2002 CHRYSLER TOWN AND COUNTRY oil

CONDITION POSSIBLE CAUSES CORRECTION
GROWLING, GRATING OR
SCRAPING NOISES1. Drive Plate Broken. 1. Replace.
2. Torque Converter Bolts Hitting
Dust Shield.2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/
Seized.3. Check for debris in oil pan and repair as
required.
4. Overrunning Clutch Worn/Broken. 4. Inspect and check for debris in oil pan.
Repair as required.
5. Oil Pump Components Scored/
Binding.5. Remove, inspect and repair as required.
6. Output Shaft Bearing or Bushing
Damaged.6. Remove, inspect and repair as required.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair as
required.
8. Front and Rear Bands
Misadjusted.8. Adjust bands.
DRAGS OR LOCKS UP 1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed 2. Air pressure check clutch operation and
repair as required.
3. Front or Rear Band Misadjusted. 3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages in
case.
5. Servo Band or Linkage
Malfunction.5. Air pressure check servo operation and
repair as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as
required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as required
(look for debris in oil pan).
WHINE/NOISE RELATED
TO ENGINE SPEED1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing.
Should not touch engine or bell housing.
TORQUE CONVERTER
LOCKS UP IN SECOND
AND/OR THIRD GEARLockup Solenoid, Relay or Wiring
Shorted/Open.Test solenoid, relay and wiring for
continuity, shorts or grounds. Replace
solenoid and relay if faulty. Repair wiring
and connectors as necessary.
HARSH 1-2 OR 2-3
SHIFTSLockup Solenoid Malfunction. Remove valve body and replace solenoid
assembly.
NO START IN PARK OR
NEUTRAL1. Gearshift Linkage/Cable
Misadjusted.1. Adjust linkage/cable.
2. Neutral Switch Wire Open/Cut. 2. Check continuity with test lamp. Repair
as required.
3. Neutral Switch Faulty. 3. Refer to service section for test and
replacement procedure.
4. Neutral Switch Connect Faulty. 4. Connectors spread open. Repair.
5. Valve Body Manual Lever
Assembly Bent/Worn/Broken.5. Inspect lever assembly and replace if
damaged.
21 - 30 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

CONDITION POSSIBLE CAUSES CORRECTION
NO REVERSE (OR SLIPS
IN REVERSE)1. Direct Clutch Pack (front clutch)
Worn.1. Disassemble unit and rebuild clutch
pack.
2. Rear Band Misadjusted. 2. Adjust band.
3. Front Clutch Malfunctioned/Burnt. 3. Air pressure test clutch operation.
Remove and rebuild if necessary.
OIL LEAKS (ITEMS
LISTED REPRESENT
POSSIBLE LEAK POINTS
AND SHOULD ALL BE
CHECKED.1. Fluid Lines and Fittings Loose/
Leaks/Damaged.1. Tighten fittings. If leaks persist, replace
fittings and lines if necessary.
2. Filler Tube (where tube enters
case) Leaks/Damaged.2. Replace tube seal. Inspect tube for
cracks in tube.
3. Pressure Port Plug Loose
Loose/Damaged.3. Tighten to correct torque. Replace plug
or reseal if leak persists.
4. Pan Gasket Leaks. 4. Tighten pan screws to 150 inch pounds.
If leaks persist, replace gasket. Do no over
tighten screws.
5. Valve Body Manual Lever Shaft
Seal Leaks/Worn.5. Replace shaft seal.
6. Rear Bearing Access Plate Leaks. 6. Replace gasket. Tighten screws.
7. Gasket Damaged or Bolts are
Loose.7. Replace bolts or gasket or tighten both.
8. Adapter/Extension Gasket
Damaged Leaks/Damaged.8. Replace gasket.
9. Neutral Switch Leaks/Damaged. 9. Replace switch and gasket.
10. Converter Housing Area Leaks. 10. Check for leaks at seal caused by worn
seal or burr on converter hub (cutting seal),
worn bushing, missing oil return, oil in front
pump housing or hole plugged. Check for
leaks past O-ring seal on pump or past
pump-to-case bolts; pump housing porous,
oil coming out vent due to overfill or leak
past front band shaft access plug.
11. Pump Seal Leaks/Worn/
Damaged.11. Replace seal.
12. Torque Converter Weld
Leak/Cracked Hub.12. Replace converter.
13. Case Porosity Leaks. 13. Replace case.
DIAGNOSIS AND TESTING - ROAD TEST
Prior to performing a road test, check the fluid
level and throttle valve cable adjustments.
During the road test, the transaxle should be oper-
ated in each position to check for slipping and any
variation in shifting.
If vehicle operates at high speeds, but has poor
acceleration, the converter's overrunning clutch may
be slipping. If acceleration is normal, but high throt-
tle opening is needed for high speeds, the stator
clutch may have seized.Observe closely for slipping or engine speed flare-
up. Slipping or flare-up in any gear usually indicates
clutch, band, or overrunning clutch problems. If the
condition is far advanced, an overhaul will probably
be necessary to restore normal operation.
In most cases, the clutch or band that is slipping
can be determined by noting the transaxle operation
in all selector positions and then comparing which
internal units are applied in those positions. The Ele-
ments±in±Use Chart provides a basis for road test
analysis.
RS31TH AUTOMATIC TRANSAXLE21-31
31TH AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE
When diagnosing converter housing fluid leaks,
three actions must be taken before repair:
(1) Verify proper transmission fluid level.
(2) Verify that the leak originates from the con-
verter housing area and is transmission fluid.
(3) Determine the true source of the leak.
Fluid leakage at or around the torque converter
area may originate from an engine oil leak (Fig. 3).
The area should be examined closely. Factory fill
fluid is red and, therefore, can be distinguished from
engine oil.
Some suspected converter housing fluid leaks may
not be leaks at all. They may only be the result of
residual fluid in the converter housing, or excess
fluid spilled during factory fill, or fill after repair.
Converter housing leaks have several potential
sources. Through careful observation, a leak source
can be identified before removing the transmission
for repair.
Pump seal leaks tend to move along the drive hub
and onto the rear of the converter (Fig. 3). Pump
o-ring or pump body leaks follow the same path as a
seal leak. Pump attaching bolt leaks are generally
deposited on the inside of the converter housing and
not on the converter itself. Pump seal or gasket leaks
usually travel down the inside of the converter hous-
ing (Fig. 3).
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
²Torque converter weld leaks at the outside diam-
eter weld (Fig. 4).
²Torque converter hub weld (Fig. 4).
DIAGNOSIS AND TESTING - CLUTCH AND
SERVO AIR PRESSURE TESTS
A no drive condition might exist even with correct
fluid pressure, because of inoperative clutches or
bands. The inoperative units, clutches, bands, and
servos can be located through a series of tests. This
is done by substituting air pressure for fluid pressure
(Fig. 5).
The front and rear clutches, kickdown servo, and
low-reverse servo may be tested by applying air pres-
sure to their respective passages. To make air pres-
sure tests, proceed as follows:
NOTE: Compressed air supply must be free of all
dirt or moisture. Use a pressure of 30 psi.
Remove oil pan and valve body. Refer to Valve
Body for removal procedure.
FRONT CLUTCH
Apply air pressure to front clutch apply passage
and listen for a dull thud which indicates that front
clutch is operating. Hold air pressure on for a few
seconds and inspect system for excessive oil leaks.
Fig. 3 Converter Housing Leak Paths
1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK
Fig. 4 Converter Leak PointsÐTypical
1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG
RS31TH AUTOMATIC TRANSAXLE21-35
31TH AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

REAR CLUTCH
Apply air pressure to rear clutch apply passage
and listen for a dull thud which indicates that rear
clutch is operating. Also inspect for excessive oil
leaks. If a dull thud cannot be heard in the clutches,
place finger tips on clutch housing and again apply
air pressure. Movement of piston can be felt as the
clutch is applied.
KICKDOWN SERVO (FRONT)
Direct air pressure into KICKDOWN SERVO ON
passage. Operation of servo is indicated by a tighten-
ing of front band. Spring tension on servo piston
should release the band.
LOW AND REVERSE SERVO (REAR)
Direct air pressure into LOW-REVERSE SERVO
APPLY passage. Operation of servo is indicated by a
tightening of rear band. Spring tension on servo pis-
ton should release the band.
If clutches and servos operate properly, no upshift
indicates that a malfunction exists in the valve body.
Fig. 5 Air Pressure Tests
1 - PUMP SUCTION 7 - TO OIL COOLER 13 - GOVERNOR PRESSURE
2 - PUMP PRESSURE 8 - KICKDOWN SERVO OFF 14 - LINE PRESSURE TO GOVERNOR
3 - FRONT CLUTCH APPLY 9 - KICKDOWN SERVO ON 15 - GOVERNOR PRESSURE PLUG
4 - REAR CLUTCH APPLY 10 - ACCUMULATOR OFF 16 - GOVERNOR PRESSURE
5 - TO TORQUE CONVERTER 11 - ACCUMULATOR ON 17 - BYPASS VALVE BORE
6 - FROM TORQUE CONVERTER 12 - LOW-REVERSE SERVO APPLY
21 - 36 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
axle 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 tap-
ping 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 suppli-
ers.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove fluid level indicator tube bolt and tube/
indicator assembly (Fig. 6). Plug opening to prevent
debris intrusion.
(3) Disconnect torque converter clutch solenoid
(TCC) connector.
(4) Disconnect kickdown cable from lever and
bracket (Fig. 7). Position out of way.
(5) Disconnect gearshift cable from manual valve
lever and upper mount bracket (Fig. 8). Position out
of way.
(6) Disconnect back-up lamp switch connector.
(7) Remove upper two (2) transaxle-to-engine bolts.
Fig. 6 Fluid Level Indicator Assembly
1 - INDICATOR ASSEMBLY
2 - BOLT
3 - KICKDOWN CABLE BRACKET
4 - SEAL
Fig. 7 Throttle Valve Cable at Transaxle
1 - LEVER
2 - BRACKET
3 - THROTTLE VALVE CABLE
Fig. 8 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
RS31TH AUTOMATIC TRANSAXLE21-37
31TH AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(12) Remove front mount and bracket (Fig. 11).
(13) Cut transaxle oil cooler lines flush with fit-
tings. a service kit will be installed upon reintalla-
tion. Plug lines and fittings to prevent debris
intrusion.
(14) Remove structural collar (Fig. 12).
(15) Disconnect vehicle speed sensor connector.
(16) Remove rear mount shield (Fig. 13).
(17) Remove rear mount thru-bolt.
(18) Support engine with screw jack and wood
block.
(19) Remove torque converter-to-drive plate bolts.
(20) Remove left wheel splash shield.
Fig. 11 Front Mount and Bracket
1 - BRACKET - FRONT MOUNT
2 - NUT
3 - BOLT
4 - MOUNT - FRONT INSULATOR
5 - BOLT
6 - BOLT
7 - FRONT CROSSMEMBER
Fig. 12 Structural Collar
1 - BOLT - COLLAR TO OIL PAN
2 - BOLT - COLLAR TO TRANSAXLE
3 - STRUCTURAL COLLAR
4 - OIL PAN
Fig. 13 Rear Mount Heat Shield
1 - BOLT - HEAT SHIELD
2 - HEAT SHIELD
3 - CLIP
4 - REAR MOUNT
RS31TH AUTOMATIC TRANSAXLE21-39
31TH AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(21) Remove left upper mount thru-bolt (Fig. 14).
(22) Lower engine/transaxle assembly.
(23) Obtain transmission jack and helper.
(24) Remove remaining transaxle-to-engine bolts
and remove transaxle assembly from vehicle.
DISASSEMBLY
CAUTION: If transaxle failure has occured, 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 - COOL-
ING/TRANSMISSION - STANDARD PROCEDURE)
NOTE: This procedure does not include disassem-
bly of final drive (differential) components. (Refer to
21 - TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/FINAL DRIVE - DISASSEMBLY)
(1)
Measure input shaft end play before disassembly
using Tool 8266 and dial indicator C-3339 (Fig. 15):
(a) Set up tools as shown in (Fig. 15).
(b) Move input shaft in and out to obtain end
play reading. End play specifications are 0.19 to
1.50 mm (0.008 to 0.060 inch).
(c) Record indicator reading for reference when
reassembling the transaxle.
(2)
Remove transaxle oil pan-to-case bolts (Fig. 16).
Fig. 14 Left Rail-to-Mount
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
Fig. 15 Measure Input Shaft End Play using End
Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
Fig. 16 Transaxle Oil Pan Bolts
1 - TRANSAXLE OIL PAN
2 - OIL PAN BOLTS
21 - 40 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(3) Remove oil pan (Fig. 17). Clean sealing sur-
faces of old adhesive prior to reassembly.
(4) Remove oil filter-to-valve body screws (Fig. 18).(5) Remove oil filter and gasket (Fig. 19).
(6) Remove neutral starting and back-up lamp
switch.
(7) Remove park rod retainer e-clip (Fig. 20).
Fig. 17 Transaxle Oil Pan
1 - TRANSAXLE OIL PAN
2 - OIL FILTER
Fig. 18 Oil Filter Screws
1 - SCREWDRIVER HANDLE
2 - SPECIAL TOOL L-4553
3 - OIL FILTER SCREWS (2)
4 - OIL FILTER
Fig. 19 Oil Filter and Gasket
1 - OIL FILTER
2 - GASKET
3 - VALVE BODY
Fig. 20 Parking Rod E-Clip
1 - VALVE BODY
2 - SCREWDRIVER
3 - ªEº CLIP
4 - PARKING ROD
RS31TH AUTOMATIC TRANSAXLE21-41
31TH AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com