1996 CHRYSLER VOYAGER oil temperature

FUEL INJECTION SYSTEMÐ2.5L DIESEL ENGINE
INDEX
page page
GENERAL INFORMATION
INTRODUCTION....................... 43
DESCRIPTION AND OPERATION
AIR CONDITIONING (A/C) CONTROLSÐ
PCM INPUTS........................ 47
AIR CONDITIONING RELAYÐPCM OUTPUT . . 48
BATTERY VOLTAGEÐPCM INPUT.......... 45
BOOST PRESSURE SENSOR............. 45
BRAKE SWITCHÐPCM INPUT............. 47
DATA LINK CONNECTORÐ
PCM INPUT AND OUTPUT.............. 47
DIESEL PCM RELAYÐPCM INPUT......... 48
ENGINE COOLANT GAUGEÐPCM OUTPUT . . 48
ENGINE COOLANT TEMPERATURE SENSORÐ
PCM INPUT......................... 46
ENGINE OIL PRESSURE GAUGEÐ
PCM OUTPUT........................ 48
ENGINE SPEED SENSORÐPCM INPUT..... 46
EXHAUST GAS RECIRCULATION (EGR)
SOLENOIDÐPCM OUTPUT............. 50
FIVE VOLT POWERÐPCM OUTPUT........ 48
FUEL INJECTOR SENSORÐGROUND...... 46
FUEL TIMING SOLENOIDÐPCM OUTPUT.... 48
GLOW PLUG LAMPÐPCM OUTPUT........ 48
GLOW PLUG RELAYÐPCM OUTPUT....... 49
GLOW PLUGS......................... 49
IGNITION CIRCUIT SENSEÐPCM INPUT.... 45
NEEDLE MOVEMENT OR INSTRUMENTED
FIRST INJECTORÐPCM INPUT.......... 45
POWER GROUND...................... 45
POWERTRAIN CONTROL MODULE (PCM) . . . 44
SENSOR RETURNÐPCM INPUT (ANALOG
GROUND)........................... 45SIGNAL GROUNDÐPCM INPUT........... 45
SPEED CONTROLÐPCM INPUTS.......... 48
SPEED CONTROLÐPCM OUTPUTS........ 48
START SIGNALÐPCM INPUT............. 45
TACHOMETERÐPCM OUTPUT............ 49
VEHICLE SPEED SENSORÐPCM INPUT.... 47
VEHICLE THEFT ALARM................. 45
DIAGNOSIS AND TESTING
BOOST PRESSURE SENSOR............. 53
DIAGNOSTIC TROUBLE CODES........... 53
DIESEL DIAGNOSTICS.................. 50
DIESEL PCM RELAY TEST............... 50
ENGINE COOLANT TEMPERATURE
SENSOR TEST....................... 50
ENGINE SPEED SENSOR TEST........... 50
GLOW PLUG RELAY TEST............... 51
GLOW PLUG TEST..................... 51
RELAYSÐOPERATION/TESTING........... 52
VEHICLE SPEED SENSOR TEST........... 53
REMOVAL AND INSTALLATION
A/C CLUTCH RELAY.................... 53
DIESEL PCM RELAY.................... 53
ENGINE COOLANT TEMPERATURE
SENSOR............................ 54
ENGINE SPEED SENSOR................ 53
GLOW PLUG RELAY.................... 55
GLOW PLUGS......................... 54
POWERTRAIN CONTROL MODULE (PCM) . . . 55
VEHICLE SPEED SENSOR............... 55
SPECIFICATIONS
GLOW PLUG CURRENT DRAW............ 56
TORQUE CHARTÐ2.5L DIESEL............ 57
GENERAL INFORMATION
INTRODUCTION
This section will cover components either regulated
or controlled by the Powertrain Control Module
(PCM). The fuel heater relay, fuel heater and fuel
gauge are not operated by the PCM. These compo-
nents are controlled by the ignition (key) switch. All
other fuel system electrical components necessary to
operate the engine are controlled or regulated by the
PCM. Refer to the following PCM description for
more information.
Certain fuel system component failures may cause
a no start, or prevent the engine from running. It is
important to know that the PCM has a featurewhere, if possible, it will ignore the failed sensor, set
a code related to the sensor, and operate the engine
in a ªLimp Homeº mode. When the PCM is operating
in a ªLimp Homeº mode, the Diesel Glow Plug lamp
on the instrument panel will be constantly illumi-
nated, and the engine will most likely have a notice-
able loss of performance. An example of this would be
an Accelerator Pedal Position Sensor failure, and in
that situation, the engine would run at a constant
1100 RPM, regardless of the actual position of the
pedal. This is the most extreme of the three ªLimp
Homeº modes.
In addition to indicating that the glow plugs are
hot enough to start combustion, the Glow Plug Lamp
is also used in the diagnosis of the PCM, and when
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 43

STEERING
CONTENTS
page
POWER STEERINGÐ2.5L VM DIESEL....... 1
POWER STEERINGÐ2.5L VM DIESEL
INDEX
page page
GENERAL INFORMATION
POWER STEERING GEAR................ 1
POWER STEERING PUMP................ 1
STEERING GEAR OPERATIONÐRHD & LHD
VEHICLES........................... 1SERVICE PROCEDURES
POWER STEERING PUMP ± INITIAL
OPERATION.......................... 1
REMOVAL AND INSTALLATION
POWER STEERING PUMPÐ2.5L DIESEL..... 2
GENERAL INFORMATION
POWER STEERING PUMP
The power steering pump used with the 2.5L VM
Diesel engine operates the same way as the power
steering pump used with the 2.5/4.0L gasoline
engines. Refer to the Description and Operation sec-
tion for the 2.5/4.0L gasoline engine power steering
pump for more information.
STEERING GEAR OPERATIONÐRHD & LHD
VEHICLES
NOTE: The power steering gear should NOT be ser-
viced or adjusted. If a malfunction or oil leak
occurs, the complete steering gear should be
replaced.
Refer to the Power Steering Gear in group 19 for
more information
POWER STEERING GEAR
SERVICE PROCEDURES
POWER STEERING PUMP ± INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature.
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two minutes.
(2) Start the engine and let run for a few seconds
then turn engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
Fig. 1 Power Steering GearÐRHD Vehicles
NS/GSSTEERING 19 - 1

GENERAL INFORMATION
31TH TRANSAXLE
NOTE: Safety goggles should be worn at all times
when working on these transaxles.
This transaxle combines torque converter, three
speed transmission, final drive gearing, and differen-
tial into a front wheel drive system. The identifica-
tion markings and usage of the transaxle are charted
in Diagnosis and Tests.
NOTE: Transaxle operation requirements are differ-
ent for each vehicle and engine combination. Some
internal parts will be different to provide for this.
Therefore, when replacing parts, refer to the seven
digit part number stamped on rear of the transaxle
oil pan flange.
Within this transaxle, there are three primary
areas:
(1) Main center line plus valve body.
(2) Transfer shaft center line (includes governor
and parking sprag).
(3) Differential center line.
(4) Center distances between the main rotating
parts in these three areas are held precise to main-
tain a low noise level.
(5) The torque converter, transaxle area, and dif-
ferential are housed in an integral aluminum die
casting.The differential oil sump is common
with the transaxle sump. Separate filling of the
differential is NOT necessary.
(6) The torque converter is attached to the crank-
shaft through a flexible driving plate. Cooling of the
converter is accomplished by circulating the tran-
saxle fluid through a remote cooler. There are two
types of coolers used. An oil-to-water type cooler
located in the radiator side tank and/or an oil-to air
heat exchanger. The torque converter assembly is a
sealed unit that cannot be disassembled.
(7) The transaxle fluid is filtered by an internal fil-
ter attached to the lower side of the valve body
assembly.
(8) Engine torque is transmitted to the torque con-
verter then, through the input shaft to multiple-disc
clutches in the transaxle. The power flow depends on
the application of the clutches and bands. Refer to
Elements in Use Chart in Diagnosis and Tests sec-
tion.
(9) The transaxle consists of:
²Two multiple-disc clutches
²An overrunning clutch
²Two servos
²A hydraulic accumulator
²Two bands²Two planetary gear sets
This provides three forward ratios and a reverse
ratio. The common sun gear of the planetary gear
sets is connected to the front clutch by a driving
shell. The drive shell is splined to the sun gear and
front clutch retainer. The hydraulic system consists
of an oil pump, and a single valve body which con-
tains all of the valves except the governor valves.
The transaxle sump and differential sump are both
vented through the dipstick. Output torque from the
main center line is delivered through helical gears to
the transfer shaft. This gear set is a factor of the
final drive (axle) ratio. The shaft also carries the gov-
ernor and parking sprag. An integral helical gear on
the transfer shaft drives the differential ring gear.
The final drive gearing is completed with one of two
gear ratios of 2.98 or 3.19 depending on model and
application.
FLUID LEVEL AND CONDITION
NOTE: The transmission and differential sump have
a common oil sump with a communicating opening
between the two.
The torque converter fills in both the P Park and N
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate.The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground. This will assure complete oil level sta-
bilization between differential and transmis-
sion.The fluid should be at normal operating
temperature (approximately 82 C. or 180 F.). The
fluid level is correct if it is in the HOT region (cross-
hatched area) on the dipstick.
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, the air bubbles can cause overheat-
ing, fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and servo operation.
Foaming can also result in fluid escaping from the
transaxle dipstick where it may be mistaken for a
leak.
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
21 - 2 TRANSAXLE AND POWER TRANSFER UNITNS

SERVICE PROCEDURES
FLUID AND FILTER CHANGE
When the factory fill fluid is changed, only fluids
labeled MOPARtATF PLUS 3 (Automatic Transmis-
sion fluid) Type 7176 should be used.
If the transaxle is disassembled for any reason, the
fluid and filter should be changed.
30,000 MILE TRANSAXLE OIL CHANGE
When a vehicle attains 30,000 miles on its odome-
ter it is recommended that the transaxle oil be
changed. To change the oil, use the procedure that
follows:
It is recommended that a transaxle fluid exchanger
(ATF 2000+ or equivalent) be used to replace the
used fluid in the transaxle. If a fluid exchanger is not
available use a fluid suction pump (Vaculayor equiv-
alent) to draw the fluid out of the dipstick tube. If a
fluid suction pump is not available remove the oil
pan and drain the fluid.
CAUTION: Chrysler Corporation does not recom-
mend using any fluid exchanger that introduces
additives into the transaxle.TRANSAXLE FLUID EXCHANGER METHOD
(1) To perform the transaxle fluid exchange, the
transaxle must be at operating temperature. Drive
the vehicle till it reaches full operating temperature.
(2) Verify that the fill tank on the transaxle fluid
exchanger (ATF 2000+ or equivalent) is clean and
dry.
(3) Fill the tank to the recommended fill capacity
with Mopar ATF Plus 3 Type 7176.
(4) Hookup the vehicle to the machine following
the manufacturers instructions. Perform the
exchange procedure following the instructions pro-
vided with the machine.
(5) Once machine has completed the fluid
exchange. Check the fluid level and condition and fill
to proper level with Mopar ATF Plus 3 Type 7176.
NOTE: Verify that the transaxle cooler lines are
tightened to proper specifications. Cooler line
torque specification is 2 N²m (18 in. lbs.).
DIPSTICK TUBE FLUID SUCTION METHOD
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
Fig. 4 Air Pressure Tests
21 - 16 TRANSAXLE AND POWER TRANSFER UNITNS
SERVICE PROCEDURES (Continued)

(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (Vaculay
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Add 4 Quarts of Mopar ATF Plus 3 Type 7176
transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be in
the HOT range.
TRANSAXLE OIL PAN DROP METHOD
This procedure involves removing the transaxle oil
pan to drain the transaxle fluid.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N²m (165 in. lbs.).
(6) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be inthe HOT range. Drive the vehicle a minimum of 10
miles.
(10) Raise the vehicle on the hoist.
(11) Check for leaks around the transaxle oil pan
sealing surfaces.
(12) Recheck the fluid level. The level should be in
the HOT range.
SEVERE USAGE SERVICE
If the vehicle exhibits any of the following symp-
toms, it is recommended that the transaxle oil and
filter be replaced.
²Transaxle oil discolored
²Transaxle oil has high mileage
²Oil feels grimy when rubbed between fingertips
²Poor shift quality
²Delayed gear engagement
²Vehicle shudder between shifts
TRANSAXLE OIL AND FILTER REPLACEMENT
This procedure involves changing the transaxle
fluid and filter, driving the vehicle for 10 miles and
changing the transaxle fluid a second time.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Separate the filter and O-ring from the valve
body. Inspect the O-ring for cuts or improper instal-
lation. This could lead to delayed garage shifts.
(6) Install a new filter. Replace the O-ring as nec-
essary.
(7) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N²m (165 in. lbs.).
(8) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(9) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(10) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(11) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range. Drive the vehicle a minimum of
10 miles.
(12) Raise the vehicle on the hoist.
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 17
SERVICE PROCEDURES (Continued)

(13) Remove the pan and clean all sealant from
the pan and transaxle mating surfaces. Clean the
magnet and the inside of the pan.
(14) Separate the filter from the valve body to
allow additional fluid to drain from the transaxle.
Inspect the filter O-ring for any damage and replace
as necessary.
(15) After the transaxle has stopped draining,
reinstall the filter and O-ring.
(16) Apply a 1/8 inch bead of Mopar RTV Sealant
to the mounting flange of the transaxle oil pan.
Apply RTV Sealant to the underside of the attaching
bolts. Attach the oil pan to the transaxle. Tighten the
bolts to 19 N²m (165 in. lbs.).
(17) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(18) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(19) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(20) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range.
FLUID DRAIN AND REFILL
(1) Raise vehicle on a hoist (See Group 0, Lubrica-
tion). Place a drain container with a large opening,
under transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and gasket on bottom of the
valve body and tighten retaining screws to 5 N´m (40
inch-pounds).
(4) Clean the oil pan and magnet. Reinstall pan
using new sealant. Tighten oil pan bolts to 19 N´m
(165 in. lbs.).
(5) Pour four quarts of Mopar ATF PLUS 3 (Auto-
matic Transmission Fluid) Type 7176 through the
dipstick opening.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Add sufficient fluid to bring level to 1/8 inch
below the ADD mark.
(8) Recheck fluid level after transaxle is at normal
operating temperature. The level should be in the
HOT region.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum transaxle
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 tapping the hole
with a 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 suppliers.
FLUSHING COOLERS AND TUBES
When a transaxle failure has contaminated the
fluid, the oil cooler(s) must be flushed. The cooler
bypass valve in the transaxle must be replaced also.
The torque converter must also be replaced with an
exchange unit. This will ensure that metal particles
or sludged oil are not later transferred back into the
reconditioned (or replaced) transaxle.
The recommended procedure for flushing the cool-
ers and tubes is to use Tool 6906A Cooler Flusher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover plate filler plug on Tool 6906A.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906A.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
21 - 18 TRANSAXLE AND POWER TRANSFER UNITNS
SERVICE PROCEDURES (Continued)

Inspect all valve springs for distortion and col-
lapsed coils. Inspect all valves and plugs for burrs,
nicks, and scores. Small nicks and scores may be
removed with crocus cloth, providing extreme care is
taken not to round off sharp edges. The sharpness of
these edges is vitally important. It prevents foreign
matter from lodging between valve and valve body.
This reduces the possibility of sticking. Inspect all
valves and plugs for freedom of operation in valve
body bores.
When bores, valves, and plugs are clean and dry,
the valves and plugs should fall freely in the bores.
The valve body bores do not change its dimensions
with use. Therefore, a valve body that was function-
ing properly when vehicle was new, will operate cor-
rectly if it is properly and thoroughly cleaned. There
is no need to replace valve body unless it is damaged
in handling.
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT
Lift and rotate the gearshift hand lever into the
park (P) gate position and remove the ignition key.
This confirms the shift lever is in the gated park (P)
position.
After confirming the park gate position, turn the
ignition switch. If the starter will operate, the park
gate position is correct. Move the shift lever into the
neutral (N) position. If the starter will operate in this
position, the linkage is properly adjusted. If the
starter fails to operate in either position, linkage
adjustment is required.
(1) Park the vehicle on level ground and set the
parking brake.
(2) Place the gearshift lever in park (P) gate posi-
tion and remove key.
(3) Loosen the cable adjustment screw at the tran-
saxle operating lever (Fig. 160).
(4) Pull the transaxle operating lever fully forward
to the park detent position.
(5) Release the park brake, then rock the vehicle
to assure it is in park lock. Reset the park brake.
(6) Tighten the cable adjustment screw to 8 N´m
(70 in. lbs.). Gearshift cable should now be properly
adjusted.
(7) Verify PRNDL indicator still displays the corre-
sponding gear completely. If not, readjustment of
PRNDL may be required.
(8) Check adjustment by using the preceding pro-
cedure.
THROTTLE PRESSURE LINKAGE ADJUSTMENT
The throttle pressure rod adjustment is very
important to proper transaxle operation. This adjust-
ment positions a valve which controls shift speed,shift quality, and part throttle downshift sensitivity.
If the setting is too short, early shifts and slippage
between shifts may occur. If the setting is too long,
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 Group
14, Fuel System for idle speed Specifications and
adjustment.
ROD ADJUSTMENT PROCEDURE
(1) Perform transaxle throttle pressure adjustment
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. Disassem-
ble and clean or repair parts to assure free action, if
necessary.
(4) Hold transaxle throttle lever firmly toward
engine, against its internal stop. Tighten swivel lock
screw to 11 N´m (100 in. lbs.)
(5) The adjustment is finished and linkage back-
lash was automatically removed by the preload
spring.
(6) I
f lubrication is required see Group 0, Lubrica-
tion.
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, tighten adjusting screw to 8
N´m (72 in. lbs.).
Fig. 160 Gearshift Cable Adjustment
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 51
CLEANING AND INSPECTION (Continued)

OPERATION
The gear ratios for the 41TE transaxle are as fol-
lows:
²1stÐ2.84
²2ndÐ1.57
²3rdÐ1.00
²ODÐ0.69
²ReverseÐ2.21
Final Drive Ratio is dependent on which engine
option is selected.
²2.4 Liter: 3.91 FDR
²3.3 Liter: 3.62 FDR
²3.8 Liter: 3.45 FDR
The torque converter clutch is available in 2nd,
direct, or overdrive gear;. The shift lever is conven-
tional with six positions: P, R, N, OD, 3, and L avail-
able. When OD is selected the transaxle shifts
through all four speeds with torque converter clutch
available in overdrive. This position is recommended
for most driving. The 3 position is tailored for use in
hilly or mountainous driving. When 3 is selected, the
transmission uses only 1st, 2nd, and direct gears
with 2nd-direct shift delayed to 40 mph or greater.
When operating in 3 or L positions torque converter
clutch application occurs in direct gear. This
improves transmission cooling under heavy loads. If
high engine coolant temperature occurs, the torque
converter clutch will also engage in 2nd gear. The L
position provides maximum engine braking for
descending steep grades. Unlike most current tran-
saxles, upshifts are provided to 2nd or direct gear at
peak engine speeds if the accelerator is depressed.
This provides engine over-speed protection and max-
imum performance.
FLUID LEVEL AND CONDITION
NOTE: The transmission and differential sump have
a common oil sump with an opening between the
two.
The torque converter fills in both the (P) Park and
(N) Neutral positions. Place the selector lever in (P)
Park to check the fluid level.The engine should be
running at idle speed for at least one minute,
with the vehicle on level ground. This will
assure complete oil level stabilization between
differential and transmission.The fluid should be
at normal operating temperature (approximately 82
C. or 180 F.). The fluid level is correct if it is in the
HOTregion (cross-hatched area) on the oil level indi-
cator.
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, the air bubbles can cause overheat-
ing, fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transaxle vent where it may be mistaken
for a leak.
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
If there is any doubt about its condition, drain out a
sample for a double check.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
SELECTION OF LUBRICANT
It is important that the proper lubricant be used in
the 41TE transaxle. MOPARtATF PLUS 3 (Auto-
matic Transmission FluidÐtype 7176) should be used
to aid in assuring optimum transmission perfor-
mance. Fluids of the type labeled DEXRON II Auto-
matic Transmission Fluid arenot recommended.It
is important that the transmission fluid be main-
tained at the prescribed level using the recommended
fluids.
SPECIAL ADDITIVES
Chrysler Corporation does not recommend the
addition of any fluids to the transaxle, other than the
fluid listed above. An exception to this policy is the
use of special dyes to aid in detecting fluid leaks. The
use of transmission sealers should be avoided, since
they may adversely affect seals.
DESCRIPTION AND OPERATION
CLUTCH AND GEAR
The transaxle consists of:
²Three multiple disc input clutches
²Two multiple disc grounded clutches
²Four hydraulic accumulators
²Two planetary gear sets
This provides four forward ratios and a reverse
ratio. The input clutch-apply pistons were designed
with centrifugally balanced oil cavities so that quick
response and good control can be achieved at any
speed. A push/pull piston is incorporated for two of
the three input clutches.
21 - 72 TRANSAXLE AND POWER TRANSFER UNITNS
GENERAL INFORMATION (Continued)