2001 DODGE TOWN AND COUNTRY transmission oil

SERVICE DIAGNOSIS - CLUTCH SLIPS
CONDITION POSSIBLE CAUSES CORRECTION
DISC FACING WORN OUT Normal wear. Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Driver frequently rides (slips) clutch,
results in rapid wear, overheating.Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Insufficient clutch cover diaphragm
spring tensionReplace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
CLUTCH DISC FACING
CONTAMINATED WITH
OIL OR GREASELeak at rear main oil seal or
transaxle input shaft sealReplace leaking seals. Replace modular
clutch assembly (2.4L Gas) or clutch cover
and disc (2.5L TD).
Excessive amount of grease applied
to input shaft splinesApply less grease to input shaft. Replace
modular clutch assembly (2.4L Gas) or
clutch cover and disc (2.5L TD).
Road splash, water entering housing Seal housing. Inspect clutch assembly.
CLUTCH IS RUNNING
PARTIALLY DISENGAGEDRelease bearing sticking or binding,
does not return to normal running
position.Verify that bearing is actually binding. Then,
replace bearing and transmission front
bearing retainer if sleeve surface is
damaged.
Clutch pedal not returning to static
position.Inspect pedal assembly for damage and/or
obstructions. Replace componnents as
necessary.
Cable self-adjuster mechanism (LHD
Models) sticking or binding causing
high preload.Verify that self-adjuster is free to move.
Replace clutch release cable if necessary.
Clutch master cylinder (RHD Models)
or pushrod damaged causing high
preload.Replace clutch master cylinder assembly.
Slave cylinder binding or stuck (RHD
Models).Replace slave cylinder.
CLUTCH DISC FACINGS
HAVE FRACTURED INTO
SMALL PIECESLeak at rear main or transaxle input
shaft sealReplace seal. Replace modular clutch
assembly (2.4L Gas) or clutch cover and
disc (2.5L TD)..
Excessive heat from slippage Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
RGCLUTCH6a-5
CLUTCH (Continued)
ProCarManuals.com

DIAGNOSIS AND TESTING - DRIVE PLATE
MISALIGNMENT
Common causes of misalignment are:
²Heat warping
²Mounting drive plate on a dirty crankshaft
flange
²Incorrect bolt tightening
²Improper seating on the crankshaft shoulder
²Loose crankshaft bolts
Clean the crankshaft flange before mounting the
drive plate. Dirt and grease on the flange surface
may misalign the flywheel, causing excessive runout.
Use new bolts when mounting drive plate to crank-
shaft. Tighten drive plate bolts to specified torque
only. Over-tightening can distort the drive plate hub
causing excessive runout.
DIAGNOSIS AND TESTING - CLUTCH COVER
AND DISC RUNOUT
Check condition of the clutch cover before installa-
tion. A warped cover or diaphragm spring will cause
grab and/or incomplete release or engagement. Use
care when handling the clutch assembly. Impact can
distort the cover, diaphragm spring, and release fin-
gers.
DIAGNOSIS AND TESTING - CLUTCH CHATTER
COMPLAINTS
For all clutch chatter complaints, perform the fol-
lowing:
(1) Check for loose, misaligned, or broken engine
and transmission mounts. If present, they should be
corrected at this time. Test vehicle for chatter. If
chatter is gone, there is no need to go any further.
(2) If chatter persists, check hydraulic clutch
release system is functioning properly.
(3) Check for loose connections in drivetrain. Cor-
rect any problems and determine if clutch chatter
complaints have been satisfied. If not:
(a) Remove transaxle.
(b) Check to see if the release bearing is sticky
or binding. Replace bearing, if needed.
(c) Check linkage for excessive wear on the pivot
stud and fork fingers. Replace all worn parts.
(d) Check clutch assembly for contamination
(dirt, oil). Replace clutch assembly, if required.
(e) Check to see if the clutch disc hub splines
are damaged. Replace with new clutch assembly, if
necessary.
(f) Check input shaft splines for damage.
Replace, if necessary.
(g) Check for uneven wear on clutch fingers.
(h) Check for broken clutch cover diaphragm
spring fingers. Replace with new clutch assembly,
if necessary.
SPECIAL TOOLS
SPECIAL TOOLS - T850 TRANSAXLE
CLUTCH RELEASE CABLE -
LHD
REMOVAL
(1) Disconnect battery negative cable.
(2) Raise vehicle on hoist.
(3)Diesel models:Remove underbody splash
shield.
(4) Remove clutch bellhousing cap.
(5) Some models will have a clutch cable retainer
clip at the transaxle to secure it to the case (Fig. 9).
If retainer clip is installed, dislodge clip from from
inside bellhousing using a suitable screwdriver (Fig.
10), pull outward on cable conduit, guiding cable core
wire through slot in bellhousing and disengaging
cable ªTº from clutch release lever (Fig. 11). If
retainer is not installed, disengage clutch cable from
transaxle by pulling outward on cable conduit, guid-
Disconnect Tool, 6638A
Remover/Installer, 6891
RGCLUTCH6a-7
CLUTCH (Continued)
ProCarManuals.com

COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION............................1
OPERATION.............................1
DIAGNOSIS AND TESTING..................3
COOLING SYSTEM LEAK TEST.............3
COOLING SYSTEM FLOW CHECK..........3
COOLING SYSTEM AERATION.............3
COOLING SYSTEM DEAERATION...........3
STANDARD PROCEDURE...................4COOLING SYSTEM - DRAINING............4
COOLING SYSTEM - REFILLING............4
COOLANT - ADDING ADDITIONAL...........4
COOLANT LEVEL CHECK - ROUTINE........5
SPECIFICATIONS.........................6
SPECIAL TOOLS..........................6
ACCESSORY DRIVE.......................7
ENGINE................................13
TRANSMISSION.........................36
COOLING
DESCRIPTION - COOLING SYSTEM
The cooling system components consist of a radia-
tor, electric fan motors, shroud, pressure cap, thermo-
stat, transmission oil cooler, water pump, hoses,
clamps, coolant, and a coolant reserve system to com-
plete the circuit.
DESCRIPTION - HOSE CLAMPS
The cooling system uses spring type hose clamps.
If a spring type clamp replacement is necessary,
replace with the original Mopartequipment spring
type clamp.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 1).
OPERATION - COOLING SYSTEM
The engine cooling systems primary purpose is to
maintain engine temperature in a range that will
provide satisfactory engine performance and emission
levels under all expected driving conditions. It also
provides hot water (coolant) for heater performance
and cooling for automatic transmission oil. It does
this by transferring heat from engine metal to cool-
ant, moving this heated coolant to the radiator, and
then transferring this heat to the ambient air.²When engine is cold: thermostat is closed, cool-
ing system has no flow through the radiator. The
coolant bypass flows through the engine only.
²When engine is warm: thermostat is open, cool-
ing system has bypass flow and coolant flow through
radiator.
Coolant flow circuits for the 2.4L and 3.3/3.8L
engines are shown in (Fig. 2).
Fig. 1 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
RSCOOLING7-1
ProCarManuals.com

REMOVAL
There are no repairs to be made to the fan or
shroud assembly. If the fan is warped, cracked, or
otherwise damaged, it must be replaced as an assem-
bly (Fig. 21).
(1) Remove the radiator upper crossmember. (Refer
to 23 - BODY/EXTERIOR/GRILLE OPENING REIN-
FORCEMENT - REMOVAL)
(2) Disconnect the radiator fan electrical connec-
tors.
(3) Remove radiator fan(s) retaining screw (Fig.
21).
(4) Remove the radiator fan(s) by lifting upward to
release from mounts.
INSTALLATION
(1) Install the radiator fan(s) into mounts and
attaching clips on the radiator.
(2) Install radiator fan(s) attaching screws (Fig.
21). Tighten to 5 N´m (45 in. lbs.).
(3) Connect the radiator fan(s) electrical connec-
tors.
(4) Install the radiator upper support crossmem-
ber. (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - INSTALLATION)
(5) Install the upper radiator mounts to the cross-
member bolts, if removed. Tighten to 8 N´m (70 in.
lbs.).
(6) Install the radiator upper hose to the support
clip (2.4L engine).
RADIATOR FAN RELAY
DESCRIPTION
The radiator fan relay is a solid state type and is
located on the front bumper reinforcment (Fig. 22).
Refer to WIRING DIAGRAMS for a circuit sche-
matic.
OPERATION
The solid state radiator fan relay is controlled by
the Powertrain Control Module (PCM) by way of a
Pulse Width Modulated (PWM) signal. The relay con-
trol circuit supplies a 12 volt signal to the PCM. The
PCM then pulses the ground circuit to achieve fan on
time. The relay provides a voltage to the fan motors
which is proportional to the pulse width it receives
from the PCM. The duty cycle ranges from 30% for
low speed operation, then ramps-up to 100% for high
speed operation. This fan control system provides
infinitely variable fan speeds, allowing for improved
fan noise, A/C performance, better engine cooling,
and additional vehicle power.
To control operation of the relay, the PCM looks at
inputs from:
²Engine coolant temperature
²A/C pressure transducer
²Ambient temperature from the body controller
²Vehicle speed
²Transmission oil temperature
The PCM uses these inputs to determine when the
fan should operate and at what speed. For further
information on fan operation, (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - OPERATION).
REMOVAL
(1) Open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the radiator crossmember to front fas-
cia closure panel.
(4) Disconnect the relay electrical connector (Fig.
22).
(5) Remove the rivet attaching the relay to the
front bumper beam (Fig. 22).
(6) Remove the relay.
INSTALLATION
CAUTION: The relay mounting location is designed
to dissipate heat. Ensure the relay is securely
attached to prevent relay ªthermalº shutdown and
relay damage, resulting in possible engine over-
heating.
Fig. 21 Radiator Fans
1 - SCREWS - RADIATOR FAN ATTACHING
2 - RADIATOR FAN - RIGHT
3 - MOUNT - RIGHT RADIATOR FAN
4 - CLIPS - RADIATOR FAN LOWER
5 - MOUNT - LEFT RADIATOR FAN
6 - RADIATOR FAN - LEFT
RSENGINE7-29
RADIATOR FAN (Continued)
ProCarManuals.com

TRANSMISSION
TABLE OF CONTENTS
page page
TRANSMISSION
DIAGNOSIS AND TESTING.................36
TRANS OIL COOLER FLOW TESTING.......36
STANDARD PROCEDURE..................37
FLUSHING COOLERS AND TUBES.........37
TRANS COOLER
DESCRIPTION...........................38REMOVAL..............................38
CLEANING..............................38
INSPECTION............................38
INSTALLATION...........................38
TRANS COOLER LINES
REMOVAL..............................38
INSTALLATION...........................39
TRANSMISSION
DIAGNOSIS AND TESTING - TRANSMISSION
OIL COOLER FLOW
To determine proper transmission oil flow through
the oil cooler perform the following procedure:
(1) Disconnect the hose from the ªcooler returnº
fitting on the transmission. (Refer to 7 - COOLING/
TRANSMISSION/TRANS COOLER LINES -
REMOVAL)
(2) Using Special Tool adaptors 6906-1-3 with a 9
mm (3/8 in.) transmission hose attached to oneadapter, connect Special Tool 8392 flow meter in-se-
ries with the oil cooler flow circuit (Fig. 1).
(3) Start engine and run at curb idle speed.
Observe the flow meter gauge. Refer to the following
chart for specifications.
COOLER FLOW SPECIFICATION (Min.)
2.6 LPM (0.7 GPM)
(4) If oil flow is below minimum specifications, fur-
ther diagnosis must be performed.
(a) Perform Oil Pump Volume Check. (Refer to
21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
Fig. 1 TRANS COOLER FLOW TEST
1 - SPECIAL TOOL 8392 4 - TRANS HOSE-9mm(3/89I.D.)
2 - SPECIAL TOOL 6906-1-3 5 - FROM COOLER
3 - TO TRANS
7 - 36 TRANSMISSIONRS
ProCarManuals.com

- 31TH/OIL PUMP - STANDARD PROCEDURE)
(Refer to 21 - TRANSMISSION/TRANSAXLE/AU-
TOMATIC - 41TE/OIL PUMP - STANDARD PRO-
CEDURE)
(b) If oil pump volume is within specification, a
possible restriction in the cooler lines or cooler has
occurred.
(c) If oil pump volume is not within specification,
possible internal transmission restrictions, compo-
nent wear or damage has occurred. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH - DIAGNOSIS AND TESTING) (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
41TE - DIAGNOSIS AND TESTING)
(d) If an oil cooler restriction is suspected, per-
form further inspections and flow meter testing by
isolating components (i.e. lines, coolers).
(e) After a restriction is isolated, perform cooler
flush procedure. (Refer to 7 - COOLING/TRANS-
MISSION - STANDARD PROCEDURE)
(f) Re-test cooler flow. If cooler flow does not
exceed minimum specification, replace compo-
nent(s) as necessary.
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES
The recommended procedure for cooler flushing is
to use Tool 6906 Cooler Flusher.
WARNING:
WEAR PROTECTIVE EYEWEAR THAT MEETS THE
REQUIREMENTS OF OSHA AND ANSI Z87.1±1968.
WEAR STANDARD INDUSTRIAL RUBBER 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 FOR15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
(1) Remove cover plate filler plug on Tool 6906.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Use MopartTransmission Cooler Flush (MS-552) or
equivalent solution conforming to MS-552. Flushing
solvents are petroleum based solutions generally
used to clean automatic transmission components.
DO NOTuse solvents containing acids, water, gaso-
line, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906.
(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.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
(4) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(5) Connect the CLEAR return line to the INLET
(To) cooler line
(6) Turn pump ON for two to three minutes to
flush cooler and lines.
(7) Turn pump OFF.
(8) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(9) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(10) Place CLEAR suction line into a one quart
container of MopartATF+4 (Automatic Transmission
FluidÐType 9602).
(11) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(12) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
RSTRANSMISSION7-37
TRANSMISSION (Continued)
ProCarManuals.com

TRANS COOLER
DESCRIPTION
The transmission oil cooler is an external oil-to-air
type cooler is mounted between the front of the radi-
ator and back side of the A/C condensor (Fig. 3). Use
only approved transmission oil cooler hoses that are
molded to fit the space available.
REMOVAL
(1) Remove the radiator. (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL)
(2) Disconnect lines from oil cooler (Fig. 2).
(3) Remove oil cooler attaching screws (Fig. 3).
(4) Remove the oil cooler.
CLEANING
Check the external cooler for debris on the cooling
fin surfaces. Clean as necessary. For internal clean-
ing/flushing procedures, (Refer to 7 - COOLING/
TRANSMISSION - STANDARD PROCEDURE).
INSPECTION
Inspect all hoses, tubes, clamps and connections for
leaks, cracks, or damage. Replace as necessary. Use
only approved transmission oil cooler hoses that are
molded to fit the space available.
Inspect external coolers for leaks, loose mounts, or
damage. Replace as necessary.
INSTALLATION
(1) Install transaxle oil cooler and mounting
screws (Fig. 3).
NOTE: When replacing the transmission oil cooler,
the cooler hoses must be replaced.
(2) Connect the new cooler hoses and install
clamps (Fig. 2).
(3) Install the radiator. (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION)
(4) Start engine. Check and adjust the fluid level
as necessary.
TRANS COOLER LINES
REMOVAL
(1) Using appropriate hose clamp pliers, release
tension on clamps and move off fittings.
NOTE: When the transaxle cooler lines are removed
from the rolled-groove type fittings at the cooler
and transaxle, damage to the inner wall of hose will
occur. To prevent potential leakage, the cooler
hoses must be replaced.
(2) Remove the hoses (Fig. 4) or (Fig. 5).
Fig. 2 TRANSMISSION COOLER HOSES
1 - TRANSAXLE COOLER HOSES
2 - FITTING - COOLER OUTLET
3 - FITTING - COOLER INLET
Fig. 3 Transmission Oil Cooler
1 - TRANSAXLE OIL COOLER
2 - SCREWS
3 - A/C CONDENSOR (REAR SIDE)
7 - 38 TRANSMISSIONRS
ProCarManuals.com

INSTALLATION
NOTE: When the transaxle cooler lines are removed
from the rolled-groove type fittings at the cooler
and transaxle, damage to the inner wall of hose willoccur. To prevent potential leakage, the cooler
hoses must be replaced.
(1) Connect hoses to cooler and transaxle fittings
(Fig. 4) or (Fig. 5).
(2) Using appropriate pliers, position clamps over
fittings and release tension.
(3) Start engine and check transaxle fluid level.
Adjust fluid level as necessary.
Fig. 4 TRANS OIL COOLER LINES - 41TE
1 - FITTING - COOLER RETURN
2 - FITTING - COOLER SUPPLY
3 - HOSES - TRANSAXLE COOLER
4 - FITTING - COOLER OUTLET
5 - FITTING - COOLER INLET
Fig. 5 TRANSAXLE OIL COOLER LINES - 31TH
1 - FITTING - COOLER RETURN
2 - FITTING - COOLER SUPPLY
3 - HOSES - TRANSAXLE COOLER
4 - FITTING - COOLER OUTLET
5 - FITTING - COOLER INLET
RSTRANSMISSION7-39
TRANS COOLER LINES (Continued)
ProCarManuals.com