2003 CHRYSLER CARAVAN ESP

OPERATION
The function of an accumulator is to cushion the
application of a frictional clutch element. When pres-
surized fluid is applied to a clutch circuit, the appli-
cation force is dampened by fluid collecting in the
respective accumulator chamber against the piston
and spring(s). The intended result is a smooth, firm
clutch application.
AUTOSTICK SWITCH
DESCRIPTION
Autostick is a driver-interactive transaxle feature
that offers manual gear shifting capability. The control
switch is part of the transaxle gear shift lever as
shown in (Fig. 171). It can only be serviced by replac-
ing the gearshift lever assembly. (Refer to 19 - STEER-
ING/COLUMN/GEAR SHIFT LEVER - REMOVAL)
OPERATION
When the shift lever is moved into the Autostick
position (as indicated by the Shift Lever Position
Indicator in the cluster), the transaxle remains in
whatever gear it was using before Autostick was acti-
vated. The TCM sends a 5 volt signal through the
switch and then monitors the signal for voltage drop.
Each switch state (driver command) results in a spe-
cific voltage reading sensed by the TCM. The TCM
then determines transaxle operation (upshift/down-
shift/OD Lockout) based on their corresponding volt-
age. Refer to the following chart for corresponding
switch states and voltage readings:
Switch State Voltage Reading
Autostick DOWN
depressed0.3V-1.6V
Autostick UP depressed 1.6V-2.8V
Overdrive OFF9Lockout9
depressed2.8V-3.8V
All switches open 3.8V-4.8V
-Voltage values <.3V and >4.8V are considered
INVALID and will result in a DTC
Fig. 169 Low/Reverse Accumulator Assembly
1 - ACCUMULATOR PISTON
2 - SEAL RINGS
3 - RETURN SPRINGS
4 - (NOTE NOTCH)
Fig. 170 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - SPRINGS
5 - SEALS
6 - PISTON
Fig. 171 Autostick Switch Location (if equipped)
RS41TE AUTOMATIC TRANSAXLE21 - 189
ACCUMULATOR (Continued)
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Moving the switch up causes an upshift and moving
the switch down causes a downshift. The instrument
cluster will illuminate the selected gear. The vehicle
can be launched in 1st, 2nd, or 3rd gear while in the
Autostick mode. The speed control is operable in 3rd
and 4th gear Autostick mode. Speed control will be
deactivated if the transaxle is shifted to 2nd gear.
Shifting into OD position cancels the Autostick mode,
and the transaxle resumes the OD shift schedule.
DRIVING CLUTCHES
DESCRIPTION
Three hydraulically applied input clutches are used
to drive planetary components. The underdrive, over-
drive, and reverse clutches are considered input
clutches and are contained within the input clutch
assembly (Fig. 172). The input clutch assembly also
contains:
²Input shaft
²Input hub
²Clutch retainer
²Underdrive piston
²Overdrive/reverse piston
²Overdrive hub
²Underdrive hub
OPERATION
The three input clutches are responsible for driving
different components of the planetary geartrain.
NOTE: Refer to the ªElements In Useº chart in Diag-
nosis and Testing for a collective view of which
clutch elements are applied at each position of the
selector lever.
UNDERDRIVE CLUTCH
The underdrive clutch is hydraulically applied in
first, second, and third (direct) gears by pressurized
fluid against the underdrive piston. When the under-
drive clutch is applied, the underdrive hub drives the
rear sun gear.
OVERDRIVE CLUTCH
The overdrive clutch is hydraulically applied in
third (direct) and overdrive gears by pressurized fluid
against the overdrive/reverse piston. When the over-
drive clutch is applied, the overdrive hub drives the
front planet carrier.
REVERSE CLUTCH
The reverse clutch is hydraulically applied in
reverse gear only by pressurized fluid against the
overdrive/reverse piston. When the reverse clutch is
applied, the front sun gear assembly is driven.
FINAL DRIVE
DISASSEMBLY
NOTE: The differential is serviced as an assembly.
Differential service is limited to bearing cups and
cones. Any other differential component failure
must be remedied by differential assembly and
transfer shaft replacement.
Fig. 172 Input Clutch Assembly
1 - INPUT SHAFT
2 - UNDERDRIVE CLUTCH
3 - OVERDRIVE CLUTCH
4 - REVERSE CLUTCH
5 - OVERDRIVE SHAFT
6 - UNDERDRIVE SHAFT
21 - 190 41TE AUTOMATIC TRANSAXLERS
AUTOSTICK SWITCH (Continued)
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A conventional mechanical interlock system is also
used. This system manually prohibits shifter move-
ment when the ignition switch is in the LOCK or
ACC positions. Solenoid operation is not required in
these key positions.
For intended BTSI system operation, refer to the
following chart:
ACTION EXPECTED RESPONSE
1. Turn key to the9OFF9
position.1. Shifter CAN be shifted
out of park with brake
pedal applied.
2. Turn key to the
9ON/RUN9position.2. Shifter CANNOT be
shifted out of park.
3. Turn key to the
9ON/RUN9position and
depress the brake pedal.3. Shifter CAN be shifted
out of park.
4. Leave shifter in any
gear and try to return key
to the9LOCK9or9ACC9
position.4. Key cannot be
returned to the9LOCK9or
9ACC9position.
5. Return shifter to
9PARK9and try to remove
the key.5. Key can be removed
(after returning to9LOCK9
position).
6. With the key removed,
try to shift out of9PARK9.6. Shifter cannot be
shifted out of9PARK9.
NOTE: Any failure to meet these expected
responses requires system adjustment or repair.
Fig. 293 Ignition Key/Switch Positions
1 - ACC
2 - LOCK
3 - OFF
4 - ON/RUN
5-START
Fig. 294 Pawl Engaged to Shift Lever
1 - GEAR SHIFT LEVER
2 - GEAR SHIFT LEVER PAWL
Fig. 295 Pawl Disengaged From Shift Lever
1 - GEAR SHIFT LEVER
2 - GEAR SHIFT LEVER PAWL
21 - 234 41TE AUTOMATIC TRANSAXLERS
SHIFT INTERLOCK SOLENOID (Continued)
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DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK SOLENOID
For intended BTSI system operation, refer to the
following chart:
ACTION EXPECTED RESPONSE
1. Turn key to the9OFF9
position.1. Shifter CAN be shifted
out of park with brake
pedal applied.
2. Turn key to the
9ON/RUN9position.2. Shifter CANNOT be
shifted out of park.
3. Turn key to the
9ON/RUN9position and
depress the brake pedal.3. Shifter CAN be shifted
out of park.
4. Leave shifter in any
gear and try to return key
to the9LOCK9or9ACC9
position.4. Key cannot be
returned to the9LOCK9or
9ACC9position.
5. Return shifter to
9PARK9and try to remove
the key.5. Key can be removed
(after returning to9LOCK9
position).
6. With the key removed,
try to shift out of9PARK9.6. Shifter cannot be
shifted out of9PARK9.
NOTE: Any failure to meet these expected
responses requires system repair. Refer to the
appropriate Diagnostic Information.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove instrument panel lower shroud (Fig.
296).(3) Remove knee bolster (Fig. 297).
(4) Remove steering column lower shroud.
(5) Disconnect brake/transmission shift interlock
(BTSI) solenoid connector (Fig. 298).
(6) Remove two (2) solenoid-to-column screws (Fig.
299).
(7) Remove solenoid.
Fig. 296 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 297 Knee Bolster
1 - KNEE BOLSTER
Fig. 298 BTSI Solenoid Connector
1 - BTSI SOLENOID
2 - SOLENOID CONNECTOR
RS41TE AUTOMATIC TRANSAXLE21 - 235
SHIFT INTERLOCK SOLENOID (Continued)
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Since there are four switches, there are 16 possible
combinations of open and closed switches (codes).
Seven of these codes are related to gear position and
three are recognized as ªbetween gearº codes. This
results in six codes which should never occur. These
are called ªinvalidº codes. An invalid code will result
in a DTC, and the PCM/TCM will then determine the
shift lever position based on pressure switch data.
This allows reasonably normal transmission opera-
tion with a TRS failure.
TRS SWITCH STATES
SLP T42 T41 T3 T1
PCL CL CL OP
RCL OP OP OP
NCL CL OP CL
ODOP OP OP CL
3OP OP CL OP
LCL OP CL CL
TRANSMISSION TEMPERATURE SENSOR
The TRS has an integrated thermistor (Fig. 329)
that the PCM/TCM uses to monitor the transmis-
sion's sump temperature. Since fluid temperature
can affect transmission shift quality and convertor
lock up, the PCM/TCM requires this information to
determine which shift schedule to operate in. The
PCM also monitors this temperature data so it can
energize the vehicle cooling fan(s) when a transmis-
sion ªoverheatº condition exists. If the thermistor cir-
cuit fails, the PCM/TCM will revert to calculated oil
temperature usage.
CALCULATED TEMPERATURE
A failure in the temperature sensor or circuit will
result in calculated temperature being substituted for
actual temperature. Calculated temperature is a pre-
dicted fluid temperature which is calculated from a
combination of inputs:
²Battery (ambient) temperature
²Engine coolant temperature
²In-gear run time since start-up
REMOVAL
(1) Remove valve body assembly from transaxle.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/VALVE BODY - REMOVAL)
(2) Remove transmission range sensor retaining
screw and remove sensor from valve body (Fig. 330).
(3) Remove TRS from manual shaft.
INSTALLATION
(1) Install transmission range sensor (TRS) to the
valve body and torque retaining screw (Fig. 330) to 5
N´m (45 in. lbs.).
(2) Install valve body to transaxle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
41TE/VALVE BODY - INSTALLATION)
TRD LINK
DESCRIPTION
The Torque Reduction Link (TRD) is a wire
between the PCM and TCM that is used by the TCM
to request torque management. Torque management
controls or reduces torque output of the engine dur-
ing certain shift sequences, reducing torque applied
to the transaxle clutches.
OPERATION
The torque management signal is basically a
12-volt pull-up supplied by the PCM to the TCM over
the torque reduction link (TRD). Torque management
is requested when the TCM pulses this signal to
ground. The PCM recognizes this request and
responds by retarding ignition timing, killing fuel
injectors, etc. The PCM sends a confirmation of the
request to the TCM via the communication bus.
Torque reduction is not noticable by the driver, and
usually lasts for a very short period of time.
If the confirmation signal is not received by the
TCM after two sequential request messages, a diag-
nostic trouble code will be set.
Fig. 330 Remove Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
RS41TE AUTOMATIC TRANSAXLE21 - 249
TRANSMISSION RANGE SENSOR (Continued)
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MANUAL VALVE
The manual valve is operated by the mechanical
shift linkage. Its primary responsibility is to send
line pressure to the appropriate hydraulic circuits
and solenoids. The valve has three operating ranges
or positions.
CONVERTER CLUTCH SWITCH VALVE
The main responsibility of the converter clutch
switch valve is to control hydraulic pressure applied
to the front (off) side of the converter clutch piston.
Line pressure from the regulator valve is fed to the
torque converter regulator valve, where it passes
through the valve, and is slightly regulated. The
pressure is then directed to the converter clutch
switch valve and to the front side of the converter
clutch piston. This pressure pushes the piston back
and disengages the converter clutch.
CONVERTER CLUTCH CONTROL VALVE
The converter clutch control valve controls the
back (on) side of the torque converter clutch. When
the PCM/TCM energizes or modulates the LR/CC
solenoid to apply the converter clutch piston, both
the converter clutch control valve and the converter
control valve move, allowing pressure to be applied to
the back side of the clutch.
T/C REGULATOR VALVE
The torque converter regulator valve slightly regu-
lates the flow of fluid to the torque converter.
LOW/REVERSE SWITCH VALVE
The low/reverse clutch is applied from different
sources, depending on whether low (1st) gear or
reverse is selected. The low/reverse switch valve
alternates positions depending on from which direc-
tion fluid pressure is applied. By design, when the
valve is shifted by fluid pressure from one channel,
the opposing channel is blocked. The switch valve
alienates the possibility of a sticking ball check, thus
providing consistent application of the low/reverse
clutch under all operating conditions.
REMOVAL
NOTE: If valve body is replaced or reconditioned,
the TCM Quick Learn Procedure must be per-
formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)(1) Disconnect battery negative cable.
(2) Disconnect gearshift cable from manual valve
lever.
(3) Remove manual valve lever from manual shaft.
(4) Raise vehicle on hoist.
(5) Remove oil pan bolts (Fig. 332).
(6) Remove oil pan (Fig. 333).
Fig. 332 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 333 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
RS41TE AUTOMATIC TRANSAXLE21 - 251
VALVE BODY (Continued)
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testing must be performed as outlined in previous
sections of this diagnosis and testing procedure.
Use the Radial Force equipment to identify suspect
assemblies and minimize the radial forces. After all
suspect assemblies are optimized, reinstall the
assemblies and road test the vehicle. If a disturbance
still exists and all other vibration diagnostic proce-
dures have been completed, replace one tire or one
wheel at a time, starting with the assembly having
the highest force variation. Be sure to minimize each
new assembly. Road test the vehicle following each
replacement. Continue this process until the distur-
bance is resolved.
NOTE: When using Radial Force equipment, it is
critically important to set proper tire inflation pres-
sure and ensure centering of the wheel on the
equipment spindle.
RADIAL FORCE VARIATION REFERENCE
VALUES
DESCRIPTION SPECIFICATION
Total Radial Force
Variation (RFV)Less Than 22 Lbs.   2
Lbs.
Radial First Harmonic
(R1H)Less Than 16 Lbs.   2
Lbs.
Radial Second Harmonic
(R2H)Less Than 12 Lbs.   2
Lbs.
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE AND WHEEL
BALANCE
NOTE: Balance equipment must be calibrated and
maintained per equipment manufacturer's specifica-
tions.
Wheel balancing can be accomplished with either
on-vehicle or off-vehicle equipment.
NOTE: If using on-vehicle balancing equipment, on
the driving axle, remove the opposite wheel and tire
assembly.It is recommended that a two-plane dynamic bal-
ancer be used when a wheel and tire assembly
requires balancing. A static balancer should only be
used when a two-plane balancer is not available.
Balance wheel and tire assemblies dynamically and
statically to less than 0.25 (
1¤4) ounce.
For static balancing, find location of heavy spot
causing imbalance. Counter balance wheel directly
opposite the heavy spot. Determine weight required
to counterbalance the area of imbalance. Place half of
this weight on theinnerrim flange and the other
half on theouterrim flange (Fig. 8).
For dynamic balancing, the balance equipment is
designed to indicate the location and amount of
weight to be applied to both the inner and outer rim
flanges (Fig. 9).
The aluminum wheels on this vehicle use a unique
wheel weight (Fig. 10). This wheel weight is designed
to fit the contoured surface of the wheel (Fig. 10).
When balancing an aluminum wheel, this wheel
weight must be used. Do not use any other type of
wheel weight. It will not properly fit the contour of
the wheel.
Always verify the Balance. When using off-vehicle
equipment, rotate assembly 180 degrees on balance
equipment to verify balance. Variation should not be
more than 0.125 (
1¤8) ounce. If variation is more than
0.125 ounce, balancing equipment could be malfunc-
tioning.
If difficult to balance, break down the wheel and
tire assembly and check for loose debris inside tire.
Prior to disassembly, mark (index) the tire at the
valve stem. Use this mark in order to remount the
tire in its original orientation with respect to the
wheel.
RSTIRES/WHEELS22-5
TIRES/WHEELS (Continued)
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STANDARD PROCEDURE - TIRE AND WHEEL
MATCH MOUNTING
Wheels and tires are match mounted at the factory.
This means that the high spot of the tire is matched
to the low spot on the wheel rim. This technique is
used to reduce runout in the wheel and tire assem-
bly. The high spot on the tire is marked with a paint
mark or a bright colored adhesive label on the out-
board sidewall. The low spot on the wheel is identi-
fied with a label on the outside of the rim and a dot
or line in the drop well area of the rim (inside where
the tire mounts). If the outside label has been
removed, the tire will have to be removed to locate
the dot or line on the inside of the rim. The tire can
then be match mounted to the tire.
Information on match mounting the tire to the
wheel can be found in Tire and Wheel Runout/Match
Mounting, items (2) through (5), within Diagnosis
And Testing - Tire And Wheel Vibration. (Refer to 22
- TIRES/WHEELS - DIAGNOSIS AND TESTING)
STANDARD PROCEDURE - TIRE AND WHEEL
ROTATION
NON-DIRECTIONAL TREAD PATTERN TIRES
Tires on the front and rear axles operate at differ-
ent loads and perform different functions. For these
reasons, they wear at unequal rates, and tend to
develop irregular wear patterns. These effects can be
reduced by timely rotation of tires. The benefits of
rotation are especially worthwhile. Rotation will
increase tread life, help to maintain mud, snow, and
wet traction levels, and contribute to a smooth, quiet
ride.
The suggested rotation method is the forward-cross
tire rotation method (Fig. 11). This method takesadvantage of current tire industry practice which
allows rotation of radial-ply tires. Other rotation
methods may be used, but may not have all the ben-
efits of the recommended method.
NOTE: Only the 4 tire rotation method may be used
if the vehicle is equipped with a low mileage or tem-
porary spare tire.
DIRECTIONAL TREAD PATTERN TIRES
Some vehicles are fitted with special high-perfor-
mance tires having a directional tread pattern. These
tires are designed to improve traction on wet pave-
ment. To obtain the full benefits of this design, the
tires must be installed so that they rotate in the cor-
rect direction. This is indicated by arrows on the tire
sidewalls.
When wheels and tires are being installed, extra
care is needed to ensure that this direction of rota-
tion is maintained.
Refer to Owner's Manual for rotation schedule.
REMOVAL
REMOVAL - TIRE AND WHEEL ASSEMBLY
(ALUMINUM WHEEL)
(1) Raise the vehicle so the tire and wheel assem-
bly clears ground level.
(2) Remove the 5 wheel mounting nuts from the
studs.
(3) Remove the tire and wheel from the hub.
Fig. 10 Aluminum Wheel Weight
1 - TIRE
2 - WHEEL
3 - WHEEL WEIGHT
Fig. 11 Forward-Cross Tire Rotation Method
RSTIRES/WHEELS22-7
TIRES/WHEELS (Continued)
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