Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 73
High oil level can result in oil leakage out the vent in
the dipstick. If the fluid level is high, adjust to proper
level.
After performing this operation, inspect for leakage.
If a leak persists, perform the following operation on
the vehicle to determine if it is the torque converter or
transaxle that is leaking.
LEAKAGE TEST PROBE
(1) Remove torque converter housing dust shield.
(2) Clean the inside of torque converter housing
(lower area) as dry as possible. A solvent spray followed
by compressed air drying is preferable.
(3) Fabricate and fasten test probe (Fig. 5) securely
to convenient dust shield bolt hole. Make certain
torque converter is cleared by test probe. Tool must be
clean and dry.
(4) Run engine at approximately 2,500 rpm with
transaxle in neutral, for about 2 minutes. Transaxle
must be at operating temperature.
(5) Stop engine and carefully remove tool.
(6) If upper surface of test probe is dry, there is no
torque converter leak. A path of fluid across probe
indicates a torque converter leak. Oil leaking under the
probe is coming from the transaxle pump area.
(7) Remove transaxle and torque converter assembly
from vehicle for further investigation.The fluid should
be drained from the transaxle. Reinstall oil pan (with
Mopar
t Silicone Rubber Adhesive Sealant or equiva-
lent) at specified torque.
Possible sources of transaxle torque converter area
fluid leakage are:
(1) Torque converter hub seal.
• Seal lip cut, check torque converter hub finish.
• Bushing moved and/or worn.
• Oil return hole in pump housing plugged or omitted.
• Seal worn out (high-mileage vehicles).
Fig. 4 Air Pressure Tests
Fig. 5 Leak Locating Test Probe Tool
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TRANSAXLE
21 - 41
(2) Fluid leakage at the outside diameter from pump
housing O-ring.
(3) Fluid leakage at the pump to case bolts. Check
condition of washers on bolts and use new bolts if
necessary.
(4) Fluid leakage due to case or pump housing po-
rosity.
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
• Torque converter weld leaks at the outside diameter
(peripheral) weld.
• Torque converter hub weld.
• Torque converter impeller shell cracked adjacent to
hub.
• At drive lug welds.
Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter.
AIR PRESSURE TEST OF TRANSAXLE
Fabricate equipment needed for test as shown in
figures 6 and 7.
The transaxle should be prepared for pressure test as
follows after removal of the torque converter:
(1) Install a dipstick bore plug and plug oil cooler
line fitting (lower fitting).
(2) With rotary motion, install converter hub seal
cup over input shaft, and through the converter hub
seal until the cup bottoms against the pump gear lugs.
Before use, inspect hub seal cup (Fig. 6) for nicks or
burrs that could damage seal. Secure with cup retainer
strap (Fig. 7) using starter upper hole and opposite
bracket hole.
(3) Attach and clamp hose from nozzle of Tool C-4080
to the upper cooler line fitting position in case.
CAUTION: Do not, under any circumstances, pressur-
ize a transaxle to more than 10 psi.
(4) Pressurize the transaxle using Tool C-4080 until
the pressure gauge reads 8 psi. Position transaxle so
that pump housing and case front may be covered with
soapy solution or water. Leaks are sometimes caused
by porosity in the case or pump housing.
If a leak source is located, that part and all associ-
ated seals, O-rings, and gaskets should be replaced
with new parts.
Fig. 6 Torque Converter Hub Seal Cup
Fig. 7 Hub Seal Cup Retaining Strap
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TRANSAXLE
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GEARSHIFT LINKAGE ADJUSTMENT
Normal operation of the neutral safety switch pro-
vides a quick check to confirm proper manual linkage
adjustment.
Move the selector level slowly upward until it clicks
into the ‘‘P’’ Park notch in the selector gate. If the
starter will operate, the ‘‘P’’ position is correct.
After checking ‘‘P’’ position, move the selector slowly
toward ‘‘N’’ Neutral position until lever drops at the
end of the ‘‘N’’ stop. If the starter will also operate at
this point the gearshift linkage is properly adjusted. If
the starter fails to operate in either position, linkage
adjustment is required.
CAUTION: When it is necessary to disassemble link-
age cable from levers, which use plastic grommets as
retainers, the grommets should be replaced with new
grommets. Use a prying tool to force rod from grom-
met in lever, then cut away old grommet. Use pliers to
snap new grommet into lever and rod into grommet.
(1) Set parking brake.
(2) Place gearshift lever in ‘‘P’’ (PARK) position.
(3) Loosen clamp bolt on gearshift cable bracket.
(4) Column shift: Insure that preload adjustment
spring engages fork on transaxle bracket.
(5) Pull the shift lever by hand all the way to the
front detent position (PARK) and tighten lock. Tighten
screw to 11 N
Im (100 in. lbs.). Gearshift linkage should
now be properly adjusted.
(6) Check adjustment as follows:
(a) Detent position for neutral and drive should be
within limits of hand lever gate stops.
(b) Key start must occur only when shift lever is in
park or neutral positions.
(7) If console removal is required, disconnect battery
ground cable. To remove button assembly, insert a 1/16
inch diameter wire in hole in bottom of knob and push
up on wire. To remove knob retainer clip, insert long-
nose plier tips in clip holes, push downward lightly and
turn counterclockwise (action similar to a light bulb
socket). Pull knob straight up to remove from gearshift
lever. Proceed as outlined in console removal,‘‘Group
23’’.
After console is back in place, install shift knob and
button by reversing the above procedure.
(8) To remove button assembly, completely remove
knob attaching fasteners. Pull knob ‘‘up’’ sharply. Pro-
ceed as outlined in console removal, ‘‘Group 23.’’
After console is back in place, install knob and button
by reversing the above procedure.
THROTTLE PRESSURE LINKAGE ADJUSTMENT
The throttle pressure cable adjustment is very im-
portant to proper transaxle operation. This adjustment
positions a valve which controls shift speed, shift
quality, and part throttle downshift sensitivity. If the
setting is too long, early shifts and slippage between
shifts may occur. If the setting is too short, shifts may
be delayed and part throttle downshifts may be very
sensitive.
With engine at operating temperature, adjust idle
speed of engine using a tachometer. Refer to ‘‘Fuel
System’’ Group 14 for idle speed Specifications and
adjustment.
CABLE ADJUSTMENT PROCEDURE (4-CYL.)
(1) Perform transaxle throttle pressure cable adjust-
ment while engine is at normal operating temperature.
(2) Loosen cable mounting bracket lock screw.
(3) Bracket should be positioned with both bracket
alignment tabs touching the transaxle cast surface.
Tighten lock screw to 12 N
Im (105in. lbs.) see Figure 8.
(4) Release cross-lock on the cable assembly (pull
cross-lock upward) see Figure 8.
(5) To insure proper adjustment, the cable must be
free to slide all the way toward the engine, against its
stop, after the cross-lock is released.
(6) Move transaxle throttle control lever fully clock-
wise, against its internal stop, and press cross-lock
downward into locked position.
(7) The adjustment is complete and transaxle
throttle cable backlash was automatically removed.
(8) Test cable freedom of operation by moving the
transaxle throttle lever forward (counterclockwise) and
slowly release it to confirm it will return fully rearward
(clockwise).
(9) No lubrication is required for any component of
the throttle cable system.
ROD ADJUSTMENT PROCEDURE (6-CYL.)
(1) Perform transaxle throttle pressure cable adjust-
ment while engine is at normal operating temperature.
(2) Loosen adjustment swivel lock screw.
(3) To insure proper adjustment, swivel must be free
to slide along flat end of throttle rod so that pre-
Fig. 8 Throttle Pressure Cable (Typical)
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TRANSAXLE
21 - 43
load spring action is not restricted. Disassemble and
clean or repair parts to assure free action, if necessary.
(4) Hold transaxle throttle lever firmly toward en-
gine, against its internal stop and tighten swivel lock
screw to 11 N
Im (100 in. lbs.)
(5) The adjustment is finished and linkage back lash
was automatically removed by the preload spring.
(6) If lubrication is required see Lubrication, Group
0.
BAND ADJUSTMENT
KICKDOWN BAND (FRONT)
The kickdown band adjusting screw is located on left
side (top front) of the transaxle case.
(1) Loosen locknut and back off nut approximately
five turns. Test adjusting screw for free turning in the
transaxle case.
(2) Using wrench, Tool C-3880-A with adapter Tool
C-3705, tighten band adjusting screw to 5 N
Im (47 to
50 in. lbs.). If adapter C-3705 is not used, tighten
adjusting screw to 8 N
Im (72 in. lbs.) which is the true
torque.
(3) Back off adjusting screw the number of turns
listed in ‘‘Specifications’’. Hold adjusting screw in this
position and tighten locknut to 47 N
Im (35ft. lbs.)
LOW/REVERSE BAND (REAR)
To adjust low-reverse band, proceed as follows:
(1) Loosen and back off locknut approximately 5
turns.
(2) Using an inch-pound torque wrench, tighten ad-
justing screw to 5 N
Im (41 in. lbs.) true torque.
(3) Back off adjusting screw the number of turns
listed under ‘‘Specifications’’ in the rear of the Tran-
saxle Section in this service manual.
(4) Tighten locknut to 14 N
Im (10 ft. lbs.).
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
LINE PRESSURE
An incorrect throttle pressure setting will cause
incorrect line pressure readings even though line pres-
sure adjustment is correct. Always inspect and correct
throttle pressure adjustment before adjusting the line
pressure.
The approximate adjustment for line pressure is
1-5/16 inches, measured from valve body to inner edge
of adjusting nut. However, due to manufacturing toler-
ances, the adjustment can be varied to obtain specified
line pressure.
The adjusting screw may be turned with an Allen
wrench. One complete turn of adjusting screw changes
closed throttle line pressure approximately 1-2/3 psi.
Turning adjusting screw counterclockwise increases
pressure, and clockwise decreases pressure.
THROTTLE PRESSURE
Throttle pressures cannot be tested accurately;
therefore, the adjustment should be measured if a
malfunction is evident.
(1) Insert gauge pin of Tool C-3763 between the
throttle lever cam and kickdown valve.
(2) By pushing in on tool, compress kickdown valve
against its spring so throttle valve is completely bot-
tomed inside the valve body.
(3) While compressing spring, turn throttle lever
stop screw with adapter C-4553. Turn until head of
screw touches throttle lever tang, with throttle lever
cam touching tool and throttle valve bottomed. Be sure
adjustment is made with spring fully compressed and
valve bottomed in the valve body.
DISTANCE SENSOR PINION GEAR
When the distance sensor is removed for any reason,
a NEW O-ring must be installed on its outside diam-
eter.
REMOVAL AND INSTALLATION
(1) Remove speedometer cable (if so equipped).
(2) Remove harness connector from sensor. Make
sure weatherseal stays on harness connector.
(3) Remove bolt securing the distance sensor in the
extension housing.
(4) Carefully pull sensor and pinion gear assembly
out of extension housing.
(5) Remove pinion gear from sensor.
(6) To install, reverse the above procedure. Make
sure extension housing and sensor flange are clean
prior to installation. Always use a NEW sensor O-ring.
(7) Tighten securing bolt to 7 N
Im (60 in. lbs.).
Tighten speedometer cable to 4 N
Im (35 in. lbs.).
NEUTRAL STARTING AND BACK-UP LAMP SWITCH
REPLACEMENT AND TEST
The neutral starting switch is the center terminal of
the 3 terminal switch. It provides ground for the
starter solenoid circuit through the selector lever in
only Park and Neutral positions.
(1) To test switch, remove wiring connector from
switch and test for continuity between center pin of
switch and transaxle case. Continuity should exist only
when transaxle is in Park or Neutral.
(2) Check gearshift cable adjustment before replac-
ing a switch which tests bad.
(3) Unscrew switch from transaxle case allowing
fluid to drain into a container. Move selector lever to
Park and then to Neutral positions, and inspect to see
that the switch operating lever fingers are centered in
switch opening in the case.
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TRANSAXLE
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