain/
Transmission Control Module initial setting so that
the speedometer readings will be correct. To properly
read and/or reset the Pinion Factor, it is necessary to
use a DRBIII
t scan tool.
(1) Plug the DRBIII
t scan tool into the diagnostic
connector located under the instrument panel.
(2) Select the Transmission menu.
(3) Select the Miscellaneous menu.
(4) Select Pinion Factor. Then follow the instruc-
tions on the DRBIII
t scan tool screen.
STANDARD PROCEDURE - QUICK LEARN
PROCEDURE
The quick learn procedure requires the use of the
DRBIII
t scan tool. This program allows the PCM/
TCM to recalibrate itself. This will provide the best
possible transaxle operation.
NOTE: The quick learn procedure should be per-
formed if any of the following procedures are per-
formed:
• Transaxle Assembly Replacement
• Powertrain/Transmission
Control
Module
Replacement
• Solenoid/Pressure Switch Assembly Replacement
• Clutch Plate and/or Seal Replacement
• Valve Body Replacement or Recondition
To perform the Quick Learn Procedure, the follow-
ing conditions must be met:
• The brakes must be applied
• The engine speed must be above 500 rpm
• The throttle angle (TPS) must be less than 3
degrees
• The shift lever position must stay until
prompted to shift to overdrive
• The shift lever position must stay in overdrive
after the Shift to Overdrive prompt until the
DRBIII
t indicates the procedure is complete
• The calculated oil temperature must be above
60° and below 200°
(1) Plug the DRBIII
t scan tool into the diagnostic
connector. The connector is located under the instru-
ment panel.
(2) Go to the Transmission screen.
(3) Go to the Miscellaneous screen.
(4) Select Quick Learn Procedure. Follow the
instructions of the DRBIII
t to perform the Quick
Learn Procedure.
REMOVAL
NOTE: If transmission control module is being
replaced with a new or replacement unit, the Pinion
Factor and Quick Learn procedures must be per-
formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL
MODULES/TRANSMISSION
CONTROL
MODULE - STANDARD PROCEDURE) (Refer to 8 -
ELECTRICAL/ELECTRONIC
CONTROL
MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
(1) Disconnect battery negative cable.
(2) Raise vehicle on hoist.
(3) Remove left front tire/wheel assembly.
(4) Pull back splash shield to gain access to TCM
location.
(5) Disconnect TCM 60-way connector (Fig. 18).
(6) Remove
three
(3)
TCM-to-rail
screws
and
remove TCM from vehicle (Fig. 19).
Fig. 18 Transmission Control Module 60-way
Connector
1 - TRANSMISSION CONTROL MODULE (TCM)
2 - 60-WAY CONNECTOR
RS
ELECTRONIC CONTROL MODULES
8E - 23
TRANSMISSION CONTROL MODULE (Continued)
INSTALLATION
NOTE: If transmission control module is being
replaced with a new or replacement unit, the Pinion
Factor and Quick Learn procedures must be per-
formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL
MODULES/TRANSMISSION
CONTROL
MODULE - STANDARD PROCEDURE) (Refer to 8 -
ELECTRICAL/ELECTRONIC
CONTROL
MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
(1) Install TCM into position (Fig. 20). Install
three (3) screws and torque to 3 N·m (30 in. lbs.).
(2) Install TCM harness 60–way connector (Fig.
21) and torque to 4 N·m (35 in. lbs.).
(3) Install splash shield into position with fasten-
ers.
(4) Install left front wheel/tire assembly.
(5) Lower vehicle.
(6) Connect battery negative cable.
(7) If TCM was replaced, reset Pinion Factor and
Quick Learn. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC
CONTROL
MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL
MODULES/TRANSMISSION
CONTROL
MODULE - STANDARD PROCEDURE).
Fig. 19 Transmission Control Module Removal/
Installation
1 - SCREW
2 - TRANSMISSION CONTROL MODULE (TCM)
3 - CLIP
4 - LEFT RAIL
Fig. 20 Transmission Control Module Removal/
Installation
1 - SCREW
2 - TRANSMISSION CONTROL MODULE (TCM)
3 - CLIP
4 - LEFT RAIL
Fig. 21 Transmission Control Module 60-way
Connector
1 - TRANSMISSION CONTROL MODULE (TCM)
2 - 60-WAY CONNECTOR
8E - 24
ELECTRONIC CONTROL MODULES
RS
TRANSMISSION CONTROL MODULE (Continued)
ENGINE SYSTEMS
TABLE OF CONTENTS
page
page
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
BATTERY SYSTEM
TABLE OF CONTENTS
page
page
BATTERY SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - BATTERY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . 6
BATTERY
. . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - BATTERY
STANDARD PROCEDURE - SPIRAL PLATE
BATTERY CHARGING . . . . . . . . . . . . . . . . . . 10
CONVENTIONAL BATTERY CHARGING . . . . . 11
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 13
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . 13
BATTERY ELECTROLYTE LEVEL . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . 15
BATTERY HOLDDOWN
. . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . 16
BATTERY CABLES
. . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - BATTERY CABLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . 18
BATTERY TRAY
. . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . 19
THERMOWRAP
. . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . 19
BATTERY SYSTEM
DESCRIPTION
A single 12-volt battery is standard factory-in-
stalled equipment on this model. All of the compo-
nents of the battery system are located within the
engine compartment of the vehicle. The battery sys-
tem for this vehicle covers the following related com-
ponents, which are covered in further detail later in
this section of the service manual:
• Battery - The storage battery provides a reli-
able means of storing a renewable source of electrical
energy within the vehicle.
• Battery Cable - The battery cables connect the
battery terminal posts to the vehicle electrical sys-
tem.
RS
ENGINE SYSTEMS
8F - 1
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