2005 CHRYSLER CARAVAN Service Manual

gas tank size parking sensors relay fuel consumption manual transmission service indicator

Page 1545 of 2339

CHRYSLER CARAVAN 2005 Service Manual (6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7)

(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 190).
(8) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.). Refer
to Fluid Level and Condition Check for the proper
fluid fill procedure.
(9) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
DIPSTICK TUBE FLUID SUCTION METHOD
(ALTERNATIVE)
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (VaculaŸ
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) through the dipstick opening.(7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 190).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/FLUID - STANDARD PROCEDURE)
(10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
GEAR SHIFT CABLE
REMOVAL
(1) Disconnect battery cables.
(2) Remove battery shield.
(3) Remove battery.
(4) Remove speed control servo and position out of
way.
(5) Disconnect gear shift cable at manual valve
lever (Fig. 191).
(6) Disconnect gear shift cable from upper mount
bracket (Fig. 191).
Fig. 190 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
Fig. 191 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 84 40TE AUTOMATIC TRANSAXLERS
FLUID (Continued)

Page 1546 of 2339

CHRYSLER CARAVAN 2005 Service Manual (7) Remove instrument panel lower silencer (Fig.
192).
(8) Remove knee bolster (Fig. 193).
(9) Disconnect gear shift cable from gear shift
lever (Fig. 194).
(10) Remove gear shift cable from column br

Page 1547 of 2339

CHRYSLER CARAVAN 2005 Service Manual HOLDING CLUTCHES
DESCRIPTION
Two hydraulically applied multi-disc clutches are
used to hold planetary geartrain components station-
ary while the input clutches drive others. The 2/4
and Low/Reverse c

Page 1548 of 2339

CHRYSLER CARAVAN 2005 Service Manual (4) Pry up and remove reverse clutch reaction
plate (Fig. 199).
(5) Remove reverse clutch pack (Fig. 200).Ta g
components for assembly identification.
Fig. 199 Pry Reverse Clutch Reaction Plate
1 - RE

Page 1549 of 2339

CHRYSLER CARAVAN 2005 Service Manual (6) Remove the OD/Reverse pressure plate snap
ring (Fig. 201).
(7) Remove OD/Reverse pressure plate (Fig. 201).
(8) Remove OD/Reverse pressure plate wave snap
ring (Fig. 201).
(9) Remove OD clutch pac

Page 1550 of 2339

CHRYSLER CARAVAN 2005 Service Manual (10) Remove and inspect OD and UD Shafts, as
well as #3 thrust washer and plate, and #2 needle
bearing (Fig. 202).
Fig. 202 Overdrive/Underdrive Shafts
1 - OVERDRIVE SHAFT
2 - #3 THRUST PLATE (3 TABS)

Page 1551 of 2339

CHRYSLER CARAVAN 2005 Service Manual (11) Remove the OD/UD reaction plate tapered
snap ring, reaction plate, and first friction disc (Fig.
203).
(12) Remove the UD clutch flat snap ring and rest
of UD clutch pack (Fig. 203).Tag clutch pa

Page 1552 of 2339

CHRYSLER CARAVAN 2005 Service Manual CAUTION: Compress return spring just enough to
remove or install snap ring.
(13) Using Tool 5059A and an arbor press, com-
press UD clutch piston/spring enough to remove snap
ring (Fig. 204) (Fig. 205

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