2002 CHRYSLER CARAVAN transfer

ries the governor and parking sprag. An integral heli-
cal gear on the transfer shaft drives the differential
ring gear.
OPERATION
Transmission output is directed to an integral dif-
ferential by a transfer gear system in the following
input-to-output ratios:
FIRST 2.69:1
SECOND 1.55:1
THIRD 1.00:1
REVERSE 2.10:1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRELIMINARY
DIAGNOSIS
Automatic transaxle malfunctions are usually
caused by the following general conditions:
²Improper fluid level/condition²Poor engine performance
²Improper engine or transaxle adjustments
²Transaxle hydraulic malfunctions
²Transaxle mechanical malfunctions
Diagnosis of transaxle problems should always
begin with checking the easily accessible variables:
²Fluid level and condition
²Gearshift cable adjustment
²Throttle valve cable adjustment
After verifying or adjusting these variables, road
test the vehicle to determine if the problem has been
corrected or that further diagnosis is necessary. If the
problem still exists, refer to the following diagnosis
charts to aid in determining the source or cause of
failure.
Hydraulic pressure tests should be performed
when a transaxle internal failure is suspected. The
hydraulic flow charts, in the Schematics and Dia-
grams section of this group, outline fluid flow and
hydraulic circuitry. Circuit operation is provided for
all gear ranges. Normal working pressures are also
supplied for each of the gear ranges.
21 - 24 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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(8) Remove park rod from transaxle (Fig. 21).
(9) Remove cooler bypass valve and seal (Fig. 22).(10) Remove valve body-to-transaxle bolts (Fig.
23).
(11) Remove valve body from transaxle (Fig. 24).
Note orientation and location of governor tubes.
Fig. 21 Parking Rod
1 - VALVE BODY
2 - PARKING ROD
Fig. 22 Cooler Bypass Valve and Seal
1 - TRANSFER PLATE
2 - BYPASS VALVE
3 - SEAL
Fig. 23 Valve Body Attaching Bolts
1 - VALVE BODY
2 - VALVE BODY ATTACHING BOLTS (7)
3 - GOVERNOR TUBES
Fig. 24 Valve Body and Governor Tubes
1 - VALVE BODY ASSEMBLY
2 - GOVERNOR TUBES
21 - 42 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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(23) Remove park sprag rod support-to-case bolts
(Fig. 37).
(24) Remove support and bolts (Fig. 38).
NOTE: To remove pawl, spring, and pivot shaft, the
governor support retainer must be removed. (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/TRANSFER SYSTEM - REMOVAL)(25) Remove park pawl, spring, and pivot shaft
(Fig. 39).
(26) Remove oil pump-to-transaxle case bolts (Fig.
40).
Fig. 37 Parking Sprag Rod Support
1 - PARKING SPRAG ROD SUPPORT
2 - BOLT (2)
3 - OUTPUT SHAFT GEAR
Fig. 38 Support and Bolts
1 - BOLT (2)
2 - PARKING SPRAG ROD SUPPORT
Fig. 39 Parking Pawl, Return Spring, and Pivot Shaft
1 - PARK PAWL
2 - RETURN SPRING
3 - NOTE: SMALL DIAMETER TO REAR
4 - PIVOT SHAFT
Fig. 40 Oil Pump Attaching Bolts
1 - SEAL
2 - PUMP ATTACHING BOLTS (7)
3 - PUMP HOUSING
21 - 46 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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(42) Remove low/reverse band (Fig. 57).
(43)
Remove and inspect #11 thrust washer (Fig. 58).
ASSEMBLY
CAUTION: If transaxle failure has occurred, it is nec-
essary to flush the transaxle oil cooler and lines to
remove debris and particles that could contaminate
and/or fail a new or rebuilt unit. (Refer to 7 - COOLING/
TRANSMISSION - STANDARD PROCEDURE)
NOTE: This procedure does not include assembly
of final drive (differential) components. (Refer to 21- TRANSMISSION/TRANSAXLE/AUTOMATIC - 31TH/
FINAL DRIVE - ASSEMBLY)
NOTE: This procedure does not include assembly
of transfer system (transfer shaft and output shaft)
components. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 31TH/TRANSFER SYSTEM -
INSTALLATION)
(1) Install #11 thrust washer (Fig. 59).
(2) Install low/reverse band (Fig. 60). Do not
install strut or adjust at this time.
Fig. 57 Low/Reverse Band and Strut
1 - #11 THRUST WASHER
2 - LOW-REVERSE BAND
3 - STRUT
Fig. 58 No. 11 Thrust Washer
1 - #11 THRUST WASHER
2 - OUTPUT SHAFT
Fig. 59 No. 11 Thrust Washer
1 - #11 THRUST WASHER
2 - OUTPUT SHAFT
Fig. 60 Low/Reverse Band and Strut
1 - #11 THRUST WASHER
2 - LOW-REVERSE BAND
3 - STRUT
RS31TH AUTOMATIC TRANSAXLE21-51
31TH AUTOMATIC TRANSAXLE (Continued)
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(36) Install valve body assembly (Fig. 89). Make
sure governor tubes are properly engaged to the
transaxle case and valve body.
(37) Install and torque valve body-to-transaxle
case bolts (Fig. 90) to 12 N´m (105 in. lbs.) torque.(38) Install cooler bypass valve and seal (Fig. 91).
Torque bolts to 5 N´m (40 in. lbs.)..
(39) Install park rod into position and retain with
e-clip (Fig. 92).
Fig. 89 Valve Body and Governor Tubes
1 - VALVE BODY ASSEMBLY
2 - GOVERNOR TUBES
Fig. 90 Valve Body Attaching Bolts
1 - VALVE BODY
2 - VALVE BODY ATTACHING BOLTS (7)
3 - GOVERNOR TUBES
Fig. 91 Cooler Bypass Valve and Seal
1 - TRANSFER PLATE
2 - BYPASS VALVE
3 - SEAL
Fig. 92 Parking Rod E-Clip
1 - VALVE BODY
2 - SCREWDRIVER
3 - ªEº CLIP
4 - PARKING ROD
RS31TH AUTOMATIC TRANSAXLE21-59
31TH AUTOMATIC TRANSAXLE (Continued)
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SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE
GENERAL SPECIFICATIONS
Transaxle TypeThree speed automatic with torque converter and
integral differential
Cooling Method Air to oil heat exchanger
Lubrication Method Pump (internal-external gear-type)
GEAR RATIOS
1st Gear 2.69
2nd Gear 1.55
3rd Gear 1.00
Reverse Gear 2.10
BAND ADJUSTMENT
Kickdown (Front)ÐBacked Off From 8 N²m (72 in. lbs.) 21¤4turns
Low-Reverse (Rear)ÐBacked Off From 5 N²m (41 in.
lbs.)3
1¤2Turns
BEARING SETTINGS (END PLAY & TURNING TORQUE)
Description Metric Standard
Differential Assembly 0.7-1.4 N´m 6-12 in. lbs.
Output Shaft 0-0.3 N´m 0-3 in. lbs.
Transfer Shaft 0.051-0.254 mm 0.002-0.010 in. (end play)
Overall Drag At Output Hub 0.03-1.8 N´m 3-16 in. lbs.
CLUTCH CLEARANCES
Description Metric Standard
Front Clutch (Not Adjustable) 1.27-2.79 mm 0.050-0.110 in.
Rear Clutch 0.71-1.10 mm 0.028-0.043 in.
END PLAY
Description Metric Standard
Input Shaft 0.19-1.50 mm 0.008-0.060 in.
Front Clutch Retainer 0.76-2.69 mm 0.030-0.106 in.
Front Carrier 0.18-1.45 mm 0.007-0.057 in.
Front Annulus Gear 0.09-0.50 mm 0.0035-0.020 in.
Planet Pinion 0.15-0.59 mm 0.006-0.023 in.
Reverse Drum 0.76-3.36 mm 0.030-0.132 in.
21 - 72 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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TORQUE SPECIFICATIONS
Description N´m Ft. Lbs. In. Lbs.
Bolt, Differential Bearing Retainer-to-Case 34 Ð 300
Bolt, Differential Cover-to-Case 19 Ð 165
Bolt, Differential Ring Gear-to-Case 95 70 Ð
Bolt, Extension Housing-to-Case 28 Ð 250
Bolt, Drive Plate-to-Crankshaft 95 70 Ð
Bolt, Drive Plate-to-Torque Converter 68 50 Ð
Bolt, Governor-to-Support 7 Ð 60
Bolt, Output Gear Strap 23 17 Ð
Bolt, Oil Pan-to-Case 19 Ð 165
Bolt, Oil Pump-to-Case 31 Ð 275
Bolt, Park Rod Support-to-Case 28 Ð 250
Bolt, Reaction Support-to-Pump Body 28 Ð 250
Bolt, Sprag Retainer-to-Case 28 Ð 250
Bolt, Starter Motor-to-Transaxle 54 40 Ð
Bolt, Transaxle Case-to-Engine Block 95 70 Ð
Bolt, Transfer Gear Cover-to-Case 19 Ð 165
Bolt, Transfer Gear Strap 23 17 Ð
Bolt, Valve Body-to-Case 12 Ð 105
Fitting, Transaxle Oil Cooler-to-Case 7 Ð 60
Screw, Fluid Filter 5 Ð 45
Screw, Cooler Bypass Valve-to-Transfer Plate 5 Ð 40
Screw, Governor Counterweight 28 Ð 250
Screw, Manual Valve Lever-to-Shaft 12 Ð 105
Screw, Speedo Adapter-to-Extension Housing 7 Ð 60
Screw, Valve Body-to-Transfer Plate 5 Ð 45
Nut, Kickdown Band Adjuster Lock 47 35 Ð
Nut, Output Gear-to-Shaft 271 200 Ð
Nut, Reverse Band Adjuster Lock 14 Ð 125
Nut, Transfer Gear-to-Shaft 271 200 Ð
Plug, Pressure Tap 5 Ð 45
Plug, Rear Band Lever Pivot Shaft 7 Ð 60
Switch, Park/Neutral 34 25 Ð
21 - 74 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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Differential Tool L-4436A
Housing Remover Adapter L-4437
Starter Nut L-4439
Transfer Shaft Remover-Installer L-4512
Bearing Cup Remover L-4517
Special Jaw Set L-4518
Installer L-4520
End Play Socket Set 8266
Bearing Splitter P-334
21 - 78 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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