2002 CHRYSLER CARAVAN Service Manual

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Page 1705 of 2399

CHRYSLER CARAVAN 2002 Service Manual (14) Remove valve body from transaxle. Note ori-
entation of governor tubes (Fig. 305).
DISASSEMBLY
CAUTION: Do not clamp any portion of valve body
or transfer plate in a vise. Any slight distortion o

Page 1706 of 2399

CHRYSLER CARAVAN 2002 Service Manual (3) Separate transfer and separator plate from
valve body assembly (Fig. 309). Note check ball loca-
tions (Fig. 310) for proper reassembly.(4) Remove throttle valve shaft-to-manual valve
shaft e-clip

Page 1707 of 2399

CHRYSLER CARAVAN 2002 Service Manual (5) Remove manual valve shaft/lever from throttle
valve shaft (Fig. 313).
(6) Remove throttle valve lever/shaft (Fig. 314).(7) Remove manual valve from valve body (Fig.
315).
(8) Remove pressure regul

Page 1708 of 2399

CHRYSLER CARAVAN 2002 Service Manual (9) Remove springs and valves as shown in (Fig.
317).
Fig. 317 Pressure Regulators and Manual Controls
1 - VALVE BODY 7 - SPRING
2 - LINE PRESSURE VALVE 8 - KICKDOWN VALVE
3 - SPRING 9 - SPRING
4 - AD

Page 1709 of 2399

CHRYSLER CARAVAN 2002 Service Manual (10) Remove governor plugs as shown in (Fig. 318).
Fig. 318 Governor Plugs
1 - SHUTTLE VALVE SECONDARY SPRING 5 - SCREW (4)
2 - SHUTTLE VALVE 6 - END COVER
3 - 1-2 SHIFT VALVE GOVERNOR PLUG 7 - 2-3 SH

Page 1710 of 2399

CHRYSLER CARAVAN 2002 Service Manual (11) Remove torque converter clutch solenoid,
spring, and plug as shown in (Fig. 319).
Fig. 319 Torque Converter Clutch Solenoid and Regulator/Control Valves
1 - CONVERTER PRESSURE CONTROL
VA LV E3 -

Page 1711 of 2399

CHRYSLER CARAVAN 2002 Service Manual (12) Remove shift/shuttle valves and springs as
shown in (Fig. 320).
CLEANING
Clean the valve body components in a parts clean-
ing solution only. Do not use gasoline, kerosene, or
any type of caustic

Page 1712 of 2399

CHRYSLER CARAVAN 2002 Service Manual valve or plug edges. Squareness of these edges is
vitally important. These edges prevent foreign matter
from lodging between the valves, plugs and bore.
INSPECTION
Inspect the throttle and manual valv

valve or plug edges. Squareness of these edges is
vitally important. These edges prevent foreign matter
from lodging between the valves, plugs and bore.
INSPECTION
Inspect the throttle and manual valve levers and
shafts. Do not attempt to straighten a bent shaft or
correct a loose lever. Replace these components if
worn, bent, loose or damaged in any way.
Inspect all of the valve body mating surfaces for
scratches, nicks, burrs, or distortion. Use a straight-
edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light
pressure.
Inspect the valves and plugs for scratches, burrs,
nicks, or scores. Also inspect the coating on the alu-
minum valves and plugs. If the coating is damaged
or worn through, the valve (or valve body) should be
replaced.
Inspect all the valve and plug bores in the valve
body. Use a penlight to view the bore interiors.
Replace the valve body if any bores are distorted or
scored. Inspect all of the valve body springs. The
springs must be free of distortion, warpage or broken
coils.
Trial fit each valve and plug in its bore to check
freedom of operation. When clean and dry, the valves
and plugs should drop freely into the bores. Valve
body bores do not change dimensionally with use. If
the valve body functioned correctly when new, it will
continue to operate properly after cleaning and
inspection. It should not be necessary to replace a
valve body assembly unless it is damaged in han-
dling.
ASSEMBLY
(1) Install shift/shuttle valves and springs as
shown in (Fig. 320).
(2) Install torque converter clutch solenoid, spring,
and plug as shown in (Fig. 319).
(3) Install governor plugs as shown in (Fig. 318).
(4) Install pressure regulator and manual control
springs and valves as shown in (Fig. 317).
(5) Install pressure regulator spring retainer/ad-
justing screw bracket (Fig. 321).
(6) Install manual valve from valve body (Fig.
322).
Fig. 321 Pressure Regulator and Adjusting Screw
Bracket
1 - SCREWDRIVER HANDLE
2 - PRESSURE REGULATOR SPRING RETAINER AND
ADJUSTING SCREW BRACKET
3 - VALVE BODY
4 - SCREWS
Fig. 322 Install Manual Valve
1 - MANUAL VALVE
2 - VALVE BODY
RS31TH AUTOMATIC TRANSAXLE21 - 155
VALVE BODY (Continued)
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