2002 CHRYSLER CARAVAN shaft

(13) Install halfshafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(14) Lower vehicle.
(15) Torque rear mount bracket-to-transaxle verti-
cal bolts (Fig. 98) to 102 N´m (75 ft. lbs.).
(16) Connect back up lamp switch connector.
(17) Connect gearshift cable to manual valve and
left upper mount bracket (Fig. 102).
(18) Connect throttle valve cable to lever and
bracket (Fig. 103).
(19) Connect torque converter clutch connector.
(20) Install fluid level indicator/tube assembly
(Fig. 104).
(21) Raise vehicle on hoist.
(22) Torque rear mount bracket-to-transaxle case
horizontal bolt (Fig. 98) to 102 N´m (75 ft. lbs.).
(23) Torque rear mount thru-bolt to 54 N´m (40 ft.
lbs.).
(24) Lower vehicle.
(25) Connect battery negative cable.
(26) Fill transaxle with ATF+4 transmission fluid.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/FLUID - STANDARD PROCEDURE)
Fig. 102 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 103 Kickdown Cable at TransaxleÐTypical
1 - LEVER
2 - BRACKET
3 - THROTTLE VALVE CABLE
Fig. 104 Fluid Level Indicator Assembly
1 - INDICATOR ASSEMBLY
2 - BOLT
3 - KICKDOWN CABLE BRACKET
4 - SEAL
RS31TH AUTOMATIC TRANSAXLE21-63
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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OIL PUMP CLEARANCE
Description Metric Standard
Outer Gear-to-Pocket 0.045-0.141mm 0.0018-0.0056 in.
Outer Gear Side Clearance 0.020-0.046mm 0.0008-0.0018 in.
Inner Gear Side Clearance 0.020-0.046mm 0.0008-0.0018 in.
THRUST WASHERS
Description Metric Standard
Reaction Shaft Support (No. 1) 1.34-1.62 mm 0.053-0.064 in.
Rear Clutch Retainer (No. 2) 1.53-1.62 mm 0.060-0.064 in.
Output Shaft (No. 3) (Select) 1.96-2.03 mm 0.077-0.080 in
Output Shaft (No. 3) (Select) 2.15-2.22 mm 0.085-0.087 in.
Output Shaft (No. 3) (Select) 2.34-2.41 mm 0.092-0.095 in.
Front Annulus (No. 4) 2.95-3.05 mm 0.116-0.120 in.
Front Carrier (Nos. 5&6) 1.21-1.28 mm 0.048-0.050 in.
Sun Gear-Front (No. 7) 0.85-0.91 mm 0.033-0.036 in
Sun Gear-Rear (No. 8) 0.85-0.91 mm 0.033-0.036 in.
Rear Carrier (Nos. 9&10) 1.21-1.28 mm 0.048-0.050 in.
Rev. Drum (No. 11) 1.53-1.62 mm 0.060-0.064 in.
RS31TH AUTOMATIC TRANSAXLE21-73
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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CLUTCH - FRONT
DESCRIPTION
The front clutch assembly (Fig. 119) is composed of
the front clutch retainer, pressure plate, clutch
plates, driving discs, piston, piston return spring,
return spring retainer, and snap-rings. The front
clutch is the forward-most component in the trans-
mission geartrain and is directly behind the oil
pump. It is considered a driving component.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
OPERATION
To apply the clutch, pressure is applied between
the clutch retainer and piston. The fluid pressure is
provided by the oil pump, transferred through the
control valves and passageways, and enters the
clutch through the hub of the reaction shaft support.
With pressure applied between the clutch retainer
and piston, the piston moves away from the clutch
retainer and compresses the clutch pack. This action
applies the clutch pack, allowing torque to flow
through the input shaft into the driving discs, and
into the clutch plates and pressure plate that are
lugged to the clutch retainer. The waved snap-ring is
used to cushion the application of the clutch pack. In
some transmissions, the snap-ring is selective and
used to adjust clutch pack clearance.
When pressure is released from the piston, the
spring returns the piston to its fully released position
and disengages the clutch. The release spring also
helps to cushion the application of the clutch assem-
bly. When the clutch is in the process of being
released by the release spring, fluid flows through a
vent and one-way ball-check-valve located in the
clutch retainer. The check-valve is needed to elimi-
nate the possibility of plate drag caused by centrifu-
gal force acting on the residual fluid trapped in the
clutch piston retainer.
DISASSEMBLY
(1) Remove front clutch waved snap ring using a
suitable screwdriver (Fig. 114).
(2) Remove waved snap ring and reaction plate
(Fig. 115).
Fig. 114 Front Clutch Waved Snap Ring
1 - WAVED SNAP RING
2 - SCREWDRIVER
3 - FRONT CLUTCH ASSEMBLY
Fig. 115 Thick Steel Plate and Waved Snap Ring
1 - WAVED SNAP RING
2 - THICK STEEL PLATE
3 - FRONT CLUTCH RETAINER
21 - 82 31TH AUTOMATIC TRANSAXLERS
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(5) Using feeler gauge, measure front clutch clear-
ance (Fig. 125).Front clutch clearance should be
within 1.27-2.79 mm (0.050-0.110 in.) and is not
adjustable.
CLUTCH - REAR
DESCRIPTION
The rear clutch assembly (Fig. 132) is composed of
the input shaft, rear clutch retainer, pressure plate,
clutch plates, driving discs, piston, Belleville spring,
and snap-rings. The Belleville spring acts as a lever
to multiply the force applied on to it by the apply pis-
ton. The increased apply force on the rear clutch
pack, in comparison to the front clutch pack, is
needed to hold against the greater torque load
imposed onto the rear pack. The rear clutch is
directly behind the front clutch and is considered a
driving component.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
OPERATION
To apply the clutch, pressure is applied between
the clutch retainer and piston. The fluid pressure is
provided by the oil pump, transferred through the
control valves and passageways, and enters the
clutch through the hub of the reaction shaft support.
With pressure applied between the clutch retainer
and piston, the piston moves away from the clutch
retainer and compresses the clutch pack. This action
applies the clutch pack, allowing torque to flow
through the input shaft into the driving discs, and
into the clutch plates and pressure plate that are
lugged to the clutch retainer. The waved snap-ring is
used to cushion the application of the clutch pack. In
some transmissions, the snap-ring is selective and
used to adjust clutch pack clearance.
When pressure is released from the piston, the
spring returns the piston to its fully released position
and disengages the clutch. The release spring also
helps to cushion the application of the clutch assem-
bly. When the clutch is in the process of being
released by the release spring, fluid flows through a
vent and one-way ball-check-valve located in the
clutch retainer. The check-valve is needed to elimi-
nate the possibility of plate drag caused by centrifu-
gal force acting on the residual fluid trapped in the
clutch piston retainer.
Fig. 124 Front Clutch Waved Snap Ring
1 - WAVED SNAP RING
2 - SCREWDRIVER
3 - FRONT CLUTCH ASSEMBLY
Fig. 125 Measuring Front Clutch Plate Clearance
1 - FEELER GAUGE
2 - FRONT CLUTCH ASSEMBLY
21 - 86 31TH AUTOMATIC TRANSAXLERS
CLUTCH - FRONT (Continued)
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(4) Remove rear clutch piston and belleville spring
(Fig. 129).
Remove input shaft-to-clutch retainer snap ring
(Fig. 130) (Fig. 131). Press input shaft out of retainer
if necessary.
Fig. 129 Rear Clutch Piston and Piston Spring
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - PISTON SPRING
4 - WAVED SNAP RING
5 - PISTON
6 - PISTON SEALS
Fig. 130 Input Shaft Snap Ring
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - SNAP RING PLIERS
4 - SNAP RING
Fig. 131 Input Shaft Snap Ring
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - SNAP RING
21 - 88 31TH AUTOMATIC TRANSAXLERS
CLUTCH - REAR (Continued)
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