1993 CHEVROLET DYNASTY Service Manual

headrest clock reset adding oil octane oil viscosity fuses

Page 2057 of 2438

CHEVROLET DYNASTY 1993 Service Manual first separator plate and watch carefully for the pis-
ton to move forward. The piston should return to its
original position after the air pressure is removed.
UNDERDRIVE CLUTCH
Because this clutch

first separator plate and watch carefully for the pis-
ton to move forward. The piston should return to its
original 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 ro-
tate with hand torque. Release the air pressure and
confirm that the input shaft will rotate.
FLUID LEAKAGE-TORQUE CONVERTER HOUSING
AREA
(1) Check for source of leakage.
Since fluid leakage at or around the torque con-
verter area may originate from an engine oil leak,
the area should be examined closely. Factory fill
fluid is dyed red and, therefore, can be distinguished
from engine oil. (2) Prior to removing the transaxle, perform the
following checks: When leakage is determined to originate from the
transaxle, check fluid level prior to removal of the
transaxle and torque converter. High oil level can result in oil leakage out the vent
in the manual shaft. If the fluid level is high, adjust
to proper level. After performing this operation, inspect for leak-
age. If a leak persists, perform the following opera-
tion 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 fol-
lowed by compressed air drying is preferable. (3) Fabricate and fasten test probe (Fig. 4) 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 torque converter
area. (7) Remove transaxle and torque converter assembly
from vehicle for further investigation. The fluid should
be drained from the transaxle. Re install oil pan (with
MOPAR tAdhesive Sealant) at specified torque.
Possible sources of transaxle torque converter area
fluid leakage are: (1) Torque converter hub seal.
² Seal lip cut, check torque converter hub finish.
² Bushing moved and/or worn.
² Oil return hole in pump housing plugged or omitted.
² Seal worn out (high-mileage vehicles).
(2) Fluid leakage at the outside diameter from pump
housing O-ring. (3) Fluid leakage at the front pump to case bolts.
Check condition of washers on bolts and use new bolts,
if necessary. (4) Fluid leakage due to case or front pump housing
porosity.
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
² Torque converter weld leaks at the out side (periph-
eral) weld.
² Torque converter hub weld.
Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter. If the torque converter must be replaced, refer
to Torque Converter Clutch Break-in Procedure
in this section. This procedure will reset the
transmission control module break-in status.
Failure to perform this procedure may cause
transaxle shutter.
AIR PRESSURE TEST OF TRANSAXLE
Fabricate equipment needed for test as shown in
Figures 5 and 6. The transaxle should be prepared for pressure test as
follows after removal of the torque converter: (1) Plug dipstick tube and plug oil cooler line fitting.
Remove vent from manual shaft and in stall a 1/8 inch
pipe plug.Fig. 4 Leak Locating Test Probe Tool
Ä TRANSAXLE 21 - 97

Page 2058 of 2438

CHEVROLET DYNASTY 1993 Service Manual CAUTION: Prevent manual shaft rotation during in-
stallation and removal. (2) With rotary motion, install converter hub seal
cup over input shaft. It must go through the con-
verter hub seal until t

CAUTION: Prevent manual shaft rotation during in-
stallation and removal. (2) With rotary motion, install converter hub seal
cup over input shaft. It must go through the con-
verter hub seal until the cup bottoms against the
pump gear lugs. Secure with cup retainer strap 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, pres-
surize a transaxle to more than 10 psi.
(4) Pressurize the transaxle using Tool C-4080 un-
til the pressure gauge reads 8 psi. Position transaxle
so that pump housing and case front may be covered
with soapy solution of 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.
GEARSHIFT LINKAGE ADJUSTMENT
Normal operation of the transmission range switch
(PRNDL) and park/neutral position switch provides a
quick check to confirm proper manual linkage adjust-
ment. 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 selector toward
``N'' Neutral position until lever drops in the ``N''
stop. If the starter will also operate at this point the
gearshift linkage is properly adjusted.
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
grommet 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 to the front detent
position (PARK) and tighten lock screw to 11 N Im
(100 in. lbs.). Gearshift linkage should now be prop-
erly 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.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum tran-
saxle case and valve body can be repaired by the use
of Heli-Coils, or equivalent. This repair consists of
drilling out the worn-out damaged threads. Then tap
the hole with a special Heli-Coil tap, or equivalent,
and installing a Heli-Coil insert, or equivalent, into
the hole. This brings the hole back to its original
thread size. Heli-Coil, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
COOLERS AND TUBES REVERSE FLUSHING
When a transaxle failure has contaminated the
fluid, the oil cooler(s) must be flushed and the cooler
bypass valve in the transaxle must be replaced. The
torque converter must also be replaced with an ex-
change unit. This will insure that metal particles or
sludged oil are not later transferred back into the re-
conditioned (or replaced) transaxle.
Fig. 5 Torque Converter Hub Seal Cup
Fig. 6 Hub Seal Cup Retaining Strap
21 - 98 TRANSAXLE Ä

Page 2059 of 2438

CHEVROLET DYNASTY 1993 Service Manual CAUTION: If the vehicle is equipped with two oil
coolers (one in the radiator tank, one in front of the
radiator) they must be flushed separately. Do not
attempt to flush both coolers at one time. (1

CAUTION: If the vehicle is equipped with two oil
coolers (one in the radiator tank, one in front of the
radiator) they must be flushed separately. Do not
attempt to flush both coolers at one time. (1) Disconnect the cooler lines at the transmission.
(2) Using a hand suction gun filled with mineral
spirits, reverse flush the cooler. Force mineral spirits
into the From Cooler line of the cooler (Fig. 7) and
catch the exiting spirits from the To Coolerline.
Observe for the presence of debris in the exiting
fluid. Continue until fluid exiting is clear and free
from debris.
(3) Using compressed air in intermittent spurts,
blow any remaining mineral spirits from the cooler,
again in the reverse direction. (4) To remove any remaining mineral spirits from
the cooler, one (1) quart of automatic transmission
fluid should be pumped through the cooler before re-
connecting. (5) If at any stage of the cleaning process, the
cooler does not freely pass fluid, the cooler must be
replaced.
OIL COOLER FLOW CHECK
After the new or repaired transmission has been
installed, filled to the proper level with automatic
transmission fluid. The flow should be checked using
the following procedure: (1) Disconnect the From coolerline at the trans-
mission and place a collecting container under the
disconnected line. (2) Run the engine at curb idle speed , with the
shift selector in neutral. (3) If the fluid flow is intermittent or it takes more
than 20 seconds to collect one quart of automatic
transmission fluid, the cooler should be replaced. CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(4) If flow is found to be within acceptable limits,
reconnect the cooler line. Then fill transmission to
the proper level, using the approved type of auto-
matic transmission fluid.
TRANSAXLE REMOVAL AND INSTALLATION
Transaxle removal does NOT require engine re-
moval. See Group 7-Cooling, to drain engine cooling sys-
tem and remove coolant return extension (3.0 liter
engine only). (1) The transaxle and torque converter must be re-
moved as an assembly; otherwise, the torque con-
verter drive plate, pump bushing or oil seal may be
damaged. The drive plate will not support a load;
therefore, none of the weight of the transaxle should
be allowed to rest on the drive plate during removal. (2) Disconnect negative battery cable.
(3) Disconnect transaxle shift linkage.
(4) Install engine support fixture and support en-
gine (Fig.1).
(5) Remove upper bell housing upper bolts.
(6) Raise vehicle. Remove front wheels. Refer to
Suspension, Group 2 to remove wheel hub nut and
both drive shafts. (7) Remove left plastic splash to gain access to the
transaxle (Fig. 2). (8) Remove torque converter dust shield to gain ac-
cess to torque converter bolts (Fig. 3). (9) Mark torque converter and drive plate with
chalk, for reassembly. Remove torque converter
mounting bolts. (10) Disconnect electrical connectors at transmis-
sion range switch and Park/Neutral Position Switch
(Fig. 4).
Fig. 7 Cooler Line Location
Fig. 1 Engine Support Fixture (Typical)
Ä TRANSAXLE 21 - 99

Page 2060 of 2438

CHEVROLET DYNASTY 1993 Service Manual (11) Remove front engine mount insulator and
bracket (Fig. 5). (12) On vehicles equipped with D.I.S. ignition sys-
tem, remove crankshaft position sensor from bell
housing. For installation procedu

Page 2061 of 2438

CHEVROLET DYNASTY 1993 Service Manual If the torque converter has been replaced, refer
to Torque Converter Clutch Break-in Procedure
in this section. This procedure will reset the transmission control module break-in status.
Failure to

Page 2062 of 2438

CHEVROLET DYNASTY 1993 Service Manual TRANSMISSION RANGE SWITCH
The transmission range switch is the white switch
located on the front of the transaxle, just above the
transaxle oil pan. CAUTION: Switch seal washer must be seated prop-

Page 2063 of 2438

CHEVROLET DYNASTY 1993 Service Manual SPEED SENSOR-OUTPUT
CAUTION: When disconnecting speed sensor con-
nector, be sure that the weather seal does not fall
off or remain in old sensor. The output speed sensor is located to the left of th

SPEED SENSOR-OUTPUT
CAUTION: When disconnecting speed sensor con-
nector, be sure that the weather seal does not fall
off or remain in old sensor. The output speed sensor is located to the left of the
manual shift lever (Fig. 8).
TRANSMISSION CONTROL MODULE
When replacing a transmission control module, do
not interchange transmission control modules with
previous year transmission control modules. If a
same year transmission control module is being used
from a different vehicle, the following procedures
must be performed before operating the transaxle:
² Quick Learn Procedure
² Torque Converter Clutch Break-in Procedure
² Electronic Pinion Procedure
The transmission control module is located on the
passenger side of the engine compartment. It is held
in place by four mounting screws. If the transmission control module has been
replaced, the following procedures must be per-
formed:
² ``Quick Learn Procedure''. This procedure will al-
low the transmission control module to learn the
characteristics of the vehicle.
² ``Electronic Pinion Procedure''. This procedure will
reprogram settings within the transmission control
module to compensate for different tire sizes and fi-
nal drive ratios.
² ``Converter Clutch Break-In Procedure'' This proce-
dure will reset the torque converter clutch status.
REMOVAL AND INSTALLATION
(1) Loosen 60 way retaining screw, located in the
center of the 60 way connector. Then disconnect the
60 way connector on transmission control module. (2) Remove transmission control module mounting
screws and lift module from vehicle. To install, reverse removal procedure.
TRANSAXLE QUICK LEARN PROCEDURE
The quick learn procedure requires the use of the
DRB II scan tool and the 1993 DRB II scan tool car-
tridge. This program allows the electronic transaxle sys-
tem to recelebrate itself to provide the best possible
transaxle operation. The quick learn procedure
should be performed if any of the following proce-
dures are performed:
² Transaxle Assembly Replacement
² Transmission Control Module Replacement
² Solenoid Pack Replacement
² Clutch Plate and/or Seal Replacement
² Valve Body Replacement or Recondition
(1) Plug the DRB II scan tool into the blue CCD
Buss connector. The connector is located under the
instrument panel on the drivers side of the vehicle. (2) Insert the 1993 DRB II scan tool cartridge into
the DRB II scan tool. (3) The red and green lights on the DRB II scan
tool will light up and then begin flashing. Wait until
the lights stop flashing before continuing with this
procedure. (4) Press the number 4 key on the DRB II scan
tool key pad. Item number 4 will not appear on the
DRB II scan tool screen unless you scroll down. It is
not necessary to scroll down to be able to choose item
4. (5) Press the number 2 on the DRB II scan tool
key pad (Transmission). (6) Press the number 1 on the DRB II scan tool
key pad. Wait for the DRB II scan tool to perform the
following three tests before continuing (These tests
are done automatically by the DRB II scan tool).
² Buss Test
² Initialize
² Controller Part Number
Fig. 7 Park/Neutral Position Switch
Fig. 8 Output Speed Sensor
Ä TRANSAXLE 21 - 103

Page 2064 of 2438

CHEVROLET DYNASTY 1993 Service Manual (7) Press the number 5 on the DRB II scan tool
key pad (Adjustments). (8) Press the number 3 on the DRB II scan tool
key pad (Quick Learn). Then follow the instructions
on the DRB II scan tool screen

(7) Press the number 5 on the DRB II scan tool
key pad (Adjustments). (8) Press the number 3 on the DRB II scan tool
key pad (Quick Learn). Then follow the instructions
on the DRB II scan tool screen.
PINION FACTOR PROCEDURE
The vehicle speed readings for the speedometer are
taken from the output speed sensor. Because of dif-
ferent tire sizes and final drive ratios, the transmis-
sion control module must be calibrated to reflect the
different combinations of equipment. A procedure has
been developed called Pinion Factor. It allows the
technician to set the transmission control module ini-
tial setting so that the speedometer readings will be
correct. Failure to perform this procedure will cause a ``No
Speedometer Operation'' condition. This procedure must be performed if the transmis-
sion control module has been replaced. To properly read or reset the Pinion Factor, it is
necessary to use a DRB II scan tool. Perform the fol-
lowing steps with the DRB II scan tool to read or re-
set the Pinion Factor: (1) Plug the DRB II scan tool into the blue CCD
Bus connector. The connector is located under the in-
strument panel on the drivers side of the vehicle. (2) Insert the 1993 DRB II scan tool cartridge into
the DRB II scan tool. (3) The red and green lights on the DRB II scan
tool will light up and then begin flashing. Wait until
the lights stop flashing before continuing with this
procedure. (4) Press the number 4 key (Select System) on the
DRB II scan tool key pad. Item number 4 will not ap-
pear on the DRB II scan tool screen unless you scroll
down. It is not necessary to scroll down to be able to
choose item 4. (5) Press the number 2 on the DRB II scan tool
key pad (Transmission). (6) Press the number 1 on the DRB II scan tool
key pad. Wait for the DRB II scan tool to perform the
following three tests before continuing (These tests
are done automatically by the DRB II scan tool).
² Bus Test
² Initialize
² Transmission Control Module Part Number
(7) Press the number 5 on the DRB II scan tool
key pad (Adjustments). (8) Press the number 2 on the DRB II scan tool
key pad (Pinion Factor). Then follow the instructions
on the DRB II scan tool screen.
TORQUE CONVERTER CLUTCH BREAK-IN
PROCEDURE
A torque converter clutch break-in program is be-
ing used on all models with a 41TE. This program
will properly condition the torque converter clutch. This will eliminate shudder during partial torque
converter clutch operation on a new torque converter.
If the torque converter is replaced, the new clutch
within the torque converter will require break-in.
The current break-in status stored in the transmis-
sion control module will have to be reset to the start
of break-in with the DRB II scan tool. If a new transmission control module is put on the
vehicle, the status will be at the start of break-in.
This status is acceptable regardless of the mileage on
the torque converter. No modification of the break-in
status is required. To properly service these vehicles, it is necessary to
use a DRB II scan tool to read or reset the break-in
status. Perform the following steps with the DRB II
scan tool to reset the break-in status: (1) Plug the DRB II scan tool into the blue CCD
Bus connector. The connector is located under the in-
strument panel on the drivers side of the vehicle. (2) Insert the 1993 DRB II scan tool cartridge into
the DRB II scan tool. (3) The red and green lights on the DRB II scan
tool will light up and then begin flashing. Wait until
the lights stop flashing before continuing with this
procedure. (4) Press the number 4 key (Select System) on the
DRB II scan tool key pad. Item number 4 will not ap-
pear on the DRB II scan tool screen unless you scroll
down. It is not necessary to scroll down to be able to
choose item 4. (5) Press the number 2 on the DRB II scan tool
key pad (Transmission). (6) Press the number 1 on the DRB II scan tool
key pad. Wait for the DRB II scan tool to perform the
following three tests before continuing (These tests
are done automatically by the DRB II scan tool).
² Bus Test
² Initialize
² Transmission Control Module Part Number
(7) Press the number 5 on the DRB II scan tool
key pad (Adjustments). (8) Press the number 1 on the DRB II scan tool
key pad (Reset LU Clutch). The DRB II scan tool will
display one of three screens. (a) LU Clutch Break-in Status: Start
(b) LU Clutch Break-in Status: In-progress
Press ENTER to Reset Break-in status (c) LU Clutch Break-in Status: CompletePress
ENTER to Reset Break-in status
If screen (a) appears, the transmission control mod-
ule is at the beginning of its break-in program. No
further action is required. If screen (b) appears, the transmission control mod-
ule is in the middle of a its break-in program. Press
the enter key on the DRB II scan tool key pad to re-
turn the status to the start of break-in.
21 - 104 TRANSAXLE Ä

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