Eja 21

JA TRANSAXLE 21 - 1
TRANSAXLE
CONTENTS
page page
41TE TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . 42 NV T350 (A-578) MANUAL TRANSAXLE . . . . . . . 1
NV T350 (A-578) MANUAL TRANSAXLE
INDEX
page page
GENERAL INFORMATION GEARSHIFT MECHANISM REPLACEMENT . . . . . 6

GEAR RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SELECTOR LEVER . . . . . . . . . . . . . . . . . . . . . . . 7
GEARSHIFT PATTERN . . . . . . . . . . . . . . . . . . . . . 3 SHIFT SHAFT SEALS . . . . . . . . . . . . . . . . . . . . . . 8
NV T350 MANUAL TRANSAXLE . . . . . . . . . . . . . . 1 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 VEHICLE SPEED SENSOR DRIVE GEAR . . . . . . 6
SELECTION OF LUBRICANT . . . . . . . . . . . . . . . . 2 DISASSEMBLY AND ASSEMBLY
SPECIAL ADDITIVES . . . . . . . . . . . . . . . . . . . . . . 2 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . 25
TRANSAXLE IDENTIFICATION INFORMATION . . . 2 INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DESCRIPTION AND OPERATION OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 25
AXLE SEALS . . . . . . . . . . . . . . . . . . . . . . . . . ... 3 SHIFT RAILS OVERHAUL . . . . . . . . . . . . . . . . . 31
GEARSHIFT LEVERS . . . . . . . . . . . . . . . . . . . ... 3 SYNCHRONIZER . . . . . . . . . . . . . . . . . . . . . . . . 30
DIAGNOSIS AND TESTING TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CLUTCH PROBLEMS . . . . . . . . . . . . . . . . . . . . . . 3 TRANSAXLE CASE OVERHAUL . . . . . . . . . . . . . 31
COMMON PROBLEM CAUSES . . . . . . . . . . . . . . 3 CLEANING AND INSPECTION
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . 3 SYNCHRONIZER . . . . . . . . . . . . . . . . . . . . . . . . 36
LOW LUBRICANT LEVEL . . . . . . . . . . . . . . . . . . . 3 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
NOISY OPERATION . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS
SLIPS OUT OF GEAR . . . . . . . . . . . . . . . . . . . . . 3 BEARING ADJUSTMENT PROCEDURE . . . . . . . 37
SERVICE PROCEDURES DIFFERENTIAL BEARING PRELOAD
FLUID DRAIN AND FILL . . . . . . . . . . . . . . . . . ... 4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL AND INSTALLATION GEARSHIFT CROSSOVER CABLE
AXLE SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 36
BACK-UP LAMP SWITCH . . . . . . . . . . . . . . . . . . . 7 SPECIFICATIONS
CROSSOVER LEVER . . . . . . . . . . . . . . . . . . . . . . 7 NV T350 (A-578) . . . . . . . . . . . . . . . . . . . . . . . . . 38
GEARSHIFT BOOT . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS
GEARSHIFT CABLES . . . . . . . . . . . . . . . . . . . . . . 5 NV T350 (A-578) MANUAL TRANSAXLE . . . . . . . 38
GEARSHIFT KNOB . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION nized. The reverse gear utilizes a brake and blocking
ring for shifting ease. The reverse idler gear is sup-
NV T350 MANUAL TRANSAXLE ported on a sliding spindle idler shaft. The transaxle
case is aluminum with a steel end–plate bearing
NOTE: Safety goggles should be worn at all times cover. It is housed in a die-cast aluminum case fea-
when working on these transaxles. turing a two–piece, middle split design (Fig. 1).
The NV T350 (A-578) transaxle internal compo-
This five speed is a constant-mesh manual tran- nents can be serviced only by separating the gear
saxle. All gear ranges, except reverse, are synchro- case from the bellhousing case.
21 - 2 TRANSAXLE JA
GENERAL INFORMATION (Continued)
Fig. 3 Bar Code Label

Fig. 1 External Transaxle Components
NOTE: There are four different versions of this
CAUTION: The transaxle output shaft is serviced as transaxle. There are no external differences
a unit. No disassembly and reassembly is possible. between the models. Refer to the identification tag
Damage to the transaxle may result. on the transaxle to determine which transaxle the
vehicle is equipped with.
TRANSAXLE IDENTIFICATION INFORMATION

The transaxle model, assembly number, and build SELECTION OF LUBRICANT
date are on a metal I.D. tag that is attached to the NV T350 (A-578) transaxles use Mopart Type M.S.
end cover of the transaxle (Fig. 2). This information 9417 Manual Transaxle Fluid. Hypoid gear lube,
is also shown on a bar code label that is attached to engine oil, and/or automatic transmission fluid
the front of the transaxle (Fig. 3). should not be used in this transaxle. Hard shift-
ing effort, bearing, gear, and/or synchronizer failure
may occur if incorrect fluid is used.
SPECIAL ADDITIVES
The addition of any fluids to the transaxle, other
than the fluid listed above, is not recommended. An
exception to this policy is the use of special dyes to
aid in detecting fluid leaks. The use of transmission
sealers should be avoided, since they may adversely
affect seals.
SEALANTS
The sealant used to seal the transaxle case halves
and input bearing is Mopart Gasket Maker, Loctitet
518, or equivalent. The sealant used for the bearing
end plate cover is Mopart RTV.
Fig. 2 Metal I.D. Tag
GEAR RATIOS
NOTE: Transaxles use various final drive gear
ratios in different vehicle applications. Therefore, it CAUTION: All gears and shafts must not be inter-
is necessary that the correct transaxle assembly changed with other transaxles; they will not func-
number is used when ordering service parts. tion correctly.
The last eight digits of the Vehicle Identification The differential is a conventional arrangement of
Number (V.I.N.) are stamped on the case, below the gears that is supported by tapered roller bearings. The
back–up lamp switch. final output gear turns the ring gear and differential
assembly, thereby turning the drive axle shafts.
JA TRANSAXLE 21 - 3
All JA transaxles have a torque capacity of 136 lb. DIAGNOSIS AND TESTING
ft. The gear ratios of each transaxle are shown in the
following chart. The chart also shows which transax- COMMON PROBLEM CAUSES
les are available with the reverse–input shaft brake. The majority of transaxle malfunctions are a result
This brake allows easier shifting into reverse and of:
helps eliminate reverse gear clash. • Insufficient lubrication
GEAR • Incorrect lubricant
• Misassembled or damaged internal components
1st 3.54 • Improper operation
2nd 2.13
3rd 1.36 HARD SHIFTING
Hard shifting may be caused by a misadjusted
4th 1.03
crossover cable. If hard shifting is accompanied by
5th 0.72 gear clash, synchronizer clutch and stop rings or gear
FINAL DRIVE 3.94 teeth may be worn or damaged.
REVERSE BRAKE YES Misassembled synchronizer components also cause
shifting problems. Incorrectly installed synchronizer
CLUTCH RELEASE CABLE sleeves, struts, or springs can cause shift problems.
SYSTEM
NOISY OPERATION
GEARSHIFT PATTERN Transaxle noise is most often a result of worn or
The NV T350 (A-578) transaxle shift pattern is a damaged components. Chipped, broken gear or syn-
modified H–pattern (Fig. 4). Overdrive fifth and chronizer teeth, and brinnelled, spalled bearings all
reverse gears are in–line and outboard of the first cause noise.
through fourth gear positions. Abnormal wear and damage to the internal compo-
nents is frequently the end result of insufficient
lubricant.
SLIPS OUT OF GEAR

Transaxle disengagement may be caused by mis-
aligned or damaged shift components, or worn teeth
on the drive gears or synchronizer components. Incor-
rect assembly also causes gear disengagement.
LOW LUBRICANT LEVEL

Insufficient transaxle lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method. Leakage is evident by the presence of oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill.
If air–powered lubrication equipment is used to fill
a transaxle, be sure the equipment is properly cali-
Fig. 4 NV T350 (A-578) Shift Pattern
brated. Equipment out of calibration can lead to an
DESCRIPTION AND OPERATION underfill condition.
GEARSHIFT LEVERS CLUTCH PROBLEMS

The shift levers are serviceable in the vehicle. The Worn, damaged, or misaligned clutch components
shift levers are different from each other and do not can cause difficult shifting, gear clash, and noise.
interchange. A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
AXLE SEALS clash.
The axle shaft seals are identical for both sides of
the differential and will interchange.
21 - 4 TRANSAXLE JA
SERVICE PROCEDURES REMOVAL AND INSTALLATION

FLUID DRAIN AND FILL GEARSHIFT KNOB
All NV T350 (A-578) transaxles are equipped with
a fill plug. The fill plug is located on the left side of REMOVAL
the transaxle differential area (Fig. 5). The fluid level (1) Pull shifter boot down and away from shifter
should be within 3/16 inch from the bottom of the roll pin.
transaxle fill hole (vehicle must be level when check- (2) Pry legs of shift knob away from shift lever roll
ing). pin using a flat blade pry tool (Fig. 7).
Fig. 5 Fill Plug Location Fig. 7 Gearshift Knob

All NV T350 (A-578) transaxles are equipped with (3) Remove knob from shifter handle (Fig. 8).
a drain plug. The drain plug is located on the lower
right side of the transaxle differential housing (Fig. INSTALLATION
6). Tighten drain plug to 28 N·m (250 in. lbs.) (1) For installation, reverse removal procedure.
Fig. 6 Drain Plug Location Fig. 8 Knob Removal

Dry fill lubricant capacity is approximately 1.9-2.2 GEARSHIFT BOOT
liters (4.0-4.6 pints). Wipe the outside of the tran-
saxle if any lubricant spills. REMOVAL
(1) Remove shifter knob. Refer to gearshift knob
removal.
(2) Squeeze together the boot bezel at base. Pull
up on boot and remove (Fig. 9).
JA TRANSAXLE 21 - 5
REMOVAL AND INSTALLATION (Continued)
(5) Pull cables up out of transaxle bracket.
(6) Remove gearshift knob and boot. Refer to Knob
and Boot Removal in this section.
(7) Remove console front screws (Fig. 11). Remove
console rear screws (Fig. 12).
Fig. 9 Boot Removal

INSTALLATION
(1) For installation, reverse removal procedure.
GEARSHIFT CABLES
Fig. 11 Console Front Screws
REMOVAL
(1) Disconnect battery negative cable at shock
tower.
(2) Remove air cleaner assembly.
(3) Disconnect gear shift cable ends from transaxle
shift levers (Fig. 10).
Fig. 12 Console Rear Screws

(8) Pull up on parking brake handle. Pull up on
rear of console and remove console.
(9) Remove floor pan grommet from floor pan.
(10) Remove cable retaining clips at shifter (Fig.
13).
Fig. 10 Shift Cable Removal
CAUTION: It is recommended that new cable retain-
CAUTION: Pry up with equal force on both sides of
ing clips be used for reinstallation.
shifter cable isolator bushings to avoid damaging
cable isolator bushings. (11) Disconnect shift cables from shifter. Pry with
equal force on both sides of shifter cable isolator
(4) Remove cable to bracket retaining clips at tran-
bushings to avoid damaging bushings.
saxle.
(12) Lift vehicle on hoist. Pry shift cable grommet
CAUTION: It is recommended that new cable retain- from floor pan.
ing clips be used for reinstallation. (13) Detach cables from cable support clips.
(14) Remove shift cables from vehicle.
21 - 6 TRANSAXLE JA
Fig. 13 Cable Retaining Clips Fig. 14 Gearshift Mechanism

INSTALLATION from entering the transaxle during speed sensor
(1) To install, reverse removal procedure. After cables removal.
have been replaced, cable adjustment should be
checked. Refer to cable adjustment procedure in this
section.
CAUTION: Gearshift cable bushings must not be

lubricated or the bushings will swell and split.
CAUTION: Only the crossover cable is adjustable.

The selector cable does not have any adjustment
capabilities.
GEARSHIFT MECHANISM REPLACEMENT

REMOVAL
(1) Remove shifter knob and boot. refer to Shifter
Knob And Boot Removal procedure in this section. Fig. 15 Vehicle Speed Sensor
(2) Remove console assembly. Refer to Console (3) Remove speed sensor retaining bolt (Fig. 16).
Removal procedure in this section.
(3) Disconnect gearshift cables at shifter end.
Refer to Gearshift Cable Removal in this section
(4) Remove retaining nuts at the base of the gear-
shift mechanism (Fig. 14). Remove shifter.
INSTALLATION
VEHICLE SPEED SENSOR DRIVE GEAR

REMOVAL
(1) Raise vehicle on hoist.
(2) Remove wiring connector from speed sensor
(Fig. 15).
CAUTION: Clean area around speed sensor before

removing. This will prevent the possibility of dirt Fig. 16 Vehicle Speed Sensor Retaining Bolt
JA TRANSAXLE 21 - 7
(4) Remove speed sensor from transaxle. (2) Using a pin punch, remove the crossover roll
pin from lever.
CAUTION: Carefully remove vehicle speed sensor (3) Pull up and remove the crossover lever from
so that sensor drive gear does not fall into tran- the transaxle crossover shaft.
saxle. Should sensor drive gear fall into the tran-
saxle during sensor removal, drive gear must be INSTALLATION
reattached to sensor. (1) For installation, reverse removal procedure.
Replace the roll pin that was removed with a new
(5) Remove speed sensor drive gear from speed one.
sensor.
SELECTOR LEVER
INSTALLATION
(1) To install, reverse removal procedure. REMOVAL
(2) Confirm vehicle speedometer is functioning (1) Remove the selector cable. Refer to Gearshift
properly following installation. Cable removal.
(2) Using a pin punch, remove the roll pin from
BACK-UP LAMP SWITCH the lever.
The back-up lamp switch is located on the top left (3) Pull up and remove the selector lever from the
front side of the transaxle case (Fig. 17). transaxle selector shaft.
INSTALLATION
Replace the roll pin with a new one.
AXLE SEALS
The axle shaft seals are identical for both sides of
the differential and will interchange.
REMOVAL
(1) Remove axle shaft. Refer to Group 2, Suspen-
sion and Driveshafts for service procedures.
(2) Insert a flat–blade pry tool at outer edge of
axle shaft seal (Fig. 18).
(3) Tap on the pry tool with a small hammer and
remove axle shaft seal.
Fig. 17 Back-up Lamp Switch
REMOVAL
(1) Lift vehicle on hoist.
(2) From bottom side of vehicle, remove wiring
connector from switch.
(3) Unscrew switch from transaxle.
INSTALLATION
(1) To install, reverse removal procedure. Teflon
tape or equivalent must be used on switch threads.
CAUTION: Do not overtighten switch.
(2) Confirm back-up lamps are functioning prop-

erly following installation.
CROSSOVER LEVER Fig. 18 Axle Shaft Seal Removal
REMOVAL INSTALLATION
(1) Remove crossover cable. Refer to Gearshift (1) Clean axle shaft seal bore of any excess sealant.
Cable removal.
21 - 8 TRANSAXLE JA
(2) Align axle shaft seal with axle shaft seal bore.
(3) Install axle seal on tool #6709 and C-4171 and
insert into axle shaft seal bore.
(4) Tap seal into position.
SHIFT SHAFT SEALS

It is not necessary to remove the shift shafts from
the transaxle to service the shift shaft seals.
REMOVAL
(1) Using a pick tool, pry up on the shift shaft seal
and remove seal from bore.
INSTALLATION
(1) Position new shift shaft seal in bore.
(2) Install shift shaft seal into bore using an
appropriate size deep–well socket. Fig. 19 Clutch Cable Removal
CAUTION: Pry up with equal force on both sides of
TRANSAXLE shifter cable isolator bushings to avoid damaging
cable isolator bushing.
REMOVAL
(4) Remove selector lever cable at transaxle (Fig. 20).
NOTE: The transaxle can be removed from the (5) Remove crossover lever cable at transaxle (Fig.
vehicle without having to remove the engine. 20).
(6) Remove shift cable mounting bracket (Fig. 21).
Most transaxle components are serviced with the
transaxle out of the vehicle. The components that are
serviceable in the vehicle are:
• Selector shaft seal
• Crossover shaft seal
• End plate
• Axle shaft seals
• Shift levers
• Back up lamp switch
• Vehicle speed sensor
(1) Disconnect the battery negative cable at strut
tower.
(2) Remove air cleaner at throttle body base inlet.
(3) Remove clutch housing vent cap, exposing the
clutch cable end and clutch release lever. Then remove
clutch cable from transaxle bellhousing (Fig. 19).
Fig. 20 Shift Cables

JA TRANSAXLE 21 - 9
Fig. 23 Accelerator Cable Bracket
Fig. 21 Linkage Bracket Bolts

(7) Disconnect accelerator cables ends from throt-
tle body (Fig. 22).
Fig. 24 Upper Starter Bolt and Bellhousing Stud Nut
Fig. 22 Accelerator Cable Ends

(8) Remove accelerator cable bracket at throttle
body (Fig. 23).
(9) Remove upper starter bolt and upper bellhous-
ing stud nut at bellhousing (Fig. 24). Remove throttle
body support bracket (Fig. 25).
(10) Remove left transaxle mount upper bolts (Fig.
26).
(11) Remove upper bellhousing bolts (Fig. 27). Fig. 25 Throttle Body Support Bracket
(12) Remove vehicle speed sensor. (16) Drain fluid from transaxle.
(13) Remove back up lamp wiring at transaxle. (17) Remove both front driveshafts. Refer to Group
(14) Install engine bridge fixture and support 2, Suspension for procedure.
engine (Fig. 28).
(15) Lift vehicle on hoist and remove front wheels.
21 - 10 TRANSAXLE JA
(18) Remove left lower splash shield/battery cover.
(19) Remove left transaxle mount lower bracket
bolts (Fig. 29).
Fig. 26 Left Mount Upper Bolts
Fig. 29 Left Mount Lower Bolts

(20) Remove bolts retaining engine lower crossbar
(Fig. 30) (Fig. 31).
Fig. 27 Upper Bellhousing Bolts
Fig. 30 Lower Crossbar Front Bolts
Fig. 28 Engine Bridge Fixture

CAUTION: When reinstalling driveshafts, new drive-
shaft retaining clips must be used. Do not reuse old
clips. Failure to use new clips may result in disen-
Fig. 31 Lower Crossbar Rear Bolts
gagement of inner constant velocity joint.
(21) Remove front steel engine mount bracket.
JA TRANSAXLE 21 - 11
(22) Remove (3) bolts on front engine mount
bracket (aluminum) (Fig. 32).
Fig. 34 Rear Transaxle Mount Bracket
Fig. 32 Front Engine Mount Bracket (Aluminum)

(23) Remove lower starter bolt (Fig. 33).
Fig. 35 Bracket Removal
Fig. 33 Starter Bolts

(24) Remove rear transaxle mount bracket (Fig.
34).
(25) Remove transaxle to rear lateral bending
strut from engine and transaxle (Fig. 35).
(26) Remove lower dust shield screw.
(27) Support transaxle with a transmission jack.
(28) Rotate engine clockwise to gain access to Fig. 36 Rotate Engine Clockwise
driveplate clutch bolts (Fig. 36). Remove driveplate
clutch bolts (Fig. 37). INSTALLATION
(29) Remove lower transaxle to engine bellhousing (1) To install transaxle, reverse removal procedure.
bolts (Fig. 38). (2) After installing transaxle, fill transaxle to bot-
(30) Remove transaxle from vehicle. tom of fill plug hole (vehicle level on hoist). Fill tran-
(2) Remove shift levers. Remove transaxle case
half bolts (Fig. 39).
Fig. 37 Driveplate to Modular Clutch Bolts
Fig. 39 Case Bolts

(3) Place two screwdrivers into the slots provided
in the case halves near the dowels (Fig. 40). Separate
the case halves (Fig. 41).
Fig. 38 Lower Bellhousing Bolts

saxle with Mopart Type M.S.9417 Manual Transaxle
Fluid before lowering vehicle to floor.
(3) Verify that vehicle’s back-up lights and speed-
ometer are functioning properly. Crossover cable
adjustment procedure is required after installing
transaxle in car to assure proper shifter adjustment. Fig. 40 Transaxle Case Halves
Road test vehicle for proper transaxle function.
DISASSEMBLY AND ASSEMBLY

TRANSAXLE
The NV T350 (A-578) transaxle internal compo-
nents can be serviced only by separating the gear
case from the bellhousing case.
CAUTION: The transaxle output shaft is serviced as

a unit. No disassembly and reassembly is possible.
Damage to the transaxle may result.
DISASSEMBLY
(1) Place transaxle on bench. Fig. 41 Separate Case Halves
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Remove bellhousing half from gear case half
(Fig. 42).
Fig. 44 Reverse Idler Shaft Bolt Removal
Fig. 42 Bellhousing Case Half Removal

(5) Remove output shaft roller bearing from output
shaft.
(6) Remove differential assembly (Fig. 43).
Fig. 45 Reverse Idler Gear Removal
Fig. 43 Differential Assembly Removal

(7) Remove reverse idler shaft bolt (Fig. 44).
Remove reverse idler gear (Fig. 45).
(8) Remove two screws retaining reverse fork
bracket (Fig. 46). Remove reverse fork bracket and
reverse cam blockout assembly (Fig. 47).
(9) Using snap–ring pliers, remove selector shaft
spacer (Fig. 48).
(10) Pull the selector shaft shift pin out of the slot
in the blocker assembly. Turn selector shaft up and
out of the way (Fig. 49).
Fig. 46 Screws Retaining Reverse Fork Bracket

Fig. 47 Remove Reverse Fork Bracket Fig. 50 Transaxle Cover Removal

(11) Remove transaxle end cover (Fig. 50) (Fig. 51).
Fig. 51 End Cover

Fig. 48 Remove Selector Shaft Spacer
Fig. 52 Snap Rings Retaining Bearings

Fig. 49 Selector Shaft (13) Using bench fixture and shims provided (Mill-
(12) Remove two snap rings retaining the output er tools # 6785, 6785-1, and 6785-2), turn transaxle
shaft and the input shaft to the bearings (Fig. 52). over. Install transaxle onto bench fixture (Fig. 53).
Verify shim spacers are in position on bench fixture.
Install transaxle into shop press.
Fig. 55 Pressing Gears Out of Case
Fig. 53 Bench Fixture

(14) Install bearing fixture Miller tool #6768 onto
transaxle end bearings (Fig. 54). Verify tool is prop-
erly aligned to input and output shafts.
Fig. 56 Transaxle Case Removal
Fig. 54 Bearing Fixture

CAUTION: The oil dams in the input and output
shafts can be damaged while pressing on the
shafts if the bearing fixture is not used properly.
(15) Install transaxle gear case into shop press.

Press output and input shaft assemblies out of case
(Fig. 55).
(16) Remove transaxle from press.
(17) Carefully remove transaxle case from the
shaft assemblies and bench fixture (Fig. 56). Be sure
the oil–feed trough to the end bearings is not dam-
aged (Fig. 57). Fig. 57 Oil Feed Trough
(18) TRANSAXLE W/REVERSE BRAKE: (Fig. 61) (Fig. 62). TRANSAXLE W/O REVERSE
Remove the reverse brake blocking ring, shim, BRAKE: Remove plastic spacer from the input shaft
reverse brake friction cone, bearing and race from assembly.
the input shaft assembly (Fig. 58) (Fig. 59) (Fig. 60)
Fig. 58 Reverse Brake Shim Fig. 61 Reverse Brake Needle Bearing
Fig. 59 Reverse Brake Friction Cone Fig. 62 Reverse Brake Race
Fig. 60 Reverse Brake Blocking Ring Fig. 63 Shift Blocker Removal

(19) Remove the shift blocker assembly from the (21) Remove input and output shaft assemblies
bench fixture (Fig. 63). from bench fixture (Fig. 65).
(20) Remove the 1-2 shift fork from the output
shaft (Fig. 64).
Fig. 64 1–2 Shift Fork Removal Fig. 66 Bench Fixture
Fig. 65 Gear Train Removal Fig. 67 Shift Rail Installation

CAUTION: The output shaft assembly is serviced
as an assembly. Do not try to repair any component
on the output shaft. If the 1-2 synchronizer or gear
fails, it is necessary to replace the complete output
shaft assembly.
ASSEMBLY
is Mopart Gasket Maker, Loctitet 518, or equivalent.
The sealant used for the bearing end plate cover is
Mopart RTV.
(1) Verify bench fixture shims are removed from
bench fixture. Install output and input shafts into
bench fixture (Miller tool #6785) (Fig. 66).
(2) Install shift rails and forks into bench fixture
(Fig. 67). Fig. 68 Shift Blocker Installation
(3) Install shift blocker assembly into bench fix-
(6) Install reverse brake blocking ring (Fig. 71).
ture (Fig. 68).
(7) Install reverse brake friction cone (Fig. 72).
(4) Install reverse brake race onto input shaft (Fig.
(8) Install reverse brake shim (Fig. 73). Apply
69).
petroleum jelly to shim to hold in place.
(5) Install reverse brake needle bearing (Fig. 70).
Fig. 69 Reverse Brake Race Installation Fig. 72 Reverse Brake Friction Cone Installation
Fig. 70 Reverse Brake Needle Bearing Fig. 73 Reverse Brake Shim
Fig. 71 Reverse Brake Blocking Ring Installation Fig. 74 Gear Case Half
(9) Install gear–case half over bench fixture (Fig. (10) Line up reverse brake friction cone lugs to the
74). Line up shift finger over 3-4 lug. slots in the gear case (Fig. 75). Verify reverse brake
shim is in position.
Fig. 75 Friction Cone Lugs Fig. 77 Snap Rings Retaining Bearings

(11) Position input and output bearings on the
shafts. Using Miller tool C-4992-1, press on input
and output shaft bearings until they bottom into the
case and against the shafts (Fig. 76).
Fig. 78 Transaxle End Cover
Fig. 76 Installing Input and Output Bearings

(12) Install shaft snap rings at input and output
bearings (Fig. 77).
(13) Apply Mopart RTV sealant to end–cover outer
edge and around bolt holes. Install end–cover onto
gear case. Tighten end cover bolts to 29 N·m (21 ft.
lbs.) torque (Fig. 78).
(14) Remove gear case from bench fixture.
(15) Install gear case in a holding fixture with end
cover facing down.
(16) Turn selector shaft into slot on blocker assem-
bly (Fig. 79).
(17) Push selector shaft spacer clip onto selector
shaft. Install shift levers. Fig. 79 Selector Shaft
(18) Install reverse idler gear and shaft. Install (19) Install reverse fork bracket and reverse lock-
bolt into shaft. Tighten bolt on shaft to 26 N·m (19 ft. out. Tighten screws to 11 N·m (96 in. lbs.) torque
lbs.) torque (Fig. 80) (Fig. 81). (Fig. 82) (Fig. 83).
(20) Install differential into gear case (Fig. 84).
Fig. 80 Reverse Idler Gear Fig. 83 Reverse Fork Screws
Fig. 81 Reverse Idler Shaft Bolt Fig. 84 Differential Assembly

the bearing cup or cone. Burrs or nicks on the bear-
ing seat gives a false end–play reading while gauging
for proper shims. Improperly seated bearing cups and
cones are subject to low–mileage failure.
(2) Bearing cups and cones should be replaced if
they show signs of pitting or heat distress. If distress
is seen on either the cup or bearing rollers, both cup
and cone must be replaced.
(3) Bearing preload and drag torque specifications
must be maintained to avoid premature bearing fail-
ures. Used (original) bearings may lose up to 50% of
the original drag torque after break–in. All bearing
adjustments must be made with no other component
interference or gear intermesh.
(4) Replace bearings as a pair: If one differential
bearing is defective, replace both differential bear-
Fig. 82 Reverse Fork Bracket ings, if one input shaft bearing is defective, replace
BEARING ADJUSTMENT PROCEDURE both input shaft bearings.
(1) Use extreme care when removing and install- (5) Bearing cones must not be reused if removed.
ing bearing cups and cones. Use only an arbor press (6) Turning–torque readings should be obtained
for installation, as a hammer may not properly align while smoothly rotating in either direction.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT (10) Using Special Tool C-4995 and an inch-pound
torque wrench, check turning torque of the differen-
NOTE: True bearing turning–torque readings can tial assembly (Fig. 86). The turning torque should
be obtained only with the geartrain removed from be 6 to 12 in. lbs. If the turning torque is too
the case. high, install a 0.05mm (0.002 inch) thinner shim.
If the turning torque is too low, install a
(1) Remove bearing cup and existing shim from 0.05mm (0.002 inch) thicker shim.
clutch bellhousing case.
(2) Press in new bearing cup into bellhousing case
(or use a cup that has been ground down on the
outer edge for ease of measurement).
(3) Press in new bearing cup into gear case side.
(4) Oil differential bearings with Mopart type M.S.
9417 Manual Transaxle Fluid. Install differential
assembly in transaxle gear case. Install clutch bell-
housing over gear case. Install and torque case bolts
to 29 N·m (21 ft. lbs.).
(5) Position transaxle with bellhousing facing
down on workbench with C-clamps. Position dial
indicator.
(6) Apply a medium load to differential with Tool
C-4995 and a T-handle, in the downward direction.
Roll differential assembly back and forth a number of
times. This will settle the bearings. Zero the dial
Fig. 86 Checking Differential Bearing Turning
indicator. To obtain end play readings, apply a
Torque
medium load in an upward direction while rolling
differential assembly back and forth (Fig. 85). Record (11) Recheck turning torque. Repeat Step Step 10
end play. until the proper turning torque is obtained.
Once proper turning torque has been established,
place gear case on the end plate. Draw a bead of
Mopart Gasket Maker, Loctitet 518, or equivalent,
on the flat surface of the case mating flange. Install
clutch bellhousing onto gear case. Install and tighten
case bolts to 29 N·m (21 ft. lbs.).
INPUT SHAFT
DISASSEMBLY
Before disassembly of the input shaft, it is neces-
sary to check the synchronizer stop ring gap. Use a
feeler gauge to measure the gaps between the stop
rings and the speed gears. The correct gaps are listed
below:
• 1st—1.04-1.72 mm (0.041-0.069 in).
Fig. 85 Checking Differential Bearing End Play To • 2nd—0.94-1.72 mm (0.038-0.069 in).
Determine Shim Thickness • 3rd—1.37-1.93 mm (0.054-0.076 in).
• 4th—1.41-1.97 mm (0.056-0.078 in).
(7) The shim required for proper bearing preload is • 5th—1.37-1.93 mm (0.054-0.076 in).
the total of end play, plus (constant) preload of If a stop ring gap does not fall within the specifi-
0.18mm (0.007 in.). Never combine shims to obtain cations, it must be inspected for wear and replaced.
the required preload. If the 1st or 2nd synchronizer stop ring is worn
(8) Remove case bolts. Remove clutch bellhousing beyond specifications, the complete output shaft
differential bearing cup. Install shim(s) selected in assembly must be replaced.
Step Step 7. Then press the bearing cup into clutch The input shaft incorporates the 3rd, 4th, and 5th
bellhousing. speed gears and synchronizers on the assembly (Fig.
(9) Install clutch bellhousing. Install and torque 87).
case bolts to 26 N·m (19 ft. lbs.).
Fig. 87 Input Shaft Fig. 89 Remove Synchronizer Using Shop Press

(1) Install bearing splitter behind 5th speed gear.
Remove snap ring at 5th synchronizer hub on input
shaft (Fig. 88).
Fig. 90 Caged Needle Bearing Removal
Fig. 88 5th Synchro and Hub Snap Ring Removal

(2) Remove synchronizer and gear using shop
press (Fig. 89).
(3) Remove caged needle bearing (Fig. 90).
(4) Remove 4-5 gears split thrust washer ring (Fig.
91).
(5) Remove split thrust washer (Fig. 92).
(6) Remove split thrust washer separation pin
(Fig. 93).
(7) Remove 4th gear (Fig. 94).
(8) Remove 4th gear caged needle bearing (Fig.
95). Check the caged needle bearing for a broken
retention spring.
(9) Remove blocking ring. Remove 3-4 synchronizer
hub retaining snap ring (Fig. 96). Fig. 91 Split Thrust Washer Ring Removal
(10) Install input shaft in shop press. Using bear-
ing splitter, remove 3-4 synchronizer and 3rd gear (11) Remove 3rd gear caged needle bearing (Fig.
(Fig. 97). 98). Check the caged needle bearing for a broken
retention spring.
Fig. 92 Split Thrust Washer Removal Fig. 95 Caged Needle Bearing Removal
Fig. 93 Split Thrust Washer Separation Pin Fig. 96 3-4 Synchronizer Hub Snap Ring
Fig. 94 4th Gear Removal Fig. 97 3rd Gear Removal

(12) Inspect the input shaft for worn or damaged ASSEMBLY
bearing races or chipped gear teeth. Replace as nec- The snap rings that are used on the input shaft
essary. are available in select fit sizes. Use the thickest snap
ring that fits in each snap ring groove.
Fig. 98 3rd Gear Caged Needle Bearing Fig. 100 Split Thrust Washer Separation Pin
(1) Place input shaft into shop press. Installation
(2) Install 3rd gear caged needle bearing on input
shaft.
(3) Install 3rd gear and 3-4 synchronizer onto
input shaft. Install Tool #C-3717 over input shaft and
press on synchronizer hub and 3rd gear (Fig. 99).
The synchronizer hub has the letter U stamped on
the top face of the hub. This designates that the hub
must be installed with the U facing upward.
Fig. 101 Split Thrust Washer Installation
Fig. 99 Press On 3rd Gear Synchronizer Hub

(4) Install 3-4 synchronizer snap ring into slot on
input shaft.
(5) Install blocking ring into 3-4 synchronizer.
Install 4th gear caged needle bearing.
(6) Install 4th gear onto input shaft.
(7) Install 4-5 split thrust washer separation pin
(Fig. 100).
(8) Install split thrust washer onto input shaft
(Fig. 101). Fig. 102 Retaining Ring Installation
(9) Install split thrust washer retaining ring (Fig. (10) Install 5th gear caged needle bearing (Fig.
102). 103).
Fig. 105 5th Gear Synchronizer Snap Ring

Fig. 103 Caged Needle Bearing Installation Installation
(11) Using special tool #C-3717, install 5th speed • 3rd—1.37-1.93 mm (0.054-0.076 in).
gear and synchronizer (Fig. 104). The 5th gear syn- • 4th—1.41-1.97 mm (0.056-0.078 in).
chronizer hub has the letter S stamped on the top • 5th—1.37-1.93 mm (0.054-0.076 in).
face of the hub. This designates that the hub must be If a stop ring gap does not fall within the specifi-
installed with the S facing upward. cations it must be inspected for wear and replaced. If
the 1st or 2nd synchronizer stop ring is worn beyond
specifications, the complete output shaft assembly
must be replaced.
The output shaft incorporates the 1st and 2nd
gears and synchronizers on the assembly (Fig. 106).
Fig. 104 5th Speed Gear Installation

(12) Install 5th gear synchronizer snap ring (Fig.
105).
OUTPUT SHAFT Fig. 106 Output Shaft
CAUTION: The output shaft is serviced as an DIFFERENTIAL

assembly. Do not try to repair any component on Shim thickness need be determined only if any of
the output shaft. If the 1-2 synchronizer or gear the following parts are replaced:
fails, it is necessary to replace the output shaft • Transaxle gear case
assembly. • Clutch bellhousing case
• Differential case
It is necessary to check the synchronizer stop ring • Differential bearings
gap. Use a feeler gauge to measure the gaps between Refer to Bearing Adjustment Procedure in the
the stop rings and the speed gears. The correct gaps Adjustments section at the end of this section to
are listed below: determine proper shim thickness. This will provide
• 1st—1.04-1.72 mm (0.041-0.069 in). correct bearing preload and proper bearing turning
• 2nd—0.94-1.72 mm (0.038-0.069 in). torque.
DIFFERENTIAL BEARINGS
Fig. 109 Remove Differential Bearing Cone
Fig. 107 Remove Differential Bearing Cone
Fig. 110 Install Differential Bearing Cone

RING GEAR
Fig. 108 Install Differential Bearing Cone
Fig. 111 Remove or Install Ring Gear Bolts and Ring

Gear
CAUTION: Always install new ring gear bolts.
Tighten ring gear bolts to 81 N·m (60 ft. lbs.) torque.
SPEEDOMETER DRIVE GEAR

NOTE: The plastic speedometer drive gear must be
removed from the differential case in order to ser-
vice the differential gears
REMOVAL
(1) Pry the plastic speedometer drive gear off of
the differential case using a flat blade pry tool (Fig.
112) (Fig. 113).
Fig. 114 Speedometer Drive Gear

(2) Using Miller Tool # L-4440 and steel stock,
press speedometer drive gear onto differential (Fig.
115) (Fig. 116). Do not use a hammer.
Fig. 112 Pry Off Speedometer Drive Gear
Fig. 115 Press Gear onto Diferential
Fig. 113 Speedometer Drive Gear Removed

INSTALLATION
NOTE: A new speedometer drive gear must be

installed on differential assembly. The lip on the
speedometer drive gear must be positioned down-
ward when installing onto differential assembly.
Fig. 116 Drive Gear Pressed onto Differential
(1) Position speedometer drive gear onto differen-
tial assembly (Fig. 114).
DIFFERENTIAL GEARS
NOTE: The plastic speedometer drive gear must be
removed from the differential case in order to ser-
vice the differential gears. Refer to Speedometer
Drive Gear for service information.
REMOVAL
(1) Remove pinion shaft retaining pin (Fig. 117)
(Fig. 118).
Fig. 119 Pinion Shaft Removal
Fig. 117 Remove Pinion Shaft Retaining Pin
Fig. 120 Remove Pinion Gears, Side Gears, and

Thrust Washers by Rotating Side Gears to Opening
in Case
INSTALLATION
(1) Assemble the differential side gears, pinion
gears and pinion gears with the pinion gear washers.
(2) Install pinion shaft retaining pin (Fig. 122).
Fig. 118 Retaining Pin Removed

(2) Remove pinion shaft (Fig. 119).
(3) Rotate side gears to opening in differential
(Fig. 120).
(4) Remove differential gears (Fig. 121).
Fig. 121 Differential Gears
Fig. 123 Staking Retaining Pin

Fig. 122 Install Retaining Pin (4) Rotate the assembly two full revolutions both
(3) Stake pinion shaft retaining pin with a suitable clockwise and counterclockwise.
chisel (Fig. 123).
(5) Set up dial indicator as shown and record end SYNCHRONIZER
play (Fig. 124) (Fig. 125). Rotate side gear 90 degrees
and record another end play. Again, rotate side gear DISASSEMBLY
90 degrees and record a final end play. Place synchronizer in a clean shop towel and wrap.
Press on inner hub. Carefully open up shop towel
and remove springs, balls, keys, hub, and sleeve.
ASSEMBLY
(1) Position synchronizer hub onto a suitable hold-
ing fixture (input shaft). The synchronizer hubs are
directional. The hubs must be installed with the U
facing upward.
(2) Install springs into hub slot (Fig. 126).
Fig. 124 Checking Side Gear End Play (Typical)
Fig. 126 Synchronizer Assembly

(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
Insert balls into each key (Fig. 127).
Fig. 125 Checking Side Gear End Play (Typical)

(6) Using the smallest end play recorded, shim
that side gear to within 0.001 to 0.013 inch. The
other side gear should be checked using the same
procedure.
CAUTION: Side gear end play must be within 0.001

to 0.013 inch. Five select thrust washers are avail-
able: 0.027, 0.032, 0.037, 0.042, and 0.047 inch.
(7) After the end play is measured and adjusted,

replace speedometer drive gear with a new one.
Install drive gear lip downward. For service informa-
Fig. 127 Synchronizer Balls
tion, refer to Speedometer Drive Gear service in this (5) Slide sleeve over the hub and depress balls as
section. you carefully slip the sleeve into position (Fig. 128).
(6) Line up stop ring tang over the keys in the hub
(Fig. 129). Install stop rings. Center the keys and
balls by pushing on both stop rings.
The components that are left in the gear cases
when the gear train is pulled out are the:
• Axle shaft seals
• Output bearing race and retainer
• Input bearing and sleeve
• Differential bearing cones
• Shift rail bushings
• Shift shafts
• Shift shaft seals
• Shift shaft bushings
• Rear bearing oil feed trough
AXLE SHAFT SEALS

REMOVAL
(1) Insert a flat–blade pry tool at outer edge of
Fig. 128 Synchronizer Sleeve axle shaft seal (Fig. 130).
(2) Tap on the pry tool with a small hammer and
remove axle shaft seal.
Fig. 129 Keys in Hub

SHIFT RAILS OVERHAUL Fig. 130 Axle Shaft Seal Removal
(1) Remove shift rails from the geartrain.
(2) To service the 5-R shift rail, remove the C-clip INSTALLATION
retaining the reverse shift lever arm. Remove the 5th (1) Clean axle shaft seal bore of any excess sealant.
shift fork roll pin and remove the 5th shift fork. (2) Align axle shaft seal with axle shaft seal bore.
Remove the shift lug roll pin and remove the shift (3) Install axle seal on tool #6709 with C-4171 and
lug. Replace parts as necessary. insert into axle shaft seal bore.
(3) To service the 3-4 shift rail, remove the roll pin (4) Tap seal into position (Fig. 131).
retaining the 3-4 shift fork. Remove the shift fork.
Remove the shift lug roll pin and remove the shift OUTPUT BEARING
lug. Replace parts as necessary.
(4) To service the 1-2 shift rail, remove the roll pin REMOVAL
retaining the 1-2 shift fork. Remove the shift fork
and replace parts as necessary. NOTE: The position of the output shaft bearing is
critical. The bearing is not identical end–to–end.
TRANSAXLE CASE OVERHAUL Install bearing with larger diameter cage ring facing
out.
is Mopart Gasket Maker, Loctitet 518, or equivalent. (1) Remove caged roller bearing from output bear-
The sealant used for the bearing end–plate cover is ing race (Fig. 132).
Mopart RTV. (2) Remove screws at output bearing retainer
strap (Fig. 133).
Fig. 131 Axle Seal Installation

(3) Install tool #6787 and slide hammer (Fig. 134).
Tighten tool to output bearing race.
(4) Using slide hammer, remove output bearing
race.
Fig. 134 Output Bearing Race Removal

INSTALLATION
(1) Line up output bearing race to race bore.
(2) Insert tool #4628 with C-4171 into output bear-
ing race (Fig. 135). Tap race into bore. Install output
bearing into race. Verify that the larger diameter
cage is facing outward. Position bearing retaining
strap. Tighten bolts to 11 N·m (96 in. lbs.).
Fig. 132 Output Roller Bearing INPUT BEARING AND SLEEVE

The input bearing is a one–piece bearing and
sleeve unit (Fig. 136). The sleeve is the slide point for
the clutch–release bearing and lever.
REMOVAL
(1) Install tool #6342 over input bearing on the
gear case side of the transaxle clutch housing.
(2) Press the input bearing out of the housing (Fig.
137).
INSTALLATION
(1) Apply coating of Loctitet sealant on bearing
outer diameter. Position sleeve and bearing assembly
at input bearing bore.
(2) Install tool #C-4680-1 over input bearing (Fig.
138).
Fig. 133 Output Bearing Strap
Fig. 137 Input Bearing Removal
Fig. 135 Output Bearing Race Installation
Fig. 138 Input Bearing Tool
Fig. 136 Input Bearing And Sleeve

(3) Using the spacer tool #4894 and shop press,
install input bearing into bore until it is fully seated
(Fig. 139).
DIFFERENTIAL BEARING CUPS Fig. 139 Input Bearing Installed

(2) Install Miller tool #L-4518 into the differential
REMOVAL bearing cup (Fig. 140).
(1) Remove differential assembly from gear case (3) Install the tool cup over the tool (Fig. 141).
using the procedure outlined in this group.
Fig. 140 Tool Installed in Bearing Fig. 142 Shift Rail Bushing Removal
(2) Using tool #MD998343, tap bushing into bore
until flush with the chamfer in the case.
SHIFT SHAFT SEALS

It is not necessary to remove the shift shafts from
the transaxle to service the shift shaft seals.
REMOVAL
(1) Using a pick tool, pry up on the shift shaft seal
and remove seal from bore.
INSTALLATION
(1) Position new shift shaft seal in bore.
(2) Install shift shaft seal into bore using an
appropriate size deep-well socket.
Fig. 141 Tool Cup Installed SHIFT SELECTOR SHAFT

(4) Tighten the tool until the race is removed from REMOVAL
the case.
(1) Disassemble transaxle using the procedure out-
INSTALLATION lined in this group.
(2) With the transaxle disassembled, remove the
(1) Position the bearing cup into the case.
selector shaft by pushing on the shaft from the out-
(2) Install the bearing cup onto Miller tool
side. Pull shaft out from the inside.
#L-4520.
(3) Using Miller tool #L-4520 and C-4171 driver, INSTALLATION
install differential bearing cup into the transaxle
(1) Reverse removal procedure to install selector
case.
shaft.
SHIFT RAIL BUSHINGS
SHIFT CROSSOVER SHAFT
REMOVAL
REMOVAL
(1) Thread tool #6786 into shift rail bushing.
(1) Disassemble transaxle using the procedure out-
(2) Install slide hammer #3752 onto tool.
lined in this group.
(3) Remove bushing using slide hammer and tool
(2) With the transaxle disassembled, remove the
assembly (Fig. 142).
crossover shaft seal.
INSTALLATION (3) Using snap–ring pliers, remove the snap ring
at the crossover shaft bore (Fig. 143).
(1) Line up replacement bushing in bore.
Fig. 143 Crossover Shaft Snap Ring Fig. 145 Selector Shaft Bushing Installation
(4) Push the crossover shaft in the case and SHIFT CROSSOVER SHAFT BUSHING
remove the crossover assembly.
REMOVAL
INSTALLATION (1) Install slide hammer #3752 through the cross-
(1) Reverse removal procedure to install crossover over bushing.
shaft. (2) Thread nut and washer onto slide hammer.
(3) Using the slide hammer, remove the crossover
SHIFT SELECTOR SHAFT BUSHING shaft bushing (Fig. 146).
REMOVAL
(1) Remove selector shaft using procedure in this
group.
(2) Thread tool #6786 into bushing.
(3) Install slide hammer #3752 onto tool and
remove bushing using slide hammer (Fig. 144).
Fig. 146 Crossover Shaft Bushing Removal

INSTALLATION
(1) Position the replacement crossover shaft bush-
ing over the crossover shaft bushing bore.
(2) Using an appropriate size deep–well socket,
install the crossover shaft bushing into the bushing
Fig. 144 Selector Shaft Bushing Removal bore.
INSTALLATION REAR BEARING OIL FEED TROUGH
(1) Position replacement bushing over selector The bearing oil feed trough is retained in the case
shaft bore. by a pin that is molded into the case and clips that
(2) Using an appropriate size deep–well socket, are part of the trough (Fig. 147).
install bushing in selector shaft bore (Fig. 145).
INSPECT
Proper inspection of components involve:
• Teeth, for wear, scuffed, nicked, burred, or bro-
ken teeth
• Keys, for wear or distortion
• Balls and springs, for distortion, cracks, or wear
If any of these conditions exist in these compo-
nents, replace as necessary.
ADJUSTMENTS
GEARSHIFT CROSSOVER CABLE ADJUSTMENT
(1) Remove shift console from vehicle.
(2) Loosen adjusting screw on crossover cable at
Fig. 147 Oil Feed Trough shifter (Fig. 148) (Fig. 149).
REMOVAL
(1) Using light plier pressure, squeeze the clips
together at the rear of the trough.
(2) Slide the trough over the retaining pin that
locates the trough in the case.
INSTALLATION
(1) Reverse removal procedure to install oil feed
trough.
CLEANING AND INSPECTION

TRANSAXLE
Clean the gears, bearings, shafts, synchronizers,
thrust washers, oil feeder, shift mechanism, gear Fig. 148 Loosen Crossover Cable Adjustment Screw
case, and bellhousing with solvent. Dry all parts
except the bearings with compressed air. Allow the
bearings to either air dry or wipe them dry with
clean shop towels.
Inspect the gears, bearings, shafts and thrust
washers. Replace the bearings and cups if the rollers
are worn, chipped, cracked, flat spotted, or brin-
nelled, or if the bearing cage is damaged or distorted.
Replace the thrust washers if cracked, chipped, or
worn. Replace the gears if the teeth are chipped,
cracked, or worn thin. Inspect the synchronizers.
Replace the sleeve if worn or damaged in any way.
Replace the stop rings if the friction material is
burned, flaking off, or worn. Check the condition of
the synchro keys and springs. Replace these parts if
worn, cracked, or distorted.
Fig. 149 Crossover Cable Adjustment Screw
SYNCHRONIZER (3) Pin transaxle crossover lever in 3-4 neutral
position using a 1/4 inch drill bit. Align hole in cross-
CLEAN over lever with the hole in the boss on the transaxle
Do not attempt to clean the blocking rings in sol- case (Fig. 150). Make sure drill bit goes into tran-
vent. The friction material will become contaminated. saxle case at least one half inch.
Place synchronizer components in a suitable holder (4) The shifter is spring loaded and self centering.
and clean with solvent. Air dry. Allow shifter to rest in its neutral position. Torque
ADJUSTMENTS (Continued)
DIFFERENTIAL BEARING PRELOAD

ADJUSTMENT
NOTE: True bearing turning torque readings can be
obtained only with the geartrain removed from the
case.
(1) Remove bearing cup and existing shim from

clutch bellhousing case.
(2) Press in new bearing cup into bellhousing case
(or use a cup that has been ground down on the
outer edge for ease of measurement).
(3) Press in new bearing cup into gear case side.
(4) Oil differential bearings with Mopart type M.S.
9417 Manual Transaxle Fluid. Install differential
assembly in transaxle gear case. Install clutch bell-
Fig. 150 Crossover Lever Pin Procedure housing over gear case. Install and torque case bolts
adjustment screw to 8 N·m (70 in. lbs.). Care must be to 29 N·m (21 ft. lbs.).
taken to avoid moving the shift mechanism off-center (5) Position transaxle with bellhousing facing
during screw tightening. down on workbench with C-clamps. Position dial
(5) Remove drill bit from transaxle case and per- indicator.
form functional check by shifting transaxle into all (6) Apply a medium load to differential with Tool
gears. C-4995 and a T-handle, in the downward direction.
(6) Reinstall console. Reinstall boot and knob. Roll differential assembly back and forth a number of
times. This will settle the bearings. Zero the dial
BEARING ADJUSTMENT PROCEDURE indicator. To obtain end play readings, apply a
medium load in an upward direction while rolling
GENERAL RULES ON SERVICING BEARINGS differential assembly back and forth (Fig. 151).
(1) Use extreme care when removing and install- Record end play.
ing bearing cups and cones. Use only an arbor press
for installation, as a hammer may not properly align
the bearing cup or cone. Burrs or nicks on the bear-
ing seat will give a false end play reading while
gauging for proper shims. Improperly seated bearing
cups and cones are subject to low–mileage failure.
(2) Bearing cups and cones should be replaced if
they show signs of pitting or heat distress. If distress
is seen on either the cup or bearing rollers, both cup
and cone must be replaced.
(3) Bearing preload and drag torque specifications
must be maintained to avoid premature bearing fail-
ures. Used (original) bearings may lose up to 50% of
their original drag torque after break in. All bearing
adjustments must be made with no other component
interference or gear intermesh.
(4) Replace bearings as a pair: If one differential Fig. 151 Checking Differential Bearing End Play to
bearing is defective, replace both differential bear- Determine Shim Thickness
ings, if one input shaft bearing is defective, replace (7) The shim required for proper bearing preload is
both input shaft bearings. the total of end play, plus (constant) preload of
(5) Bearing cones must not be reused if removed. 0.18mm (0.007 in.). Never combine shims to obtain
(6) Turning torque readings should be obtained the required preload.
while smoothly rotating in either direction. (8) Remove case bolts. Remove clutch bellhousing
differential bearing cup. Install shim(s) selected in
Step 7. Then press the bearing cup into clutch bell-
housing.
(9) Install clutch bellhousing. Install and torque DESCRIPTION TORQUE
case bolts to 26 N·m (19 ft. lbs.). Power Hop Damper to Frame Bkt. . . . . . . . . 54 N·m
(10) Using Special Tool C-4995 and an inch-pound (40 ft. lbs.)
torque wrench, check turning torque of the differen- Power Hop Damper to Trans. Bkt. . . . . . . . . 54 N·m
tial assembly (Fig. 152). The turning torque (40 ft. lbs.)
should be 6 to 12 in. lbs. If the turning torque is Reverse Fork Bracket . . . . . . . . 11 N·m (96 in. lbs.)
too high, install a 0.05mm (0.002 inch) thinner Reverse Idler Shaft Bolt . . . . . . . 26 N·m (19 ft. lbs.)
shim. If the turning torque is too low, install a Shift Cable Bracket to Transaxle . . . . . . . . . 28 N·m
0.05mm (0.002 inch) thicker shim. (250 in. lbs.)
Transaxle Case Bolts . . . . . . . . . 29 N·m (21 ft. lbs.)
Transaxle to Engine Bolt . . . . . . 95 N·m (70 ft. lbs.)
Trans. to Eng. Intake Bkt. Bolts . . . . . . . . . 95 N·m
(70 ft. lbs.)
Vehicle Speed Sensor . . . . . . . . . . 7 N·m (60 in. lbs.)
Vertical Bending Strut to Engine . . . . . . . . 108 N·m
(80 ft. lbs.)
Vertical Bending Strut to Trans. . . . . . . . . 108 N·m
(80 ft. lbs.)
NOTE: Bolts that have thread sealer or torque lock
patches should not be reused. Always install new
bolts in these applications.
NV T350 (A-578) MANUAL TRANSAXLE FLUID
FILL
Fig. 152 Checking Differential Bearing Turning TRANSAXLE METRIC U.S. MEASURE
Torque MEASURE
(11) Recheck turning torque. Repeat Step 10 until NV T350 1.9-2.2 Liters 2.0-2.3 Quarts
the proper turning torque is obtained.
SPECIFICATIONS
SPECIAL TOOLS
NV T350 (A-578)
NV T350 (A-578) MANUAL TRANSAXLE
DESCRIPTION TORQUE
Back-up Lamp Switch . . . . . . . . 24 N·m (18 ft. lbs.)
Crossover Cable Adj. Screw . . . . . 8 N·m (70 in. lbs.)
Drain Plug . . . . . . . . . . . . . . . . 30 N·m (267 in. lbs.)
Differential Ring Gear Bolts . . . . 81 N·m (60 ft. lbs.)
Dust Shield to Transaxle . . . . . 12 N·m (105 in. lbs.)
End Plate Cover Bolts . . . . . . . . 29 N·m (21 ft. lbs.)
Front Engine Mount to Trans . . 108 N·m (80 ft. lbs.)
Front Mount Through Bolt . . . . . 61 N·m (45 ft. lbs.)
Front Mount to Engine Bolt . . . . 54 N·m (40 ft. lbs.)
Lateral Bending Strut to Engine . . . . . . . . . 54 N·m Adapter Blocks C-293–45
(40 ft. lbs.)
Lateral Bending Strut to Trans. . 54 N·m (40 ft. lbs.)
Left Mount Through Bolt . . . . . 108 N·m (80 ft. lbs.)
Left Mount to Transaxle . . . . . . . 54 N·m (40 ft. lbs.)
Output Bearing Race Ret. Strap . . . . . . . . . . 11 N·m
(96 in. lbs.)
Power Hop Damper Bkt. to Trans. . . . . . . . . 54 N·m
(40 ft. lbs.)
SPECIAL TOOLS (Continued)
Puller Press C-293–PA
Universal Handle C-4171
Dial Indicator C-3339
Bearing Installer C-4628
Sleeve C-3717
Seal Remover C-4680
Slide Hammer C-3752
Seal Installer C-4992

Torque Tool C-4995 Bearing Splitter 1130
Adapter C-4996 Driver 6342
Installer L-4410 Seal Installer 6709
Special Jaw Set L-4518 Bearing Remover 6768

Bench Fixture 6785 Remover 6786
Remover 6787
41TE TRANSAXLE
INDEX
page page
GENERAL INFORMATION FLUSHING COOLERS AND TUBES . . . . . . . . . . 58

41TE TRANSAXLE IDENTIFICATION . . . . . . . . . 42 OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . . 59
FLUID REQUIREMENTS . . . . . . . . . . . . . . . . . . . 43 PINION FACTOR PROCEDURE . . . . . . . . . . . . . 59
IN-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 43 TRANSAXLE QUICK LEARN PROCEDURE . . . . 59
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION
41TE TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . 43 AUTOSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
AUTOSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 59
BATTERY FEED (TCM) . . . . . . . . . . . . . . . . . . . . 47 GEARSHIFT MECHANISM . . . . . . . . . . . . . . . . . 61
ELECTRONICALLY MODULATED CONVERTER INTERLOCK MECHANISM . . . . . . . . . . . . . . . . . 64
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 MANUAL VALVE LEVER (SHIFT LEVER) . . . . . . 64
INPUT/OUTPUT SPEED SENSOR . . . . . . . . . . . 48 OIL PUMP SEAL . . . . . . . . . . . . . . . . . . . . . . . . . 72
PRESSURE SWITCHES . . . . . . . . . . . . . . . . . . . 47 SHIFTER IGNITION INTERLOCK CABLE . . . . . . 62
SHIFT POSITION INDICATOR . . . . . . . . . . . . . . 49 SOLENOID ASSEMBLY-REPLACE . . . . . . . . . . . 65
SHIFTER/IGNITION INTERLOCK . . . . . . . . . . . . 50 SPEED SENSOR-INPUT . . . . . . . . . . . . . . . . . . . 65
SOLENOID AND PRESSURE SWITCH SPEED SENSOR-OUTPUT . . . . . . . . . . . . . . . . . 66
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SOLENOID SWITCH VALVE . . . . . . . . . . . . . . . . 49 TRANSMISSION CONTROL MODULE . . . . . . . . 66
SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 TRANSMISSION RANGE SENSOR . . . . . . . . . . . 65
THROTTLE POSITION SENSOR . . . . . . . . . . . . 48 VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
TRANSMISSION CONTROL MODULE & DISASSEMBLY AND ASSEMBLY
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . 44 DIFFERENTIAL REPAIR . . . . . . . . . . . . . . . . . . 117
TRANSMISSION CONTROL RELAY . . . . . . . . . . 47 INPUT CLUTCHES-RECONDITION . . . . . . . . . . . 89
TRANSMISSION RANGE SENSOR . . . . . . . . . . . 48 TRANSAXLE—ASSEMBLY . . . . . . . . . . . . . . . . 101
TRANSMISSION TEMPERATURE SENSOR . . . . 48 TRANSAXLE—DISASSEMBLY . . . . . . . . . . . . . . 75
VEHICLE SPEED SIGNAL . . . . . . . . . . . . . . . . . 49 VALVE BODY RECONDITION . . . . . . . . . . . . . . . 72
DIAGNOSIS AND TESTING CLEANING AND INSPECTION
41TE TRANSAXLE GENERAL DIAGNOSIS . . . . . 51 CLEANING VALVE BODY . . . . . . . . . . . . . . . . . 122
AUTOSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 ADJUSTMENTS
CLUTCH AIR PRESSURE TESTS . . . . . . . . . . . . 54 AUTOSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
FLUID LEAKAGE-TORQUE CONVERTER GEARSHIFT LINKAGE ADJUSTMENT . . . . . . . 122
HOUSING AREA . . . . . . . . . . . . . . . . . . . . . . . 54 INTERLOCK SYSTEM ADJUSTMENT . . . . . . . . 123
HYDRAULIC PRESSURE TESTS . . . . . . . . . . . . 51 SCHEMATICS AND DIAGRAMS
INTERLOCK SYSTEM OPERATION CHECK . . . . 55 41TE TRANSAXLE HYDRAULIC
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 125
SHIFT POSITION INDICATOR . . . . . . . . . . . . . . 55 SPECIFICATIONS
SERVICE PROCEDURES 41TE AUTOMATIC TRANSAXLE . . . . . . . . . . . . 138
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . . 58 41TE TORQUE SPECIFICATIONS . . . . . . . . . . 138
FLUID AND FILTER SERVICE— SPECIAL TOOLS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 56 41TE AUTOMATIC TRANSAXLE . . . . . . . . . . . . 139
FLUID LEVEL AND CONDITION CHECK . . . . . . . 55
GENERAL INFORMATION For example, the identification code K 821 1125

1316 can be broken down as follows:
41TE TRANSAXLE IDENTIFICATION • K = Kokomo Transmission Plant
The 41TE transaxle identification code is a series • 821 = Last three digits of the transaxle part
of digits printed on a bar-code label that is fixed to number
the transaxle case as shown in (Fig. 1). • 1125 = Build date
• 1316 = Build sequence number
DESCRIPTION AND OPERATION

41TE TRANSAXLE
The 41TE is a four speed transaxle that is a con-
ventional hydraulic/mechanical assembly with adap-
tive electronic controls and monitors. Adaptive
electronic controls take transmission wear and driver
habits into consideration to provide smooth shifting
for the life of the transaxle. An input clutch assembly
which houses the underdrive, overdrive, and reverse
clutches is used. It also utilizes separate holding
clutches: 2nd/4th gear and Low/Reverse. Transmis-
sion output is directed to an integral differential by a
transfer gear system in the following input-to-output
ratios:
Fig. 1 Transaxle Identification Label First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.84 : 1

If the tag is not legible or missing, the “PK” num- Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57 : 1
ber (stamped into the transaxle case) can be referred Third . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 : 1
to for identification. This number differs slightly in Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.69 : 1
that it contains the entire transaxle part number, Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 : 1
rather than the last three digits. Final Drive Ration is dependent on which engine
option is selected:
IN-VEHICLE SERVICE 2.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.08 FDR
The following components are serviceable in the 2.4L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.91 FDR
vehicle without transaxle removal:
2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.91 FDR
• Valve Body Assembly
• Solenoid Pack HYDRAULICS
• Transmission Range Sensor (TRS) The hydraulic portion of the transaxle consists of
• Input Speed Sensor the transaxle fluid, fluid passages, hydraulic valves,
• Output Speed Sensor and various line pressure control components.
• Transfer Gears The hydraulic control system design (without elec-
Refer to Removal and Installation in this group for tronic assist) provides the transmission with PARK,
applicable procedures. REVERSE, NEUTRAL, and SECOND gears, based
solely on driver shift lever selection. This design
FLUID REQUIREMENTS allows the vehicle to be driven (in “limp-in” mode) in
the event of a failure of the electronic control system,
NOTE: Refer to Service Procedures in this group or a situation that the Transmission Control Module
for fluid level checking procedures. (TCM) recognizes as potentially damaging to the
transaxle.
NOTE: The transmission and differential sump have
MECHANICAL
a common oil sump with an opening between the
The primary mechanical components of the tran-
two.
saxle consist of the following:
• Three multiple disc input clutches
TRANSMISSION/DIFFERENTIAL • Two multiple disc holding clutches
Mopart ATF+3 (Automatic Transmission Fluid- • Four hydraulic accumulators
Type 7176) is required in this transaxle. Substitute • Two planetary gear sets
fluids can induce torque converter clutch shudder. • Hydraulic oil pump
• Valve body
FLUID ADDITIVES • Solenoid pack
Other than fluorescent leak detection dye, the use
of any fluid additives (transmission or differential) is ELECTRONICS
not recommended in this transaxle. Control of the transaxle is accomplished by fully
adaptive electronics. Optimum shift scheduling is
accomplished through continuous real-time sensor
DESCRIPTION AND OPERATION (Continued)
feedback information provided to the Transmission • Ignition “ON” voltage
Control Module (TCM). • Transmission Control Relay (Switched B+)
The TCM is the “heart” or “brain” of the electronic • Throttle Position Sensor
control system and relies on information from vari- • Crankshaft Position Sensor (CKP)
ous direct and indirect inputs (sensors, switches, etc.) • Transmission Range Sensor (TRS)
to determine driver demand and vehicle operating • Pressure Switches (L/R, 2/4, OD)
conditions. With this information, the TCM can cal- • Transmission Temperature Sensor (Integral to
culate and perform timely and quality shifts through TRS)
various output or control devices (solenoid pack, • Input Shaft Speed Sensor
transmission control relay, etc.). • Output Shaft Speed Sensor
The TCM also performs certain self-diagnostic • TRS Hall Effect Switch (Autostick)
functions and provides comprehensive information Some examples of indirect inputs to the TCM
(sensor data, DTC’s, etc.) which is helpful in proper are:
diagnosis and repair. This information can be viewed • Engine/Body Identification
with the DRBIII scan tool. • Manifold Pressure
• Target Idle
TRANSMISSION CONTROL MODULE & • Torque Reduction Confirmation
SYSTEM OPERATION • Speed Control ON/OFF Switch
• Engine Coolant Temperature
DESCRIPTION • Ambient/Battery Temperature
The Transmission Control Module (TCM) is located • Brake Switch Status
in the engine compartment on the left (driver’s) side • DRB Communication
next to the Power Distribution Center (PDC) (Fig. 2). Based on the information received from these var-
ious inputs, the TCM determines the appropriate
shift schedule and shift points, depending on the
present operating conditions and driver demand.
This is possible through the control of various direct
and indirect outputs.
Some examples of TCM direct outputs are:
• Transmission Control Relay
• Solenoids (L/R, 2/4, OD and UD)
• Vehicle Speed (to PCM)
• Torque Reduction Request (to PCM)
Some examples of TCM indirect outputs are:
• Transmission Temperature (to PCM)
• PRNDL Position (to BCM)
• Autostick Display (to BCM)
In addition to monitoring inputs and controlling
outputs, the TCM has other important responsibili-
ties and functions:
• Storing and maintaining Clutch Volume Indexes
(CVI)
• Storing and selecting appropriate Shift Sched-
Fig. 2 Transmission Control Module Location ules
(Typical) • System self-diagnostics
OPERATION • Diagnostic capabilities (with DRB III scan tool)
The TCM is the controlling unit for all electronic
NOTE: If the TCM has been replaced, the “Quick
operations of the transaxle. The TCM receives infor-
Learn Procedure” must be performed. Refer to
mation regarding vehicle operation from both direct
“Quick Learn Procedure” in Service Procedures of
and indirect inputs, and selects the operational mode
this group.
of the transaxle. Direct inputs are hardwired to, and
used specifically by the TCM. Indirect inputs origi-
nate from other components/modules, and are shared CLUTCH VOLUME INDEXES
with the TCM via the PCI bus. An important function of the TCM is to monitor
Some examples of direct inputs to the TCM are: Clutch Volume Indexes (CVI). CVIs represent the vol-
• Battery (B+) voltage ume of fluid needed to compress a clutch pack.
The TCM monitors gear ratio changes by monitor- 2:1. In direct drive (3rd gear), the gear ratio changes
ing the Input and Output Speed Sensors. The Input, to 1:1. The gear ratio changes as clutches are applied
or Turbine Speed Sensor sends an electrical signal to and released. By monitoring the length of time it
the TCM that represents input shaft rpm. The Out- takes for the gear ratio to change following a shift
put Speed Sensor provides the TCM with output request, the TCM can determine the volume of fluid
shaft speed information. used to apply or release a friction element.
By comparing the two inputs, the TCM can deter- The volume of transmission fluid needed to apply
mine transaxle gear position. This is important to the friction elements are continuously updated for
the CVI calculation because the TCM determines adaptive controls. As friction material wears, the vol-
CVIs by monitoring how long it takes for a gear ume of fluid need to apply the element increases.
change to occur (Fig. 3). Certain mechanical problems within the input
clutch assembly (broken return springs, out of posi-
tion snap rings, excessive clutch pack clearance,
improper assembly, etc.) can cause inadequate or out-
of-range element volumes. Also, defective Input/Out-
put Speed Sensors and wiring can cause these
conditions. The following chart identifies the appro-
priate clutch volumes and when they are monitored/
updated:
CLUTCH VOLUMES
Proper Clutch
Clutch When Updated
Volume
2-1 or 3-1 coast
L/R 35 to 83
downshift
2/4 1-2 shift 20 to 77
OD 2-3 shift 48 to 150
UD 4-3 or 4-2 shift 24 to 70
SHIFT SCHEDULES
As mentioned earlier, the TCM has programming
that allows it to select a variety of shift schedules.
Fig. 3 Example of CVI Calculation Shift schedule selection is dependent on the follow-
Gear ratios can be determined by using the DRB ing:
III Scan Tool and reading the Input/Output Speed • Shift lever position
Sensor values in the “Monitors” display. Gear ratio • Throttle position
can be obtained by dividing the Input Speed Sensor • Engine load
value by the Output Speed Sensor value. • Fluid temperature
For example, if the input shaft is rotating at 1000 • Software level
rpm and the output shaft is rotating at 500 rpm, As driving conditions change, the TCM appropri-
then the TCM can determine that the gear ratio is ately adjusts the shift schedule. Refer to the follow-
ing chart to determine the appropriate operation
expected, depending on driving conditions.
Schedule Condition Expected Operation

Extreme Cold Oil temperature at start-up below Park, Reverse, Neutral and 2nd
-16° F gear only (prevents shifting which
may fail a clutch with frequent
shifts)
Cold Oil temperature at start-up above – Delayed 2-3 upshift
-12° F and below 36° F (approximately 22-31 mph)
– Delayed 3-4 upshift (45-53 mph)
– Early 4-3 costdown shift
(approximately 30 mph)
– Early 3-2 coastdown shift
(approximately 17 mph)
– High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
– No EMCC
Warm Oil temperature at start-up above – Normal operation (upshift,
36° F and below 80 degree F kickdowns, and coastdowns)
– No EMCC
Hot Oil temperature at start-up above – Normal operation (upshift,
80° F kickdowns, and coastdowns)
– Full EMCC, no PEMCC except to
engage FEMCC (except at closed
throttle at speeds above 70-83 mph)
Overheat Oil temperature above 240° F or – Delayed 2-3 upshift (25-32 mph)
engine coolant temperature above – Delayed 3-4 upshift (41-48 mph)
244° F
– 3rd gear FEMCC from 30-48 mph
– 3rd gear PEMCC from 27-31 mph
Super Overheat Oil temperature above 260° F – All 9Overheat9 shift schedule
features apply
– 2nd gear PEMCC above 22 mph
– Above 22 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
SOLENOID AND PRESSURE SWITCH

ASSEMBLY
DESCRIPTION
The solenoid and pressure switch assembly is
external to the transaxle and mounted to the valve
body assembly. The assembly consists of four sole-
noids that control hydraulic pressure to four of the
five friction elements (transaxle clutches), and the
torque converter clutch. The solenoid assembly also
contains pressure switches that feed information to
the TCM.
OPERATION
The solenoids within the assembly are supplied
voltage by the Transmission Control Relay. The sole-
noids are energized when the TCM grounds the
return wire for the solenoid that is needed. The pres-
sure switches simply tell the TCM whether or not
Fig. 4 Transmission Control Relay Location
pressure exists within a clutch circuit. Refer to “Pres-
(Typical)
sure Switches” in this group for more information
regarding pressure switches. PRESSURE SWITCHES
The pressure switches are located inside the sole-
BATTERY FEED (TCM) noid pack assembly and are only serviced by replac-
A fused, direct battery feed to the TCM is used for ing the assembly.
continuous power. The battery feed is spliced and The TCM relies on three pressure switches to mon-
also fed to the contact side of the Transmission Con- itor fluid pressure in the L/R, 2/4, and OD hydraulic
trol Relay. This battery voltage is necessary to retain circuits. The primary purpose of these switches is to
adaptive learn values in the TCM’s RAM (Random help the TCM detect when clutch circuit hydraulic
Access Memory). When the battery (B+) is discon- failures occur. The switches close at 23 psi and open
nected, this memory is lost. When the battery (B+) is at 11 psi, and simply indicate whether or not pres-
restored, this memory loss is detected by the TCM sure exists. The switches are continuously monitored
and a Diagnostic Trouble Code (DTC) is set. by the TCM for the correct states (open or closed) in
each gear as shown in the following chart:
TRANSMISSION CONTROL RELAY
The transmission control relay is located in the GEAR L/R 2/4 OD
Power Distribution Center (PDC) on the left side of R OP OP OP
the engine compartment (Fig. 4). The relay is sup-
plied fused B+ voltage, energized by the TCM, and is P/N CL OP OP
used to supply power to the solenoid pack when the 1st CL OP OP
transmission is in normal operating mode. When the 2nd OP CL OP
relay is “off”, no power is supplied to the solenoid
D OP OP CL
pack and the transmission is in “limp-in” mode. After
a controller reset (ignition key turned to the “run” OD OP CL CL
position or after cranking engine), the TCM energizes
the relay. Prior to this, the TCM verifies that the A Diagnostic Trouble Code (DTC) will set if the
contacts are open by checking for no voltage at the TCM senses any switch open or closed at the wrong
switched battery terminals. After this is verified, the time in a given gear.
voltage at the solenoidpack pressure switches is The TCM also tests the 2/4 and OD pressure
checked. After the relay is energized, the TCM mon- switches when they are normally off (OD and 2/4 are
itors the terminals to verify that the voltage is tested in 1st gear, OD in 2nd gear, and 2/4 in 2rd
greater than 3 volts. gear). The test simply verifies that they are opera-
tional, by looking for a closed state when the corre-
sponding element is applied. Immediately after a
shift into 1st, 2nd, or 3rd gear with the engine speed
above 1000 rpm, the TCM momentarily turns on ele- • Supply ground to the Starter Relay in Park and
ment pressure to the 2/4 and/or OD clutch circuits to Neutral only.
identify that the appropriate switch has closed. If it • Supply ground to the Backup Lamp Relay in
doesn’t close, it is tested again. If the switch fails to Reverse only.
close the second time, the appropriate Diagnostic The TRS also has an integrated temperature sen-
Trouble Code (DTC) will set. sor (thermistor) that communicates transaxle tem-
perature to the TCM and PCM.
INPUT/OUTPUT SPEED SENSOR
OPERATION
DESCRIPTION The Transmission Range Sensor (TRS) communi-
The Input and Output Speed Sensors are two-wire cates shift lever position to the TCM as a combina-
magnetic pickup devices that generate AC signals as tion of open and closed switches. Each shift lever
rotation occurs. They are threaded into the transaxle position has an assigned combination of switch states
case and are considered primary inputs to the Trans- (open/closed) that the TCM receives from four sense
mission Control Module (TCM). circuits. The TCM interprets this information and
determines the appropriate transaxle gear position
OPERATION and shift schedule.
The Input Speed Sensor provides information on Since there are four switches, there are 16 possible
how fast the input shaft is rotating. As the teeth of combinations of open and closed switches (codes).
the input clutch hub pass by the sensor coil, an AC Seven of these codes are related to gear position and
voltage is generated and sent to the TCM. The TCM three are recognized as “between gear” codes. This
interprets this information as input shaft rpm. results in six codes which should never occur .
The Output Speed Sensor generates an AC signal These are called “invalid” codes. An invalid code will
in a similar fashion, though its coil is excited by rota- result in a DTC, and the TCM will then determine
tion of the rear planetary carrier park pawl lugs. The the shift lever position based on pressure switch
TCM interprets this information as output shaft rpm. data. This allows reasonably normal transmission
The TCM compares the input and output speed operation with a TRS failure.
signals to determine the following: The TRS has an integrated thermistor that the
• Transmission gear ratio TCM uses to monitor the transmission’s sump tem-
• Speed ratio error detection perature. This temperature is used to determine
• CVI calculation which shift schedule the TCM is to use. If the ther-
The TCM also compares the input speed signal and mistor circuit fails, the TCM will revert to calculated
the engine speed signal to determine the following: oil temperature usage.
• Torque converter clutch slippage
• Torque converter element speed ratio TRANSMISSION TEMPERATURE SENSOR
THROTTLE POSITION SENSOR DESCRIPTION
The Transmission Control Module (TCM) receives The transmission temperature sensor is a thermistor
the throttle position signal and its ground from the that is integral to the Transmission Range Sensor
Throttle Position Sensor (TPS). The TPS has a 5 volt (TRS). It can only be serviced by TRS replacement.
pull up supplied by the engine controller. The throt-
tle signal is checked by the TCM for out-of-range as OPERATION
well as intermittence (excessive signal changes). The transmission temperature sensor is used by
the TCM to sense the temperature of the fluid in the
TRANSMISSION RANGE SENSOR sump. Since fluid temperature can affect transmis-
sion shift quality and convertor lock up, the TCM
DESCRIPTION requires this information to determine which shift
The Transmission Range Sensor (TRS) is mounted schedule to operate in.
to the top of the valve body inside the transaxle and The PCM also monitors this temperature data so it
can only be serviced by removing the valve body. The can energize the vehicle cooling fan(s) when a trans-
electrical connector extends through the transaxle mission “overheat” condition exists.
case.
The Transmission Range Sensor (TRS) has four Calculated Temperature
switch contacts that: A failure in the temperature sensor or circuit will
• Determine shift lever position result in calculated temperature being substituted for
actual temperature. Calculated temperature is a pre-
dicted fluid temperature which is calculated from a OPERATION
combination of inputs: The Transmission Range Sensor (TRS) sends a sig-
• Battery (ambient) temperature nal to the Transmission Control Module (TCM)
• Engine coolant temperature regarding the position of the manual valve lever. The
• In-gear run time since start-up TCM converts this signal into a Shift Lever Position
(SLP) and sends the information to the BCM (Body
SOLENOIDS Control Module) and the instrument cluster.
To replace the shift position indicator, refer to
DESCRIPTION Group 8E, Instrument Panel And Gauges.
Solenoids are used to control the L/R, 2/4, OD, and
UD friction elements. The reverse clutch is controlled SOLENOID SWITCH VALVE
by line pressure from the manual valve in the valve
body. The solenoids are contained within the Solenoid DESCRIPTION
and Pressure Switch Assembly, and cannot be ser- The Solenoid Switch Valve (SSV) is located in the
viced individually. They can only be serviced by valve body controls the direction of the transmission
replacing the assembly. fluid when the L/R-TCC solenoid is energized.
OPERATION OPERATION
The solenoids receive electrical power from the The Solenoid Switch Valve controls line pressure
Transmission Control Relay through a single wire. from the LR-TCC solenoid. In 1st gear, the SSV will
The TCM energizes or operates the solenoids individ- be in the downshifted position, thus directing fluid to
ually by grounding the return wire of the solenoid the L/R clutch circuit. In 2nd, 3rd, and 4th, it will be
needed. When a solenoid is energized, the solenoid in the upshifted position and directs the fluid into
valve shifts, and a fluid passage is opened or closed the torque converter clutch (TCC) circuit.
(vented or applied), depending on its default operat- When shifting into 1st gear, a special hydraulic
ing state. The result is an apply or release of a fric- sequence is performed to ensure SSV movement into
tional element. the downshifted position. The L/R pressure switch is
The 2/4 and UD solenoids are normally vented to monitored to confirm SSV movement. If the move-
allow transaxle limp-in (P,R,N,2) in the event of an ment is not confirmed (the L/R pressure switch does
electrical failure. not close), 2nd gear is substituted for 1st. A DTC will
The continuity of the solenoids and circuits are be set after three unsuccessful attempts are made to
periodically tested. Each solenoid is turned on or off get into 1st gear in one given key start.
depending on its current state. An inductive spike
should be detected by the TCM during this test. It no ELECTRONICALLY MODULATED CONVERTER
spike is detected, the circuit is tested again to verify
CLUTCH
the failure. In addition to the periodic testing, the
Torque converter clutch (TCC) operation is con-
solenoid circuits are tested if a speed ratio or pres-
trolled by the TCM through the solenoid and pres-
sure switch error occurs.
sure switch assembly and valve body. When the
transaxle is in 2nd, 3rd, or 4th gear, the TCC can be
VEHICLE SPEED SIGNAL energized when certain conditions are met.
The vehicle speed signal is taken from the Output
In order to reduce heat build-up in the transmis-
Speed Sensor. The TCM converts this signal into a
sion and buffer the powertrain against torsional
pulse per mile signal and sends it to the PCM. The
vibrations, the TCM can duty cycle the L/R-CC Sole-
Pcm, in turn, sends the vehicle speed message across
noid to achieve a smooth application of the torque
the PCI Bus to the BCM. The BCM sends this signal
converter clutch. This function, referred to as Elec-
to the Instrument Cluster to display vehicle speed to
tronically Modulated Converter Clutch (EMCC) can
the driver. The vehicle speed signal pulse is roughly
occur at various times depending on the following
8000 pulses per mile.
variables:
• Shift lever position
SHIFT POSITION INDICATOR • Current gear range
• Transmission fluid temperature
DESCRIPTION • Engine coolant temperature
The shift position indicator is located in the instru- • Input speed
ment cluster. It indicates the position of the manual • Throttle angle
valve lever by illuminating an LED located under the • Engine speed
P, R, N, D, 3, or L gear symbol.
The TCM controls the torque converter by way of tem. With the ignition key in the LOCK or
internal logic software. The programming of the soft- ACCESSORY position, the interlock system prevents
ware provides the TCM with fine control over the the transmission from being shifted out of park.
L/R-CC Solenoid. There are four output logic states When the key is in the OFF or RUN position the
that can be applied as follows: shifter unlocks and can be moved to any gear posi-
• No EMCC tion. The system also prevents the operator from
• Partial EMCC turning the ignition key to the LOCK or ACCES-
• Full EMCC SORY positions.
• Gradual-to-no EMCC
NOTE: If the vehicle has column shift, install a new
NO EMCC interlock cassette (column shift) when replacing the
Under No EMCC conditions, the L/R Solenoid is ignition lock cylinder. Adjust the system after
OFF. There are several conditions that can result in replacing the cassette. Refer to procedure in this
NO EMCC operations. No EMCC can be initiated group.
due to a fault in the transaxle or because the TCM
does not see the need for EMCC under current driv-
NOTE: If the vehicle has floor shift, adjust the inter-
ing conditions.
lock cable after replacing the lock cylinder.
PARTIAL EMCC
Partial EMCC operation modulates the L/R Sole- AUTOSTICK
noid (duty cycle) to obtain partial torque converter
clutch application. Partial EMCC operation is main- OPERATION
tained until Full EMCC is called for an actuated. Autostick is a driver–interactive transaxle feature
During Partial EMCC some slip does occur. Partial that offers manual gear shifting capability. When the
EMCC will usually occur at low speeds, low load and shifter is moved into the Autostick position, the tran-
light throttle situations. saxle remains in whatever gear it was using before
Autostick was activated. Moving the shifter to the
FULL EMCC left (towards the driver) causes a downshift and mov-
During Full EMCC operation, the TCM increases ing to the right (towards the passenger) causes an
the L/R Solenoid duty cycle to full ON after Partial upshift. The instrument cluster will illuminate the
EMCC control brings the engine speed within the selected gear. The vehicle can be launched in 1st,
desired slip range of transaxle input speed relative to 2nd, or 3rd gear while in the Autostick mode. The
engine rpm. speed control is operable in 3rd and 4th gear Auto-
stick mode. Speed control will be deactivated if the
GRADUAL-TO-NO EMCC transaxle is shifted to 2nd gear. Shifting into OD
This operation is to soften the change from Full or
position cancels the Autostick mode, and the tran-
Partial EMCC to No EMCC. This is done at mid-
saxle resumes the OD shift schedule.
throttle by decreasing the L/R Solenoid duty cycle.
AUTOMATIC OVERRIDES
SHIFTER/IGNITION INTERLOCK For safety, durability, and driveability, some shifts
The ignition interlock system connects the auto- are executed automatically or prevented.
matic transmission shifter and the ignition lock sys-
AUTOMATIC SHIFTS WILL OCCUR UNDER THE FOLLOWING CONDITIONS
TYPE OF SHIFT APPROXIMATE SPEED

4-3 coast downshift 13 mph
1-2 upshift 6300 engine rpm
2-3 upshift 6300 engine rpm
4-3 kickdown shift 13-47 mph w/sufficient throttle
MANUAL SHIFTS ARE NOT PERMITTED UNDER THE FOLLOWING CONDITIONS
TYPE OF SHIFT APPROXIMATE SHIFT POINT

3-4 upshift Below 15 mph
3-2 downshift Above 74 mph @ closed throttle or 70 mph otherwise
2-1 downshift Above 41 mph @ closed throttle or 38 mph otherwise
DIAGNOSIS AND TESTING A slipping clutch may set a DTC and can be deter-
mined by operating the transaxle in all selector posi-
41TE TRANSAXLE GENERAL DIAGNOSIS tions. Then comparing which internal units are
applied in those positions. The Elements in Use
CAUTION: Before attempting any repair on a 41TE Chart provides a basis for road test analysis.
four speed automatic transaxle, check for Diagnos- The process of elimination can be used to detect
tic Trouble Codes with the DRBIII scan tool. Always any unit which slips and to confirm proper operation
use the Powertrain Diagnostic Test Procedure Man- of good units. Road test analysis can diagnose slip-
ual. ping units, but the cause of the malfunction cannot
be determined. Practically any condition can be
Transaxle malfunctions may be caused by these caused by leaking hydraulic circuits or sticking
general conditions: valves.
• Poor engine performance
• Improper adjustments HYDRAULIC PRESSURE TESTS
• Hydraulic malfunctions Pressure testing is a very important step in the
• Mechanical malfunctions diagnostic procedure. These tests usually reveal the
• Electronic malfunctions cause of most hydraulic transaxle problems.
Diagnosis of these problems should always begin Before performing pressure tests, be certain that
by checking the easily accessible variables: fluid level fluid level and condition, and shift cable adjustments
and condition, gearshift cable adjustment. Then per- have been checked and approved. Fluid must be at
form a road test to determine if the problem has been operating temperature (150 to 200 degrees F.).
corrected or that more diagnosis is necessary. If the Install an engine tachometer, raise vehicle on hoist
problem persists after the preliminary tests and cor- which allows front wheels to turn, and position
rections are completed, hydraulic pressure checks tachometer so it can be read.
should be performed. Attach 150 psi gauges to ports required for test
being conducted. A 300 psi gauge (C-3293) is required
ROAD TEST for reverse pressure test.
Prior to performing a road test, verify that the Test port locations are shown in (Fig. 6).
fluid level, fluid condition, and linkage adjustment
have been approved. TEST ONE-SELECTOR IN LOW 1st GEAR
During the road test, the transaxle should be oper- (1) Attach pressure gauge to the low/reverse clutch
ated in each position to check for slipping and any tap.
variation in shifting. (2) Move selector lever to the (L) position.
If the vehicle operates properly at highway speeds, (3) Allow vehicle wheels to turn and increase
but has poor acceleration, the converter stator over- throttle opening to achieve an indicated vehicle speed
running clutch may be slipping. If acceleration is nor- to 20 mph.
mal, but high throttle opening is needed to maintain (4) Low/reverse clutch pressure should read 115 to
highway speeds, the converter stator clutch may 145 psi.
have seized. Both of these stator defects require (5) This test checks pump output, pressure regula-
replacement of the torque converter and thorough tion and condition of the low/reverse clutch hydraulic
transaxle cleaning. circuit and shift schedule.
An engine miss could be attributed to a cracked
drive plate. A cracked drive plate could cause the
camshaft position sensor and crankshaft position sen-
sor signals to be out of synchronization. This could
cause a no-start condition.
DIAGNOSIS AND TESTING (Continued)
Fig. 5 ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER

TEST 2A–SELECTOR IN OD
NOTE: This test checks the underdrive clutch

hydraulic circuit as well as the shift schedule.
(1) Attach gauge to the UD clutch tap.

(2) Move selector lever to the OD position.
(3) Allow wheels to rotate freely and increase
throttle opening to achieve an indicated speed of 40
mph.
(4) Underdrive clutch pressure should read below
5 psi. If not, than either the solenoid assembly or
TCM is at fault.
TEST THREE-OVERDRIVE CLUTCH CHECK

(1) Attach gauge to the overdrive clutch tap.
Fig. 6 Pressure Taps (2) Move selector lever to the (Circle D) position.
(3) Allow vehicle wheels to turn and increase
TEST TWO-SELECTOR IN DRIVE 2nd GEAR throttle opening to achieve an indicated vehicle speed
of 20 mph.
NOTE: This test checks the underdrive clutch (4) Overdrive clutch pressure should read 74 to 95
hydraulic circuit as well as the shift schedule. psi.
(5) Move selector lever to the (3) position and
(1) Attach gauge to the underdrive clutch tap.
increase indicated vehicle speed to 30 mph.
(2) Move selector lever to the 3 position.
(6) The vehicle should be in second gear and over-
(3) Allow vehicle wheels to turn and increase
drive clutch pressure should be less than 5 psi.
throttle opening to achieve an indicated vehicle speed
(7) This test checks the overdrive clutch hydraulic
of 30 mph.
circuit as well as the shift schedule.
(4) In second gear the underdrive clutch pressure
should read 110 to 145 psi.
TEST FOUR-SELECTOR IN CIRCLE DRIVE, TEST SIX-SELECTOR IN REVERSE
OVERDRIVE GEAR (1) Attach gauge to the reverse and LR clutch tap.
(1) Attach gauge to the 2/4 clutch tap. (2) Move selector lever to the reverse position.
(2) Move selector lever to the (Circle D) position. (3) Read reverse clutch pressure with output sta-
(3) Allow vehicle front wheels to turn and increase tionary (foot on brake) and throttle opened to achieve
throttle opening to achieve an indicated vehicle speed 1500 rpm.
of 30 mph. (4) Reverse and LR clutch pressure should read
(4) The 2/4 clutch pressure should read 75 to 95 psi. 165 to 235 psi.
(5) This test checks the 2/4 clutch hydraulic cir- (5) This test checks the reverse clutch hydraulic
cuit. circuit.
TEST FIVE-SELECTOR IN CIRCLE DRIVE, TEST RESULT INDICATIONS

OVERDRIVE (1) If proper line pressure is found in any one test,
(1) Attach gauge to the torque converter clutch off the pump and pressure regulator are working prop-
pressure tap. erly.
(2) Move selector lever to the (Circle D) position. (2) Low pressure in all positions indicates a defec-
(3) Allow vehicle wheels to turn and increase tive pump, a clogged filter, or a stuck pressure regu-
throttle opening to achieve an indicated vehicle speed lator valve.
of 50 mph. (3) Clutch circuit leaks are indicated if pressures
do not fall within the specified pressure range.
CAUTION: Both wheels must turn at the same (4) If the overdrive clutch pressure is greater than
speed. 5 psi in Step 4 of Test Three, a worn reaction shaft
seal ring or a defective solenoid assembly is indi-
(4) Torque converter clutch off pressure should be cated.
less than 5 psi. (5) If the underdrive clutch pressure is greater
(5) This test checks the torque converter clutch than 5 psi in Step 4 of Test 2A, a defective solenoid
hydraulic circuit. assembly or TCM is the cause.
PRESSURE CHECK SPECIFICATIONS

CLUTCH AIR PRESSURE TESTS REVERSE CLUTCH

Inoperative clutches can be located using a series Apply air pressure to the reverse clutch apply pas-
of tests by substituting air pressure for fluid pressure sage and watch for the push/pull piston to move rear-
(Fig. 7) (Fig. 8). The clutches may be tested by apply- ward. The piston should return to its starting
ing air pressure to their respective passages. The position when the air pressure is removed.
valve body must be removed and Tool 6056 installed.
To make air pressure tests, proceed as follows: 2/4 CLUTCH
Apply air pressure to the feed hole located on the
NOTE: The compressed air supply must be free of 2/4 clutch retainer. Look in the area where the 2/4
all dirt and moisture. Use a pressure of 30 psi. piston contacts the first separator plate and watch
carefully for the 2/4 piston to move rearward. The
Remove oil pan and valve body. See Valve body piston should return to its original position after the
removal. air pressure is removed.
LOW/REVERSE CLUTCH
Apply air pressure to the low/reverse clutch feed
hole (rear of case, between 2 bolt holes). Then, look
in the area where the low/reverse piston contacts the
first separator plate. Watch carefully for the piston to
move forward. The piston should return to its origi-
nal position after the air pressure is removed.
UNDERDRIVE CLUTCH
Because this clutch piston cannot be seen, its oper-
ation is checked by function. Air pressure is applied
to the low/reverse and the 2/4 clutches. This locks the
output shaft. Use a piece of rubber hose wrapped
around the input shaft and a pair of clamp-on pliers
to turn the input shaft. Next apply air pressure to
Fig. 7 Air Pressure Test Plate the underdrive clutch. The input shaft should not
rotate with hand torque. Release the air pressure
and confirm that the input shaft will rotate.
FLUID LEAKAGE-TORQUE CONVERTER

HOUSING AREA
(1) Check for source of leakage.
(2) Fluid leakage at or around the torque converter
area may originate from an engine oil leak. The area
should be examined closely. Factory fill fluid is red
and, therefore, can be distinguished from engine oil.
(3) Prior to removing the transaxle, perform the
following checks:
(4) When leakage is determined to originate from
the transaxle, check fluid level prior to removal of
the transaxle and torque converter.
(5) High oil level can result in oil leakage out the
Fig. 8 Testing Reverse Clutch vent in the manual shaft. If the fluid level is high,
adjust to proper level.
OVERDRIVE CLUTCH (6) After performing this operation, inspect for
Apply air pressure to the overdrive clutch apply leakage. If a leak persists, perform the following
passage and watch for the push/pull piston to move operation on the vehicle. This will determine if the
forward. The piston should return to its starting torque converter or transaxle is leaking.
position when the air pressure is removed.
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
• Torque converter weld leaks at the outside CONDITION POSSIBLE CAUSE
(peripheral) weld.
• Torque converter hub weld. ALL PRND3L DISPLAY Check wiring and
LIGHTS 9ON9 IN P&N connectors
NOTE: Hub weld is inside and not visible. Do not GEAR POSITIONS
attempt to repair. Replace torque converter. Faulty trans. range
sensor
Faulty manual lever
INTERLOCK SYSTEM OPERATION CHECK
If the interlock system operates in any way other ALL DISPLAY LIGHTS Check wiring &
than as described below, repair of the system is 9ON9 IN ALL GEAR connectors
required. POSITIONS
(1) Place shifter in gated PARK and place ignition Faulty trans. range
key in the LOCK or ACCESSORY position. The sensor
shifter SHOULD NOT be able to move out of gated Faulty manual lever
park.
(2) Rotate the ignition key to OFF or RUN/ON. CCD communication
The shifter SHOULD BE able to move into ANY gear malfunction
position. ALL DISPLAY LIGHTS Normal transient
(3) Place shifter in the DRIVE position. The igni- 9OFF9 condition between P&R
tion key SHOULD NOT be able to rotate into the and R&N gear positions
LOCK or ACCESSORY position. Check shift lever linkage
Body controller
SHIFT POSITION INDICATOR malfunction
The transmission range sensor (on the valve body)
sends a signal to the TCM on the position of the Check wiring and
transaxle manual valve lever. The TCM receives the connectors
switch signal and processes the data. The TCM sends Faulty cluster
the Shift Lever Position (SLP) information to the ALL DISPLAY LIGHTS CCD communication
BCM via the CCD bus. The BCM then outlines the 9OFF9 ACCOMPANIED malfunction
appropriate shifter position indicator in the instru- BY A 9NO BUS9
ment cluster. MESSAGE
If a problem arises with the shifter position indica-
DISPLAY LIGHTS OUT Check wiring and
tor, consult the following chart for diagnostic infor-
OF SEQUENCE WITH connectors
mation. If the malfunction cannot be corrected using
SHIFT LEVER
the chart, consult the proper diagnostic manual.
To replace the shifter position indicator, refer to Faulty trans. range
Group 8E, Instrument Panel And Gauges. sensor
Faulty manual lever
AUTOSTICK CCD communication
The autostick feature will be deactivated if one of malfunction
the following conditions occur:
• DTC P0705–Check Shifter Signal–usually
accompanied by all PRNDL lights turning on in Park SERVICE PROCEDURES
and Neutral. This will result in a DTC P0705 if three
such errors are detected after any one “key–on”. FLUID LEVEL AND CONDITION CHECK
• DTC P1796–Autostick Input Circuit
• DTC P1797–Manual Shift Overheat–(Transmis- NOTE: The transmission and differential utilize the
sion oil temperature 275° F) or (Engine coolant tem- same fluid sump, which require Automatic Trans-
perature 255° F). mission Fluid (ATF+3/Type 7176).
Acceptable powertrain temperature must be
achieved to reactivate Autostick after a high temper-
ature fault: NOTE: The transmission fluid level should be
• Transmission Oil Temperature <255° F inspected at least every six months.
• Engine Coolant Temperature <240° F
SERVICE PROCEDURES (Continued)
FLUID LEVEL CHECK gears churn up foam and cause the same conditions
The transmission sump has a dipstick to check oil which occur with a low fluid level.
similar to most automatic transmissions. It is located In either case, air bubbles can cause overheating
on the left side of the engine. Be sure to wipe all dirt and/or fluid oxidation, and varnishing. This can
from dipstick handle before removing. interfere with normal valve, clutch, and accumulator
The torque converter fills in both the P Park and N operation. Foaming can also result in fluid escaping
Neutral positions. Place the selector lever in P Park from the transaxle vent where it may be mistaken
to be sure that the fluid level check is accurate. The for a leak.
engine should be running at idle speed for at Along with fluid level, it is important to check the
least one minute, with the vehicle on level condition of the fluid. When the fluid smells burned,
ground. At normal operating temperature (approxi- and is contaminated with metal or friction material
mately 82 C. or 180 F.), the fluid level is correct if it particles, a complete transaxle recondition is needed.
is in the HOT region (cross-hatched area) on the oil Be sure to examine the fluid on the dipstick closely.
level indicator (Fig. 9). The fluid level will be approx- If there is any doubt about its condition, drain out a
imately one-quarter inch above the lower hole of the sample for a double check.
dipstick at 70° F fluid temperature. After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
FLUID AND FILTER SERVICE—TRANSMISSION

NOTE: Refer to Group 0, Lubrication and Mainte-
nance, or the vehicle owner’s manual, for the
recommended maintenance (fluid/filter change) in-
tervals for this transaxle.
NOTE: Only fluids of the type labeled MoparT

ATF+3 (Automatic Transmission Fluid) Type 7176
should be used. A filter change should be made at
the time of the transmission oil change. The magnet
(on the inside of the oil pan) should also be cleaned
with a clean, dry cloth.
Fig. 9 Dipstick Markings

NOTE: If the transaxle is disassembled for any rea-
FLUID LEVEL CHECK USING DRB son, the fluid and filter should be changed.
NOTE: Engine and Transaxle should be at normal

operating temperature before performing this proce- FLUID/FILTER SERVICE (RECOMMENDED)
dure. (1) Raise vehicle on a hoist (See Lubrication,
Group 0). Place a drain container with a large open-
(1) Start engine and apply parking brake. ing, under transaxle oil pan.
(2) Hook up DRBIII scan tool and select transmis- (2) Loosen pan bolts and tap the pan at one corner
sion. to break it loose allowing fluid to drain, then remove
(3) Select sensors. the oil pan.
(4) Read the transmission temperature value. (3) Install a new filter and o-ring on bottom of the
(5) Compare the fluid temperature value with the valve body and tighten retaining screws to 5 N·m (40
chart. in. lbs.).
(6) Adjust transmission fluid level shown on the (4) Clean the oil pan and magnet. Reinstall pan
dipstick according to the chart. using new Mopar Silicone Adhesive sealant. Tighten
(7) Check transmission for leaks. oil pan bolts to 19 N·m (165 in. lbs.).
Low fluid level can cause a variety of conditions (5) Pour four quarts of Mopart ATF+3 (Automatic
because it allows the pump to take in air along with Transmission Fluid) Type 7176 through the dipstick
the fluid. As in any hydraulic system, air bubbles opening.
make the fluid spongy, therefore, pressures will be (6) Start engine and allow to idle for at least one
low and build up slowly. minute. Then, with parking and service brakes
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
Transmission Fluid Temperature Chart

applied, move selector lever momentarily to each ALTERNATIVE SERVICE METHODS (FLUID ONLY)
position, ending in the park or neutral position.
(7) Check the transaxle fluid level and add an TRANSAXLE FLUID EXCHANGER METHOD
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the “ADD” mark on the dip- CAUTION: The use of any fluid exchanger that
stick (Fig. 10). introduces additives into the transaxle is not rec-
(8) Recheck the fluid level after the transaxle has ommended.
reached normal operating temperature (180°F.).
(9) To prevent dirt from entering transaxle, make (1) To perform the transaxle fluid exchange, the
certain that dipstick is fully seated into the dipstick transaxle must be at operating temperature. Drive
opening. the vehicle until it reaches full operating tempera-
ture.
(2) Obtain a suitable transaxle fluid exchanger
and verify the tank is clean and dry.
(3) Fill the tank to the recommended fill capacity
with Mopart ATF+3 Type 7176.
(4) Connect the machine to the vehicle following
the manufacturers instructions. Perform the
exchange procedure following the instructions pro-
vided with the machine.
(5) Once machine has completed the fluid
exchange. Check the fluid level and condition and fill
to proper level with Mopart ATF+3 Type 7176. Refer
Fig. 10 Dipstick Markings to Fluid Level and Condition Check in this group for
the proper fluid “top-off” procedure.
NOTE: Verify that the transaxle cooler lines are or sludged oil are not later transferred back into the
tightened to proper specifications. Cooler line reconditioned (or replaced) transaxle.
torque specification is 2 N•m (18 in. lbs.). The recommended procedure for flushing the tran-
saxle cooler is to use Tool 6906A Cooler Flusher.
DIPSTICK TUBE FLUID SUCTION METHOD WARNING: WEAR PROTECTIVE EYEWEAR THAT
(1) When performing the fluid suction method, MEETS THE REQUIREMENTS OF OSHA AND ANSI
make sure the transaxle is at full operating temper- Z87.1–1968. WEAR STANDARD INDUSTRIAL RUB-
ature. BER GLOVES.
(2) To perform the dipstick tube fluid suction KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
method, use a suitable fluid suction device (Vaculay AND OTHER IGNITION SOURCES AWAY FROM THE
or equivalent). AREA TO PREVENT THE IGNITION OF COMBUSTI-
(3) Insert the fluid suction line into the dipstick BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
tube. EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
NOTE: Verify that the suction line is inserted to the KEEP THE AREA WELL VENTILATED.
lowest point of the transaxle oil pan. This will DO NOT LET FLUSHING SOLVENT COME IN CON-
ensure complete evacuation of the fluid in the pan. TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
(4) Follow the manufacturers recommended proce- INATION OCCURS, FLUSH EYES WITH WATER FOR
dure and evacuate the fluid from the transaxle. 15 TO 20 SECONDS. REMOVE CONTAMINATED
(5) Remove the suction line from the dipstick tube. CLOTHING AND WASH AFFECTED SKIN WITH
(6) Pour four quarts of Mopart ATF+3 (Automatic SOAP AND WATER. SEEK MEDICAL ATTENTION.
Transmission Fluid) Type 7176 through the dipstick
opening.
(7) Start engine and allow to idle for at least one COOLER FLUSH USING TOOL 6906A
minute. Then, with parking and service brakes (1) Remove cover plate filler plug on Tool 6906A.
applied, move selector lever momentarily to each Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
position, ending in the park or neutral position. Flushing solvents are petroleum based solutions gen-
(8) Check the transaxle fluid level and add an erally used to clean automatic transmission compo-
appropriate amount to bring the transaxle fluid level nents. DO NOT use solvents containing acids, water,
to 3mm (1/8 in.) below the “ADD” mark on the dip- gasoline, or any other corrosive liquids.
stick (Fig. 10). (2) Reinstall filler plug on Tool 6906A.
(9) Recheck the fluid level after the transaxle has (3) Verify pump power switch is turned OFF. Con-
reached normal operating temperature (180°F.). nect red alligator clip to positive (+) battery post.
(10) To prevent dirt from entering transaxle, make Connect black (-) alligator clip to a good ground.
certain that dipstick is fully seated into the dipstick (4) Disconnect the cooler lines at the transmission.
opening.
NOTE: When flushing transmission cooler and
ALUMINUM THREAD REPAIR lines, ALWAYS reverse flush.
Damaged or worn threads in the aluminum tran-
saxle case and valve body can be repaired by the use (5) Connect the BLUE pressure line to the OUT-
of Heli-Coils, or equivalent. This repair consists of LET (From) cooler line.
drilling out the worn-out damaged threads. Then tap (6) Connect the CLEAR return line to the INLET
the hole with a special Heli-Coil tap, or equivalent, (To) cooler line.
and installing a Heli-Coil insert, or equivalent, into (7) Turn pump ON for two to three minutes to
the hole. This brings the hole back to its original flush cooler(s) and lines. Monitor pressure readings
thread size. and clear return lines. Pressure readings should sta-
Heli-Coil, or equivalent, tools and inserts are bilize below 20 psi. for vehicles equipped with a sin-
readily available from most automotive parts suppli- gle cooler and 30 psi. for vehicles equipped with dual
ers. coolers. If flow is intermittent or exceeds these pres-
sures, replace cooler.
FLUSHING COOLERS AND TUBES (8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
When a transaxle failure has contaminated the
at cover plate. Disconnect CLEAR return line at
fluid, the oil cooler(s) must be flushed. The cooler
cover plate, and place it in a drain pan.
bypass valve in the transaxle must be replaced also.
(10) Turn pump ON for 30 seconds to purge flush-
The torque converter must also be replaced with an
ing solution from cooler and lines. Turn pump OFF.
exchange unit. This will insure that metal particles
(11) Place CLEAR suction line into a one quart • The brakes must be applied
container of Mopart ATF PLUS 3 Type 7176 auto- • The engine speed must be above 500 rpm
matic transmission fluid. • The throttle angle (TPS) must be less than 3
(12) Turn pump ON until all transmission fluid is degrees
removed from the one quart container and lines. This • The shift lever position must stay until
purges any residual cleaning solvent from the trans- prompted to shift to overdrive
mission cooler and lines. Turn pump OFF. • The shift lever position must stay in overdrive
(13) Disconnect alligator clips from battery. Recon- after the Shift to Overdrive prompt until the DRBIII
nect flusher lines to cover plate, and remove flushing indicates the procedure is complete
adapters from cooler lines. • The calculated oil temperature must be above
60° and below 200°
OIL PUMP VOLUME CHECK (1) Plug the DRBIII scan tool into the data link
After the new or repaired transmission has been connector. The connector is located under the instru-
installed, fill to the proper level with Mopar ATF ment panel.
PLUS 3 (Type 7176) automatic transmission fluid. (2) Go to the Transmission screen.
The volume should be checked using the following (3) Go to the Miscellaneous screen.
procedure: (4) Select Quick Learn Procedure. Follow the
(1) Disconnect the From cooler line at the trans- instructions of the DRBIII to perform the Quick
mission and place a collecting container under the Learn Procedure.
disconnected line.
PINION FACTOR PROCEDURE
CAUTION: With the fluid set at the proper level, The vehicle speed readings for the speedometer are
fluid collection should not exceed (1) quart or inter- taken from the output speed sensor. The TCM must
nal damage to the transmission may occur. be calibrated to the different combinations of equip-
ment available. A procedure has been developed
(2) Run the engine at curb idle speed , with the called Pinion Factor. It allows the technician to set
shift selector in neutral. the Transmission Control Module initial setting so
(3) If fluid flow is intermittent or it takes more that the speedometer readings will be correct.
than 20 seconds to collect one quart of ATF, discon- Failure to perform this procedure will cause a No
nect the To Cooler line at the transaxle. Speedometer Operation condition.
(4) Refill the transaxle to proper level and recheck This procedure must be performed if the Transmis-
pump volume. sion Control Module has been replaced.
(5) If flow is found to be within acceptable limits, To properly read or reset the Pinion Factor, it is
replace the cooler. Then fill transmission to the necessary to use a DRBIII scan tool. Perform the fol-
proper level, using Mopar ATF PLUS 3 (Type 7176) lowing steps with the DRBIII scan tool to read or
automatic transmission fluid. reset the Pinion Factor:
(6) If fluid flow is still found to be inadequate, (1) Plug the DRBIII scan tool into the data link
check the line pressure using the Transaxle Hydrau- connector located under the instrument panel.
lic Pressure Test procedure. (2) Select the Transmission menu.
(7) Check the cooler for debris on the external sur- (3) Select the Miscellaneous menu.
faces. Clean as necessary. (4) Select Pinion Factor. Then follow the instruc-
tions on the DRBIII scan tool screen.
TRANSAXLE QUICK LEARN PROCEDURE
The quick learn procedure requires the use of the
DRBIII scan tool. REMOVAL AND INSTALLATION
This program allows the electronic transaxle sys-
tem to recalibrate itself. This will provide the best GEARSHIFT CABLE
possible transaxle operation. The quick learn proce-
dure should be performed if any of the following pro- REMOVAL
cedures are performed: (1) Place transaxle in PARK.
• Transaxle Assembly Replacement (2) Disconnect battery negative cable at left strut
• Transmission Control Module Replacement tower.
• Solenoid Pack Replacement (3) Remove air cleaner assembly.
• Clutch Plate and/or Seal Replacement (4) Remove battery positive cable.
• Valve Body Replacement or Recondition (5) Remove Transmission Control Module (TCM)
To perform the Quick Learn Procedure, the follow- connector. Remove TCM.
ing conditions must be met:
(6) Pull Power Distribution Center (PDC) up and
out of the way.
(7) Using a pry tool, pry up on cable at manual
valve lever and remove cable from lever (Fig. 11).
(8) Remove the screw from the cable bracket at the
transaxle (Fig. 11).
Fig. 13 Gearshift Cable at Floor Shifter

(15) Hoist vehicle. Refer to Group 0, Lubrication
and Maintenance.
(16) Remove the cable grommet from the floor pan
area (Fig. 14).
(17) Carefully remove the cable from the under-
Fig. 11 Gearshift Cable at Transaxle body by unfolding the cable retainer clip (Fig. 14) as
(9) Remove the gearshift knob set screw and knob. you go along.
(10) Remove the rear half of the floor console.
Refer to Group 23, Body.
(11) Remove the front half of the floor console.
Refer to Group 23, Body.
(12) Loosen nut on shift cable adjust lever (Fig.
12).
Fig. 14 Gearshift Cable Routing

INSTALLATION
(1) Install cable assy. into floor pan tunnel hole
Fig. 12 Shift Cable Adjust Lever Nut and secure grommet. If necessary, use a synthetic
(13) Using a flat blade pry tool, remove the shifter based lubricant to aid in grommet installation.
cable core end from the shift lever pin (Fig. 13). (2) Position cable into retainer clip (Fig. 14) and
(14) Using a flat blade pry tool, pry the cable con- tighten clip to secure cable.
duit clip up from the shifter bracket. Pull up on the (3) Install cable to transaxle and tighten screw to
cable conduit and remove from bracket (Fig. 13). 14 N·m (125 in. lbs.) (Fig. 11).
(4) Install cable to transaxle shift lever (Fig. 11).
(5) Lower vehicle.
(6) Connect cable to shifter conduit bracket and
shift pin. Install cable retaining clip (Fig. 13).
(7) Verify transaxle shift lever and floor shifter
lever are in the PARK position.
(8) Tighten cable adjuster nut (Fig. 12).
(9) Reinstall front and rear floor consoles.
(10) Install gearshift handle.
GEARSHIFT MECHANISM
REMOVAL
(1) Disconnect battery and isolate cable.
(2) Remove the gearshift knob set screw and knob.
(3) Remove console assembly. Refer to Group 23,
Body.
(4) Using a flat blade pry tool, remove the shifter
cable end from the gearshift pin (Fig. 15).
(5) Pry the cable retaining clip up and off of the Fig. 16 Interlock Cable at Floor Shifter Assembly
gearshift mechanism. Remove the gearshift cable
from the gearshift mechanism (Fig. 15).
Fig. 17 Gearshift Mechanism

(3) Slip interlock cable core wire into interlock
adjustment lever groove. Make sure the interlock
cable slug is seated in the groove (Fig. 16).
(4) Slip interlock cable conduit end fitting into
Fig. 15 Gearshift Cable at Floor Shifter Assembly base and snap into place (Fig. 16).
(6) Pry up the adjuster lock on the shifter/ignition (5) Adjust the gearshift and interlock cables. Refer
interlock cable (Fig. 16). Unsnap the shifter/ignition to Adjustments in this group.
interlock cable end fitting from the groove in the
gearshift mechanism. NOTE: Gearshift and Interlock cables MUST be
(7) Remove the nuts at the base of the gearshift adjusted. Refer to the Adjustments section in this
mechanism (Fig. 17). Remove the shifter assy. and group for the correct procedures.
cable bracket.
(6) If equipped with Autostick, connect the Auto-
INSTALLATION stick connector.
(1) Install shifter assy and bracket (Fig. 17). (7) Install the console assembly. Refer to Group 23,
Tighten the nuts to 17 N·m (150 in. lbs.). Body for the correct procedures.
(2) Install gearshift cable into conduit bracket and (8) Install the gearshift knob and tighten the set
onto shift pin. Install retainer clip (Fig. 15). screw.
(9) Connect the battery negative cable.
AUTOSTICK
The autostick switch mechanism is incorporated
into the gearshift mechanism. If the switch needs to
be replaced, the gearshift mechanism must be
replaced. To replace the autostick switch, refer to
Gearshift Mechanism Replacement in this section.
SHIFTER IGNITION INTERLOCK CABLE

REMOVAL
(1) Disconnect and isolate, the battery negative (-)
cable at the left side strut tower.
Body.
(4) Remove the interlock cable from the shifter
housing. Slide the cable out of the groove in the Fig. 19 Instrument Panel Top Cover–Left Side
interlock lever (Fig. 18).
Fig. 20 Center Bezel
Fig. 18 Shifter/Ignition Interlock Cable

(5) Pull cable up and out of the gearshift mecha-
nism.
(6) Remove fuse panel cover from left end of
instrument panel. Remove screw holding end of
instrument panel top cover (Fig. 19).
(7) Pull center bezel off (Fig. 20).
(8) Remove screws holding instrument panel top
cover to center of instrument panel (Fig. 21).
(9) Pull instrument panel top cover up enough to
gain access to knee bolster screws (Fig. 22).
(10) Remove lower knee bolster screws and knee
bolster.
(11) Remove screws from lower steering column Fig. 21 Instrument Panel Top Cover–Center
shroud (Fig. 23). (13) Hold tilt wheel lever down and slide lower
(12) Pull lower shroud to clear ignition cylinder shroud forward to remove it from column (Fig. 25).
(Fig. 24). (14) Tilt wheel to full down position and remove
upper steering column shroud.
Fig. 22 Knee Bolster Attaching Points

Fig. 25 Lower Shroud Removal
Fig. 26 Ignition Key/Switch Positions

Fig. 23 Lower Steering Column Shroud Screw
Locations
Fig. 27 Interlock Cable and Connector
Fig. 24 Remove Lower Shroud From Ignition (16) Unclip the cable retaining clip located along
Cylinder the cable housing.
(17) Remove interlock cable from underside of
(15) Place the ignition key in the ON/RUN position instrument panel.
(Fig. 26). Grasp the interlock cable clip and connec-
tor. Remove the cable from the interlock housing
(Fig. 27).
INSTALLATION (16) Install screw holding end of instrument panel
top cover. Install fuse panel cover from left end of
CAUTION: When installing interlock cable assem- instrument panel.
bly, care must be taken not to bend exposed cable (17) Reconnect the battery negative (-) cable to the
wire and slug at shifter end of cable. vehicle battery.
(1) Route interlock cable into lower dash panel. INTERLOCK MECHANISM
(2) Turn the ignition switch to the ON/RUN posi-
tion (Fig. 26). REMOVAL
(3) Install the interlock cable into the interlock (1) Remove the lower column covers, knee bolster
housing at the steering column (Fig. 28). Verify the and shrouds. Refer to Interlock Cable Replacement.
cable snaps into the housing. (2) Grasp the interlock cable and connector firmly.
Remove the interlock cable.
(3) Remove the two interlock mechanism to steer-
ing column attaching screws (Fig. 29). Remove the
interlock housing.
Fig. 28 Interlock Cable At Housing

(4) Install interlock cable into routing clip located
along cable housing.
(5) Route interlock cable to the console.
(6) Snap the shifter/ignition interlock cable end fit- Fig. 29 Interlock Mechanism
ting into the groove in the gearshift mechanism (Fig. INSTALLATION
18). (1) Position the interlock housing at steering col-
(7) Adjust the Shifter/Ignition Interlock System. umn. Install the two interlock mechanism to steering
See Interlock System Adjustment, in this section of column attaching screws. Torque screws to 3 N·m (21
service manual. in. lbs.).
(2) Snap the interlock cable into the housing.
NOTE: The Interlock Cable MUST be adjusted.
(3) Install the lower column covers, shrouds and
Refer to Interlock System Adjustment, in this group.
knee bolster. Refer to Interlock Cable Replacement.
(8) Install console assembly. Refer to Group 23,
Body.
(9) Install the gearshift knob set screw and knob. MANUAL VALVE LEVER (SHIFT LEVER)
(10) Tilt wheel to full down position and install
upper steering column shroud. REMOVAL
(11) Hold tilt wheel lever down and slide lower (1) Remove shift cable from lever.
shroud in at column. (2) Loosen the lever mounting bolt. Do not remove
(12) Install screws at lower steering column bolt (not necessary).
shroud. (3) Pull up on lever and remove.
(13) Install lower knee bolster screws and knee
bolster. INSTALLATION
(14) Install screws holding instrument panel top (1) For installation, reverse removal procedure.
cover to center of instrument panel.
(15) Install center bezel.
SOLENOID ASSEMBLY-REPLACE
Fig. 33 Remove Solenoid Assembly

Fig. 30 Remove Input Speed Sensor TRANSMISSION RANGE SENSOR
The transmission range sensor is located within
the transaxle. To remove the TRS the transaxle oil
pan and valve body must be removed.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove engine air cleaner and tube.
(3) Remove gearshift cable.
(4) Remove manual valve lever.
(5) Disconnect transmission range sensor connector.
(6) Hoist vehicle.
(7) Carefully remove transaxle oil pan and drain
fluid.
(8) Remove transaxle oil filter. Let transaxle oil
drain fully.
(9) Remove valve body retaining bolts.
Fig. 31 Remove Sound Cover (10) Extract park rod from guide bracket and
remove valve body from transaxle.
(11) Place valve body on workbench (Fig. 34).
(12) Remove TRS retaining screw (Fig. 35).
(13) Remove manual shaft seal (Fig. 36).
(14) Slide Transmission Range Sensor up the man-
ual shaft and remove (Fig. 37).
INSTALLATION
Tighten TRS retaining screw to 5 N·m (45 in. lbs.)
Reseal transaxle oil pan using RTV.
SPEED SENSOR-INPUT
CAUTION: When disconnecting speed sensor con-
nector, be sure that the weather seal does not fall
off or remain in old sensor.
Fig. 32 Remove Attaching Screws
To install solenoid assembly, reverse removal pro- The input speed sensor is located to the left of the
cedure. Tighten screws to 12 N·m (105 in. lbs.). manual shift lever (Fig. 38).
Fig. 34 Valve Body W/TRS Fig. 37 Remove Transmission Range Sensor
Fig. 35 Remove Retaining Screw Fig. 38 Input (Turbine) Speed Sensor

SPEED SENSOR-OUTPUT
CAUTION: When disconnecting speed sensor con-
nector, be sure that the weather seal does not fall
off or remain in old sensor.
The output speed sensor is located to the right of

the manual shift lever (Fig. 39).
TRANSMISSION CONTROL MODULE

Do not interchange transmission control modules
with previous year transmission control modules. If a
same year TCM is being used from a different vehi-
cle, the following procedures must be performed:
• Quick Learn Procedure
• Electronic Pinion Procedure
Fig. 36 Remove Manual Shaft Seal The transmission control module is next to the bat-
tery on the left side of vehicle, in the engine compart-
ment. It is held in place by three mounting screws.
INSTALLATION
2.5 LITER ENGINE

REMOVAL
(1) Disconnect battery negative cable at the left
strut tower.
(2) Remove TCM 60 way connector.
(3) Remove three mounting screws.
(4) Remove TCM.
INSTALLATION
VALVE BODY
Fig. 39 Output Speed Sensor
NOTE: If the transmission control module has been REMOVAL
replaced, the following procedures must be per-
formed:
• Quick Learn Procedure: This procedure will

allow the transmission control module to learn the
characteristics of the vehicle.
• Electronic Pinion Factor Procedure: This proce-
dure will reprogram the TCM to compensate for dif-
ferent tire sizes and final drive ratios.
2.4 LITER ENGINE

REMOVAL
(1) Disconnect battery negative cable at the left
strut tower.
(2) Remove air cleaner clamps and air cleaner.
(3) Remove TCM 60 way connector. Fig. 41 Remove Oil Pan Bolts
(4) Remove three mounting screws.
(5) Remove TCM (Fig. 40).
Fig. 42 Remove Oil Pan
Fig. 40 Transmission Control Module NOTE: To ease removal of the valve body, turn the
manual valve lever fully clockwise.
Fig. 43 Remove Oil Filter Fig. 46 Remove Valve Body
Fig. 44 Remove Valve Body Attaching Bolts Fig. 47 Valve Body Removed
CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
NOTE: To ease installation of the valve body, turn

the manual valve lever fully clockwise.
Guide park rod rollers into guide bracket, while

shifting manual lever assembly out of the installation
position.
TRANSAXLE
REMOVAL
Transaxle removal does NOT require engine
removal.
Fig. 45 Push Park Rod Rollers from Guide Bracket
The transaxle and torque converter must be
INSTALLATION removed as an assembly; otherwise, the torque con-
To install valve body, reverse removal procedure. verter drive plate, pump bushing or oil seal may be
damaged. The drive plate will not support a load;
therefore, none of the weight of the transaxle should
be allowed to rest on the drive plate during removal.
(1) Disconnect battery negative cable at left strut
tower (Fig. 48).
Fig. 50 Solenoid Pack Connector
Fig. 48 Negative Cable

(2) Remove air cleaner duct.
(3) Remove transmission control module (TCM)
and wiring (Fig. 49).
Fig. 51 Transaxle Cooler Lines
Fig. 49 Transmission Control Module

(4) Remove solenoid pack connector (Fig. 50).
(5) Remove dipstick tube.
(6) Remove transaxle cooler lines (Fig. 51).
(7) Remove shift cable at lever and at clamp on
transaxle (Fig. 52) (Fig. 53).
(8) Install engine support fixture and support
engine (Fig. 54).
(9) Remove left upper transaxle mount top bolts
(Fig. 55). Fig. 52 Shift Cable at Lever
(10) Raise vehicle. Remove front wheels. Refer to
CAUTION: The exhaust flex joint must be discon-
Group 2, Suspension to remove wheel hub nuts and
nected from the exhaust manifold anytime the
both drive shafts.
engine is lowered. If the engine is lowered while the
(11) Remove left and right side lower splash
flex pipe is attached, damage will occur.
shields (Fig. 56).
Fig. 53 Shift Cable Clamp Fig. 56 Lower Splash Shields

(13) Remove remaining left upper mount bolts
(Fig. 57).
Fig. 54 Engine Support Fixture (Typical)
Fig. 57 Left Mount Bolts

(14) Remove engine oil filter.
(15) Remove starter and wiring (Fig. 58).
Fig. 55 Upper Transaxle Mount

(12) Remove bolts securing exhaust flex joint to
exhaust manifold. Disconnect exhaust pipe from
manifold.
Fig. 58 Starter
(16) Remove front motor mount bracket. (27) Remove left side steering gear bolts. Remove
(17) Remove rear mount bracket through-bolt. left side K-frame bolts (Fig. 61).
(18) Remove center member bolts.
(19) Remove rear mount bracket bolts, and remove
rear mount bracket.
(20) Remove radiator lower crossmember.
(21) Remove lateral bending strut brackets (front
and rear).
NOTE: The 2.4 liter engine has an oil pan collar

bracket attached to the transaxle bell housing.
Refer to Group 9–Engine, for the proper Removal
and Installation procedure.
(22) Remove flex plate cover.

(23) Rotate engine clockwise to line up converter
bolts (Fig. 59). Remove converter bolts (Fig. 60).
Mark converter for reassembly ease.
Fig. 61 Steering Gear and K-frame Bolts

(28) Remove sway bar mounts (Fig. 62).
Fig. 59 Rotate Engine Clockwise
Fig. 62 Sway Bar Mounts

(29) Position transmission jack under transaxle
and support with safety chain (Fig. 63).
(30) Remove upper and lower transaxle bell hous-
ing bolts.
(31) Move K-frame rearward and carefully lower
the transaxle assembly from vehicle.
INSTALLATION
(1) For installation of transaxle, reverse the above
procedure.
(2) Check and/or adjust gear shift cable.
(3) Refill transaxle with MOPARt ATF PLUS 3
(Automatic Transmission Fluid) Type 7176.
Fig. 60 Converter Bolts

(24) Remove crank position sensor (if equipped).
(25) Remove transaxle wiring.
(26) Loosen right side steering gear bolts. Loosen
right side K-frame bolts.
DISASSEMBLY AND ASSEMBLY

VALVE BODY RECONDITION
Fig. 63 Transmission Jack

OIL PUMP SEAL
Fig. 66 Transmission Range Sensor Screw
REMOVAL
Fig. 67 Transmission Range Sensor Removed

Fig. 64 Remove Oil Pump Seal
INSTALLATION
Fig. 68 Manual Shaft and Rooster Comb
Fig. 65 Install Oil Pump Seal

Fig. 72 Valve Body and Transfer Plate
Fig. 69 2-4 Accumulator Plate
Fig. 73 Transfer Plate and Separator Plate
Fig. 70 TRS, Manual Shaft, and 2-4 Accumulator
Fig. 71 Valve Body Screws

Fig. 74 Ball Check Location
Fig. 75 Remove Dual Retainer Plate Fig. 76 Springs and Valves Location
Fig. 77 Low/Reverse Switch Valve And T/C Limit

Valve Fig. 79 Remove Oil Pan Bolts
TRANSAXLE—DISASSEMBLY
NOTE: Tag all clutch pack assemblies, as they are
removed, for reassembly identification.
CAUTION: Do not intermix clutch discs or plates as

the unit might then fail.
(1) Remove input and output speed sensors.

(2) Remove transaxle solenoid pack (Fig. 78).
Fig. 80 Remove Oil Pan
Fig. 78 Remove Solenoid Pack
Fig. 81 Remove Oil Filter

Fig. 84 Remove Valve Body

Fig. 82 Remove Valve Body Attaching Bolts
Fig. 85 Valve Body Removed

Fig. 83 Push Park Rod Rollers from Guide Bracket
NOTE: To ease removal of the valve body, turn the
manual valve fully clockwise.
CAUTION: Do not handle the valve body from the

manual valve. Damage could result.
Fig. 86 Remove Accumulators

NOTE: Dependent on engine application, some
accumulators will have two springs and others will
have one spring. The springs are color coded
according to application and year. When disassem-
bling, mark accumulator spring location to ease
assembly.
Fig. 89 Remove Low/Reverse Accumulator Snap

Ring
Fig. 87 Accumulator (Underdrive)
Fig. 90 Remove Low/Reverse Accumulator Plug

(Cover)
Fig. 88 Accumulator (Overdrive)

Measure the input shaft end play with the tran-
saxle in the vertical position. This will ensure that
the measurement will be accurate.
Measuring input shaft end play before disassembly
will usually indicate when a #4 thrust plate change
is required. The #4 thrust plate is located behind the
overdrive clutch hub.
Attach a dial indicator to transaxle bell housing
with its plunger seated against end of input shaft
(Fig. 93).
Move input shaft in and out to obtain end play
reading. End play specifications are .13 to .64 mm
(.005 to .025 inch). Fig. 91 Remove Low/Reverse Accumulator Piston
Record indicator reading for reference when reas-
sembling the transaxle.
Fig. 92 Remove Low/Reverse Accumulator

Fig. 95 Install Tool C-3752
CAUTION: Be sure input speed sensor is removed
before removing oil pump.
Fig. 93 Measure Input Shaft End Play
Fig. 96 Remove Oil Pump
Fig. 94 Remove Pump Attaching Bolts
Fig. 97 Oil Pump Removed

Fig. 98 Remove Oil Pump Gasket Fig. 100 Measure Outer Gear to Pocket
OIL PUMP INSPECTION (7) Align the Plastigage to a flat area on the reac-
When disassembling the transaxle it is necessary tion shaft support housing.
to inspect the oil pump for wear and damage. (8) Install the reaction shaft to the pump housing.
(1) Remove the reaction shaft support bolts. Tighten the bolts to 27 N.M (20 ft. lbs.)
(2) Remove reaction shaft support from pump (9) Remove bolts and carefully separate the hous-
housing (Fig. 99). ings. Measure the Plastigage following the instruc-
tions supplied.
(10) Clearance between outer gear side and the
reaction shaft support should be 0.020-0.046mm
(0.008-0.0018 in.). Clearance between inner gear side
and the reaction shaft support should be 0.020-
0.046mm (0.008-0.0018 in.).
Fig. 99 Reaction Shaft Support

(3) Remove the pump gears and check for wear
and damage.
(4) Install the gears and check clearances.
(5) Measure the clearance between the outer gear
and the pump pocket (Fig. 100). Clearance should be
Fig. 101 Remove Bypass Valve
0.045-0.141mm (0.0018-0.0056 in.)
(6) Position an appropriate piece of Plastigage CAUTION: The cooler bypass valve must be
across both pump gears. replaced if a transaxle failure has occurred. Do not
reuse old valve or attempt to clean old valve. When
installing bypass valve, insert with O-ring end
towards rear of case.
Fig. 105 Remove Front Sun Gear Assembly

Fig. 102 Remove Caged Needle Bearing
Fig. 106 Remove Front Carrier and Rear Annulus

Fig. 103 Remove Input Clutches Assembly Assembly
Fig. 104 No. 4 Thrust Plate Fig. 107 Remove Rear Sun Gear
NOTE: Verify that Miller Tool 5058 is centered prop-
erly to the 2/4 clutch retainer before depressing the
tool.
Fig. 111 Remove 2/4 Clutch Return Spring
Fig. 108 Remove 2/4 Clutch Retainer Snap Ring
Fig. 112 Remove 2/4 Clutch Pack

NOTE: Tag 2/4 clutch pack for reassembly identifi-
cation.
Fig. 109 Remove 2/4 Clutch Retainer
Fig. 113 Remove Tapered Snap Ring

Fig. 110 2/4 Clutch Retainer
Fig. 114 Remove Low/Reverse Reaction Plate Fig. 117 Remove Low/Reverse Clutch Pack
NOTE: Tag low/reverse clutch pack for reassembly
identification.
Fig. 115 Remove One Disc
Fig. 118 Remove Rear Cover Bolts
Fig. 116 Remove Low/Reverse Reaction Plate Snap

Ring
Fig. 119 Remove Rear Cover
Fig. 120 Remove Transfer Shaft Gear Nut Fig. 123 Remove Transfer Shaft Gear and (Select)
Shim
Fig. 121 Transfer Shaft Gear Nut and Coned Washer

Fig. 124 Remove Bearing Cup Retainer
Fig. 122 Remove Transfer Shaft Gear

Fig. 125 Remove Transfer Gear Bearing Cone
Fig. 126 Remove Transfer Shaft Bearing Cup

Fig. 129 Bearing Cup Removed
Fig. 127 Remove Transfer Shaft Bearing Snap Ring

Fig. 130 Remove Transfer Shaft Bearing Cone
NOTE: Screw Tool 5049-A onto transfer shaft.
Remove transfer shaft. NOTE: Remove output gear stirrup and strap bolts.
All transaxles utilize a stirrup and retaining strap
that is attached to the output gear. The stirrup pre-
vents the output gear retaining bolt from turning
and backing out of the rear carrier. The strap is used
to hold the stirrup to the output gear and prevent
the stirrup retaining bolts from backing out.
Fig. 128 Remove Transfer Shaft

Fig. 131 Loosen Stirrup Strap Bolts

Fig. 134 Remove Stirrup
Fig. 132 Remove Strap Bolts

Fig. 135 Remove Output Gear Bolt
Fig. 133 Remove Stirrup Strap

Fig. 136 Output Gear Bolt and Washer
Fig. 137 Remove Output Gear Fig. 140 Remove Rear Carrier Assembly
Fig. 138 Output Gear and (Select) Shim Fig. 141 Remove Rear Carrier Bearing Cone
Fig. 139 Remove Bearing Cone Fig. 142 Low/Reverse Spring Compressor Tool
Fig. 146 Drive Out Anchor Shaft

Fig. 143 Compressor Tool in Use
CAUTION: When installing, be sure guide bracket
and split sleeve touch the rear of the transaxle
case.
Fig. 144 Remove Snap Ring
Fig. 147 Remove Anchor Shaft and Plug
Fig. 145 Low/Reverse Piston Return Spring
Fig. 148 Remove Guide Bracket Pivot Shaft

Fig. 149 Pivot Shaft and Guide Bracket Fig. 152 Remove Low/Reverse Clutch Piston
Fig. 150 Guide Bracket Fig. 153 Remove Piston Retainer Attaching Screws
Fig. 151 Guide Bracket Disassembled Fig. 154 Remove Piston Retainer
INPUT CLUTCHES-RECONDITION
DISASSEMBLY
Fig. 155 Remove Piston Retainer Gasket
Fig. 158 Tapping Reaction Plate
Fig. 156 Remove Output Bearing Inner Cup

CAUTION: Drift bearing cup all the way around.
Fig. 159 Reverse Clutch Snap Ring
Fig. 157 Remove Output Bearing Outer Cup

This concludes the disassemble of the transaxle
centerline. To disassemble the input clutch assembly, Fig. 160 Pry Reverse Clutch Reaction Plate
refer to Input Clutches-Recondition.
Fig. 161 Reverse Clutch Reaction Plate

Fig. 164 OD/Reverse Pressure Plate
Fig. 162 Reverse Clutch Pack

NOTE: Tag reverse clutch pack for reassembly
identification. Fig. 165 Waved Snap Ring
Fig. 163 OD/Reverse Pressure Plate Snap Ring

Fig. 166 Remove OD Clutch Pack
Fig. 170 No. 2 Needle Bearing

Fig. 167 Overdrive Clutch Pack
NOTE: The OD/UD Reaction Plate, Snap Rings, and
NOTE: Tag overdrive clutch pack for reassembly Input Clutches Retainer is not interchangeable with
identification. previous year 41TE components. The snap rings
are thicker and the position of the ring lands have
changed.
Fig. 168 Overdrive Shaft Assembly

Fig. 171 OD/UD Reaction Plate Tapered Snap Ring
NOTE: The OD/UD clutches reaction plate has a
step on both sides. Install the OD/UD clutches reac-
tion plate tapered step side up.
Fig. 169 Underdrive Shaft Assembly

Fig. 175 Underdrive Clutch Pack

Fig. 172 OD/UD Reaction Plate
NOTE: Tag underdrive clutch pack for reassembly
identification.
CAUTION: Compress return spring just enough to

remove or install snap ring.
Fig. 173 Remove One UD Clutch Disc
Fig. 176 UD Spring Retainer Snap Ring
Fig. 174 UD Clutch Flat Snap Ring
Fig. 177 UD Return Spring and Retainer

Fig. 178 Underdrive Clutch Piston Fig. 181 Input Hub Removed
Fig. 179 Input Hub Tapered Snap Ring Fig. 182 Pull Retainer from Piston
Fig. 180 Tap on Input Hub Fig. 183 Remove Snap Ring
ASSEMBLY
Use petrolatum on all seals to ease assembly of
components.
Fig. 184 Snap Ring and Return Spring

Fig. 187 Install Input Shaft
Fig. 185 Remove Input Shaft Snap Ring

Fig. 188 Install Input Shaft Snap Ring
Fig. 186 Remove Input Shaft

Fig. 189 Return Spring and Snap Ring
Fig. 190 Install Snap Ring Fig. 193 Install Input Hub Tapered Snap Ring
Fig. 191 Install OD/Reverse Piston

Fig. 194 Underdrive Clutch Piston
NOTE: The OD/UD Reaction Plate, Snap Rings, and
Input Clutches Retainer is not interchangeable with
previous year 41TE components. The snap rings
are thicker and the position of the ring lands have
changed.
Fig. 195 Seal Compressor Special Tool 5067
Fig. 192 Install Input Shaft Hub Assembly

Fig. 199 UD Clutch Flat Snap Ring

Fig. 196 UD Return Spring and Retainer
CAUTION: Compress return spring just enough to
remove or install snap ring.
Fig. 200 Install Last UD Clutch Disc
Fig. 197 Install UD Spring Retainer and Snap Ring
Fig. 201 OD/UD Reaction Plate
Fig. 198 Underdrive Clutch Pack

The OD/UD clutches reaction plate has a step on
both sides. Install the OD/UD clutches reaction plate
tapered step side up.
Fig. 204 Set Up Dial Indicator for Clutch Clearance
Fig. 202 Tapered Snap Ring

NOTE: Snap ring ends must be located within one
finger of the input clutch hub. Be sure that snap
ring is fully seated, by pushing with screwdriver,
into snap ring groove all the way around.
Fig. 205 Use Hook Tool to Raise One Clutch Disc

Underdrive clutch pack clearance must be
0.91 to 1.47 mm (.036 to .058 inch). Select the
proper reaction plate to achieve specifications:
UNDERDRIVE REACTION PLATE THICKNESS

6.03 mm (.237 in.)
Fig. 203 Seating Tapered Snap Ring 6.34 mm (.250 in.)
6.65 mm (.262 in.)
Fig. 206 Install OD Clutch Pack

Fig. 209 Pressure Plate Installed
Fig. 207 Install Waved Snap Ring

Fig. 210 Install Flat Snap Ring
Fig. 208 OD/Reverse Pressure Plate

Fig. 211 Check OD Clutch Pack Clearance
The overdrive (OD) clutch pack clearance is
1.355 to 3.188 mm (.053 to .125 inch). If not within
specifications, the clutch is not assembled properly.
There is no adjustment for the OD clutch clearance.
Fig. 215 Seating Snap Ring to Determine Reverse

Clutch Clearance
Fig. 212 Install Reverse Clutch Pack
Fig. 216 Check Reverse Clutch Pack Clearance

Fig. 213 Install Reaction Plate The reverse clutch pack clearance is 0.76 to
1.24 mm (.030 to .049 inch). Select the proper
reverse clutch snap ring to achieve specifications:
REVERSE CLUTCH SNAP RING CHART

All clutch clearances in the input clutch retainer
have now been checked and approved.
To complete the assembly of the input clutch
Fig. 214 Install Reverse Clutch Snap Ring retainer, the reverse clutch and the overdrive clutch
must be removed from the retainer.
CAUTION: Do not intermix clutch parts. Keep in
exact same order.
Now proceed with the next phase of the assembly:
Fig. 220 Install No. 3 Thrust Plate
Fig. 217 Install No. 2 Needle Bearing
Fig. 221 Install Overdrive Shaft Assembly

Reinstall overdrive clutch and reverse clutch as
shown. Rechecking these clutch clearances is
Fig. 218 Install Underdrive Shaft Assembly not necessary, as they were set and approved
previously.
Fig. 219 Install No. 3 Thrust Washer

Fig. 222 Input Clutch Assembly
TRANSAXLE—ASSEMBLY
To assemble the transaxle centerline, refer to the
following procedures.
Fig. 226 Install Retainer Attaching Screws
Fig. 223 Install Both Output Bearing Cups
Fig. 227 Install Low/Reverse Clutch Piston
Fig. 224 Install Piston Retainer Gasket
Fig. 228 Guide Bracket Disassembled

Fig. 225 Install Piston Retainer
Fig. 232 Install Anchor Shaft and Plug

Fig. 229 Guide Bracket
CAUTION: When installing, be sure guide bracket
and split sleeve touch the rear of the transaxle
case.
Fig. 230 Pivot Shaft and Guide Bracket
Fig. 233 Install Low/Reverse Piston Return Spring
Fig. 231 Install Guide Bracket Pivot Shaft
Fig. 234 Low/Reverse Spring Compressor Tool

Fig. 235 Compressor Tool in Use Fig. 238 Install Rear Carrier Assembly
Fig. 236 Install Snap Ring

Fig. 239 Install Output Gear Bearing Cone
OUTPUT GEAR BEARING ADJUSTMENT
(1) With output gear removed: install a 4.50 mm
(0.177 inch) gauging shim on the rear carrier assem-
bly hub, using grease to hold the shim in place.
(2) Using Tool 6259, install output gear and bear-
ing assembly. Torque to 271 N·m (200 ft. lbs.).
To measure bearing end play:
(3) Attach Tool L-4432 to the gear.
(4) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
(5) Using a dial indicator, mounted to the tran-
saxle case, measure output gear end play (Fig. 240).
(6) Refer to the output gear bearing shim chart for
the required shim to obtain proper bearing setting.
Fig. 237 Install Rear Carrier Bearing Cone
Fig. 240 Checking Output Gear Bearings End Play

OUTPUT GEAR BEARING SHIM CHART
End Play Shim Needed Part Number End Play Shim Needed Part Number
.05mm .002 in. 4.42mm .174 in. 4412830 .53mm .021 in. 3.94mm .155 in. 4412818
.43mm .017 in. 4.02mm .158 in. 4412820 .91mm .036in. 3.54mm .139 in. 4412808
.51mm .020 in. 3.94mm .155 in. 4412818
(7) Use Tool 6259 to remove the retaining bolt and
washer. To remove the output gear, use Tool L-4407.
(8) Remove the gauging shim and install the
proper shim (Fig. 241). Use grease to hold the shim
in place. Install the output gear and bearing assem-
bly (Fig. 242).
Fig. 243 Install Output Gear Bolt and Washer
Fig. 241 Output Gear and (Select) Shim
Fig. 244 Tighten Output Gear to 271 N•m (200 ft.

lbs.)
Fig. 242 Install Output Gear

CAUTION: Always use new retaining bolt, old
retaining bolt may not be reused.
(9) Install the new retaining bolt and washer (Fig.

243). Tighten to 271 N·m (200 ft. lbs.) (Fig. 244).
(10) Using an inch-pound torque wrench, check the
turning torque (Fig. 245). The torque should be
between 3 and 8 inch-pounds.
Fig. 245 Check Output Gear Bearings Turning

Torque
If the turning torque is too high, install a .04 mm
(.0016 inch) thicker shim. If the turning torque is too
low, install a .04 mm (.0016 inch) thinner shim.
Repeat until the proper turning torque is 3 to 8 inch
pounds.
NOTE: Install output gear stirrup and strap bolts.
All transaxles utilize a stirrup and retaining strap

that is attached to the output gear. The stirrup pre-
vents the output gear retaining bolt from turning
and backing out of the rear carrier. The strap is used
to hold the stirrup to the output gear and prevent
the stirrup retaining bolts from backing out.
Fig. 248 Install Strap Bolts
Fig. 246 Output Gear Retaining Bolt Stirrup

(Serration Side Out)
Fig. 249 Turn Stirrup Clockwise Against Flats Of

Output Gear Retaining Bolt
Fig. 247 Stirrup Strap (Align Strap Holes With

Tapped Gear Holes)
Fig. 250 Tighten Stirrup Strap Bolts To 23 N·m (200

in. lbs.)
NOTE: Screw Tool 5049-A onto transfer shaft.
Install transfer shaft.
Fig. 251 Bend Tabs On Strap Up Against Flats Of

Bolts Fig. 254 Install Transfer Shaft
Fig. 252 Install Transfer Shaft Bearing Cone Fig. 255 Install Transfer Shaft Bearing Snap Ring
Fig. 253 Install Bearing Cup To Shaft Fig. 256 Install Transfer Shaft Bearing Cup Into
Retainer
Fig. 258 Install Transfer Gear Bearing Cone

Fig. 257 Install Bearing Cup Retainer
• Attach Tool L-4432 to the transfer gear.
TRANSFER SHAFT BEARING • Mount a steel ball with grease into the end of
(1) Install a 4.66 mm (.184 inch) gauging shim on the transfer shaft.
the transfer shaft. • Push and pull the gear while rotating back and
(2) Install transfer shaft gear and bearing assem- forth to insure seating of the bearing rollers.
bly and torque the nut to 271 N·m (200 ft. lbs.). • Using a dial indicator, measure transfer shaft
To measure bearing end play: end play.
TRANSFER SHAFT BEARING SHIM CHART
.30mm .012 in. 4.38mm .172 in. 4412829 1.02mm .040 in. 3.66mm .144 in. 4412811
.71mm .028 in. 3.98mm .157 in. 4412819 1.45mm .057 in 3.26mm .128 in. 4412801
(3) Refer to the Transfer Bearing Shim Chart for CAUTION: Original retaining nut may not be
the required shim combination to obtain the proper reused. Always use a new retaining nut when reas-
bearing setting. sembling.
(4) Use Tool 6259 to remove the retaining nut and
washer. Remove the transfer shaft gear using Tool (6) Install the new retaining nut and washer and
L-4407. torque to 271 N·m (200 ft. lbs.) (Fig. 261). Measure
(5) Remove the gauging shim and install the cor- transfer shaft end play, end play should be .05
rect shim (Fig. 259). Install the transfer gear and to .10 mm (.002 to .004 inch).
bearing assembly (Fig. 260).
Fig. 259 Transfer Shaft Gear and (Select) Shim Fig. 261 Tighten Nut to 271 N·m (200 ft. lbs.)
(7) Measure bearing end play as outlined in Step
3. End play should be between .05 mm and .10 mm
(.002 to .004 inch).
NOTE: If end play is too high, install a .04 mm

(.0016 inch) thinner shim. If end play is too low,
install a .04 mm (.0016 inch) thicker shim combina-
tion. Repeat until .05 to .10 mm (.002 to .004 inch)
end play is obtained.
Fig. 260 Install Transfer Shaft Gear

Fig. 262 Install Rear Cover Fig. 265 Install Low/Reverse Reaction Plate Snap Ring
Fig. 266 Install One Disc

NOTE: Install the low/reverse reaction plate
Fig. 263 Install Rear Cover Bolts stepped side up.
Fig. 264 Install Low/Reverse Clutch Pack

Press down clutch pack with finger and zero dial
indicator. Low/Reverse clutch pack clearance is
0.89 to 1.04 (.035 to .042 inch).
Select the proper low/reverse reaction plate to
achieve specifications:
LOW/REVERSE REACTION PLATE CHART
PART NUMBER THICKNESS

4799846 5.88 mm (.232 in.)
4799847 6.14 mm (.242 in.)
4799848 6.40 mm (.252 in.)
4799849 6.66 mm (.262 in.)
4799855 6.92 mm (.273 in.)
Fig. 267 Tapered Snap Ring Instructions
Fig. 270 Install 2/4 Clutch Pack

NOTE: When installing the 2-4 clutch plates and
discs, the orientation should be alternated so the
pilot pads of adjacent plates do not align, refer to
(Fig. 271).
Fig. 268 Snap Ring Installed
Fig. 269 Check Low/Reverse Clutch Clearance Fig. 271 Stagger 2/4 Clutch Plate Pads
NOTE: Verify that Miller Tool 5058 is centered prop-
erly to the 2/4 clutch retainer before depressing the
tool.
Fig. 272 Install 2/4 Clutch Return Spring
Fig. 275 Install 2/4 Clutch Retainer Snap Ring
Fig. 273 Proper Orientation of 2/4 Clutch Retainer

and Spring
Fig. 276 Check 2/4 Clutch Clearance
Press down clutch pack with finger and zero dial
indicator. The 2/4 clutch pack clearance is 0.76 to
2.64mm (.030 to .104 inch). If not within specifica-
tions, the clutch is not assembled properly. There is
no adjustment for the 2/4 clutch clearance.
DETERMINING No. 4 THRUST PLATE

THICKNESS—INPUT SHAFT END PLAY
To determine the proper thickness of the No. 4
thrust plate, select the thinnest No. 4 thrust plate.
Using petrolatum (Fig. 280) to hold thrust plate in
position, install input clutch assembly. Be sure the
input clutch assembly is completely seated (Fig. 281).
Fig. 274 Install 2/4 Clutch Retainer CAUTION: If view through input speed sensor hole
is not as shown above, the input clutches assembly
is not seated properly.
Fig. 277 Install Rear Sun Gear Fig. 280 Select Thinnest No. 4 Thrust Plate
Fig. 278 Install Front Carrier and Rear Annulus Fig. 281 View Through Input Speed Sensor Hole
Assembly
Fig. 282 Remove Oil Pump O-Ring

Fig. 279 Install Front Sun Gear Assembly NOTE: Use screw-in dowels or phillips-head screw-
Remove the oil pump O-ring (Fig. 282). You will be drivers to align pump to case.
able to install and remove the oil pump and gasket
very easily to select the proper No. 4 thrust plate.
CAUTION: Be sure to reinstall O-ring on oil pump Reinstall the input clutches assembly with the
after selecting the proper No. 4 thrust plate. selected thrust plate.
Measure the input shaft end play with the tran-

saxle in the vertical position. This will ensure that
the measurement will be accurate.
Fig. 284 Install Input Clutches Assembly
Fig. 283 Measure Input Shaft End Play

NOTE: Input shaft end play must be .005 to .025
inch.
For example, if end play reading is .055 inch, select
No. 4 Thrust Plate which is .071 to .074 thick. This
should provide an input shaft end play reading of
.020 inch which is within specifications.
See chart to select the proper No. 4 thrust plate.
NO. 4 THRUST PLATE CHART
PART NUMBER THICKNESS
4431662 .91mm (.036 in.)
4431663 1.14mm (.045 in.)
Fig. 285 Install Caged Needle Bearing
4431664 1.37mm (.054 in.)
4431665 1.60mm (.063 in.) CAUTION: The cooler bypass valve must be
replaced if a transaxle failure has occurred. Do not
3836237 1.73mm (.068 in.)
reuse old valve or attempt to clean old valve. When
4431666 1.80mm (.071 in.) installing bypass valve, insert with O-ring end
3836238 1.96mm (.077 in.) towards rear of case.
4431667 2.03mm (.080 in.)
3836239 2.16mm (.085 in.)
4431668 2.24mm (.088 in.)
3836240 2.39mm (.094 in.)
4431669 2.46mm (.097 in.)
3836241 2.62mm (.103 in.)
4446670 2.67mm (.105 in.)
4446671 2.90mm (.114 in.)
4446672 3.15mm (.124 in.)
4446601 3.38mm (.133 in.)
Fig. 286 Install Bypass Valve Fig. 289 Install Pump Attaching Bolts
Fig. 290 Install Low/Reverse Accumulator

Fig. 287 Install Oil Pump Gasket
Fig. 291 Install Low/Reverse Accumulator Plug

Fig. 288 Install Oil Pump
(Cover)
Fig. 295 Install Accumulators

Fig. 292 Install Low/Reverse Accumulator Snap Ring
NOTE: To ease installation of the valve body, turn
NOTE: Dependent on engine application, some the manual valve fully clockwise.
accumulators will have two springs and others will
CAUTION: Do not handle the valve body from the
have one spring. The springs are color coded for
application and year. manual valve. Damage could result.
Fig. 293 Accumulator (Underdrive) Fig. 296 Install Valve Body
Fig. 294 Accumulator (Overdrive) Fig. 297 Install Valve Body Attaching Bolts
Fig. 301 Install Solenoid Pack

Fig. 298 Install Oil Filter
This concludes the assembly of the transaxle cen-
terline.
DIFFERENTIAL REPAIR
NOTE: The differential is serviced as an assembly.
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
any other part fails within the differential, you must
replace the differential assembly along with the
transfer shaft.
DISASSEMBLE
The transfer shaft should be removed for differen-
tial repair and bearing turning torque checking.
(1) Remove the differential cover and bolts (Fig.
Fig. 299 Install Oil Pan 302) (Fig. 303).
Fig. 300 Install Pan Bolts Fig. 302 Differential Cover Bolts
(1) Install transaxle solenoid pack (Fig. 301). (2) Remove the differential bearing retainer and
(2) Install input and output speed sensors. bolts (Fig. 304) (Fig. 305).
WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
(4) Use Miller Special Tool 5048, 5048-3 Collets,
and L-4539-2 Button to remove the differential bear-
ing cone on the extension housing side.
(5) Use Miller Special Tool 5048, 5048-4 Collets,
and L-4539-2 Button to remove the differential bear-
ing cone on the bearing retainer side (Fig. 306) (Fig.
307) (Fig. 308).
Fig. 303 Remove Differential Cover
Fig. 306 Position Button and Collets Onto

Differential and Bearing (Ring Gear Side)
Fig. 304 Differential Retainer Bolts
Fig. 307 Position Tool 5048 Over Button and Collets

at Differential Bearing (Ring Gear Side)
(6) Using Miller Special Tool L-4518, remove the
differential bearing race from the extension housing.
(7) Using Miller Special Tool 6062A, remove the
differential bearing race from the bearing retainer
(Fig. 309) (Fig. 310).
Fig. 305 Remove Bearing Retainer
(3) Using a plastic hammer, remove extension CHECKING SIDE GEAR END PLAY
housing/adapter plate on the right side of the tran- Check side gear end play whenever the differential
saxle. is removed for service.
DIFFERENTIAL SERVICE TOOLS
COMPONENT REMOVER INSTALLER

Diff. Bear. On 5048, 5048-4 5052, C-4171
Retainer Side Collets,
L-4539-2
Button
Diff. Bear. On 5048, 5048-3 L-4410, C-4171
Ext. Hous. Side Collets,
L-4539-2
Button
Diff. Race. On 6062-A 6061, C-4171
Retainer Side
Diff. Race. On L-4518 L-4520, C-4171
Ext. Hous. Side
Fig. 308 Remove Differential Bearing Cone (Ring
Gear Side) Extension 7794-A, C-637 L-4520, C-4171
Housing Seal Slide Hammer
Bearing 794-A, C-637 L-4520, C-4171
Retainer Seal Slide Hammer
Fig. 309 Position Bearing Cup Remover Tool in

Retainer
Fig. 311 Checking Side Gear End Play (Extension

Housing Side)
ASSEMBLE
NOTE: Use MoparT Silicone Rubber Adhesive Seal-
ant, or equivalent, on retainer and extension hous-
ing/adapter plate to seal to case.
(1) Using Miller Special Tool L-4410, and C-4171,

install differential bearing to differential (extension
housing side) (Fig. 313).
(2) Using Miller Special Tool 5052 and C-4171,
install differential bearing to differential (bearing
Fig. 310 Remove Bearing Cup
retainer side).
NOTE: Side gear end play must be BETWEEN 0.001
to 0.013 inch.
(4) Using Miller Special Tool L–4520 and C-4171,
install differential bearing to extension housing.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT

NOTE: Perform all differential bearing preload mea-
surements with the transfer shaft and gear
removed.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING

EXISTING SHIM
(1) Position the transaxle assembly vertically on
the support stand, differential bearing retainer side
up.
(2) Install Tool L-4436A into the differential and
onto the pinion mate shaft (Fig. 315).
Fig. 312 Checking Side Gear End Play (Bearing
Retainer Side)
Fig. 315 Tool L-4436 and Torque Wrench

Fig. 313 Position Bearing Cone Onto Differential (3) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
(3) Using Miller Special Tool 6061 and C-4171,
seated.
install differential bearing race to bearing retainer
(4) Using Tool L-4436A and an inch-pound torque
(Fig. 314).
wrench, check the turning torque of the differential
(Fig. 316). The turning torque should be
(5) If the turning torque is within specifications,
remove tools. Setup is complete.
(6) If turning torque is not within specifications
proceed with the following steps.
(a) Remove differential bearing retainer from
the transaxle case.
(b) Remove the bearing cup from the differential
bearing retainer using Tool 6062A.
(c) Remove the existing shim from under the
cup.
(d) Measure the existing shim.
Fig. 314 Differential Bearing Retainer

Oil Baffle is not required to be installed when
making shim selection.
(f) Install the proper shim under the bearing

cup. Make sure the oil baffle is installed properly
in the bearing retainer, below the bearing shim
and cup.
(g) Install the differential bearing retainer using
Tool 5052 and C-4171. Seal the retainer to the
housing with MOPARt Adhesive Sealant and
torque bolts to 28 N·m (250 in. lbs.).
(7) Using Tool L-4436A and an inch-pound torque
wrench, recheck the turning torque of the differential
(Fig. 316). The turning torque should be
Shim thickness need be determined only if any of
Fig. 316 Checking Differential Bearings Turning the following parts are replaced:
Torque • Transaxle case
• Differential carrier
NOTE: If the turning torque was too high when
• Differential bearing retainer
measured, install a .05 mm (.002 inch) thinner shim.
• Extension housing
If the turning torque is was too low, install a .05 mm
• Differential bearing cups and cones
(.002 inch) thicker shim. Repeat until 5 to 18 inch-
pounds turning torque is obtained.
DIFFERENTIAL BEARING SHIM CHART
PART NUMBER SHIM THICKNESS

MM INCH
4659257 .980 0.0386
4659258 1.02 0.0402
4659259 1.06 0.0418
4659260 1.10 0.0434
4659261 1.14 0.0449
4659262 1.18 0.0465
4659263 1.22 0.0481
4659264 1.26 0.0497
4659265 1.30 0.0512
4659266 1.34 0.0528
4659267 1.38 0.0544
4659268 1.42 0.0560
4659269 1.46 0.0575
4659270 1.50 0.0591
4659271 1.54 0.0607
4659272 1.58 0.0623
4659273 1.62 0.0638
4659274 1.66 0.0654
4659275 1.70 0.0670
4659283 2.02 0.0796
4659284 2.06 0.0812
PRELOAD ADJUSTMENT W/O SHIM CLEANING AND INSPECTION
(1) Remove the bearing cup from the differential
bearing retainer using Miller special Tool 6062A. CLEANING VALVE BODY
(2) Remove existing shim from under bearing cup. Prior to removing any transaxle parts, plug all
(3) Reinstall the bearing cup into the retainer openings and clean unit, preferably by steam. Clean-
using Miller Special Tool 6061, and C-4171. liness through entire disassembly and assembly can-
not be overemphasized. When disassembling, each
NOTE: Oil baffle is not required when making the part should be washed in a suitable solvent, then
shim calculation. dried by compressed air. Do not wipe parts with
shop towels. All mating surfaces in the transaxles
(4) Install the bearing retainer into the case.
are accurately machined; therefore, careful handling
Torque bolts to 28 N·m (250 in. lbs.).
of all parts must be exercised to avoid nicks or burrs.
(5) Position the transaxle assembly vertically on
the support stand and install Miller Special Tool NOTE: Tag all springs, as they are removed, for
L-4436-A into the bearing retainer. reassembly identification.
(6) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.
(7) Attach a dial indicator to the case and zero the ADJUSTMENTS
dial. Place the tip on the end of Special Tool
L-4436-A. GEARSHIFT LINKAGE ADJUSTMENT
(8) Place a large screwdriver to each side of the Normal operation of the Park/Neutral Position
ring gear and lift. Check the dial indicator for the Switch provides a quick check to confirm proper link-
amount of end play. age adjustment.
Move the selector level slowly forward until it
CAUTION: Do not damage the transaxle case clicks into the (P) Park position. The starter should
and/or differential retainer sealing surface. operate.
After checking the (P) position, move selector
(9) Using the end play measurement that was slowly toward the (N) Neutral position until lever is
determined, add .18mm (.007 inch). This should give in the (N) position. If the starter will also operate at
you between 5 and 18 inch pounds of bearing pre- this point the gearshift linkage is properly adjusted.
load. Refer to the Differential Bearing Shim Chart to If the starter fails to operate in either position, link-
determine which shim to use. age adjustment is required.
(10) Remove the differential bearing retainer.
Remove the bearing cup. ADJUSTMENT
(11) Install the oil baffle. Install the proper shim (1) Set parking brake.
combination under the bearing cup. (2) Remove the gearshift knob set screw and knob.
(12) Install the differential bearing retainer. Seal (3) Remove gearshift selector bezel and lamp wiring.
the retainer to the housing with Mopart Silicone (4) Install the gearshift knob set screw and knob.
Rubber Adhesive Sealant. Torque bolts to 28 N·m (5) Place gearshift lever in the (P) (PARK) posi-
(250 in. lbs.). tion.
(13) Using Miller Special Tool L-4436-A and an (6) Loosen the gearshift cable adjuster nut at the
inch-pound torque wrench, check the turning torque shifter assembly (Fig. 317).
of the differential (Fig. 316). The turning torque (7) Move the gearshift lever on the transaxle to
should be between 5-18 inch-pounds. the park position.
(8) Verify the shift lever and transaxle are in park
NOTE: If turning torque is too high install a .05mm
position. Tighten the gearshift cable adjuster nut at
(.002 inch) thicker shim. If the turning torque is too
the shifter assembly. The gearshift linkage should
low, install a .05mm (.002 inch) thinner shim. Repeat
now be properly adjusted.
until 5-18 inch-pounds of turning torque is
(9) Check adjustment as follows:
obtained.
• Detent position for neutral and drive should be
within limits of hand lever gate stops.
• Key start must occur only when shift lever is in
park or neutral positions.
Fig. 317 Shift Cable Adjust Lever Nut

AUTOSTICK
The autostick switch is serviced as an assembly Fig. 318 Do Not Adjust Interlock Cable Here
with the gearshift mechanism. The switch is not
adjustable. If a problem occurs with the switch, refer (6) If the interlock cable is being replaced, remove
to the Diagnosis and Testing section. the lock pin (Fig. 320). This will allow the cable to
“self adjust” to the correct position. Tighten the lock-
INTERLOCK SYSTEM ADJUSTMENT ing clip by pushing it down (Fig. 320).
If ignition switch cannot be turned to the LOCK (7) If the intelock cable is not being replaced, the
position, with shifter in PARK, an adjustment of the lock pin will not exist. Pull outward on cable locking
Interlock System may be required. To adjust Shifter/ clip (Fig. 320) to allow cable to self adjust.
Ignition Interlock System, follow procedure listed
below.
(1) Disconnect and isolate, the battery negative (-)
cable from the vehicle battery.
Body.
(4) Install the gearshift knob set screw and knob.
(5) Place the shift lever in PARK. Move the Igni-
tion key to the LOCK position (Fig. 319) and remove
the key.
NOTE: Do not adjust the interlock cable at the loca-

tion shown in (Fig. 318). Fig. 319 Ignition Key/Switch Position
(8) Verify interlock system operation:
• With the lock cylinder in LOCK position (Fig.
319) and the ignition key removed, the shifter
SHOULD NOT be able to move out of PARK.
• With the ignition key in the ON/RUN position
(Fig. 319), the shifter SHOULD be able to move out
of PARK and into ANY gear range.
• Place the shifter in DRIVE. The ignition key
SHOULD NOT be able to be removed.
• Return the shifter to PARK. The ignition key
SHOULD be able to return to LOCK (Fig. 319) and
be removed.
• Any failure to meet these correct system
responses requires system repair.
(9) Install the bezel on the shifter console.
(10) Install shifter handle.
Fig. 320 Interlock Cable and Locking Clip

SCHEMATICS AND DIAGRAMS

41TE TRANSAXLE HYDRAULIC SCHEMATICS
41TE TRANSAXLE HYDRAULIC SCHEMATIC

SCHEMATICS AND DIAGRAMS (Continued)












SPECIFICATIONS Input Shaft

End Play . . . . . . . 0.127–0.635mm (0.005–0.025 in.)
41TE AUTOMATIC TRANSAXLE Pump Clearances
Outer Gear To Pocket . . . . . . . . . . . 0.045-0.141 mm
Type . . Fully adaptive, electronically controlled, four (0.0018-0.0056 in.)
speed automatic with torque converter and Outer Gear Side Clearance . . . . . . . 0.020-0.046 mm
integral differential (0.0008-0.0018 in.)
Torque Converter Diameter . . 241 millimeters (9.48 Inner Gear Side Clearance . . . . . . . 0.020-0.046 mm
in.) (0.0008-0.0018 in.)
Oil Capacity . . . . . . . . . . . . . 8.6 Liters (18.25 pints)
Oil Type . . . . . . . . . . . . . Mopart ATF+3 Type 7176 41TE TORQUE SPECIFICATIONS
Cooling Method . . Water Heat Exchanger and/or air
to oil heat exchanger DESCRIPTION TORQUE
Lubrication . . . . . Pump (internal-external gear-type Cooler Line Fittings . . . . . . . . . 12 N·m (105 in. lbs.)
Differential Cover . . . . . . . . . . 19 N·m (165 in. lbs.)
Gear Ratios Differential Ring Gear . . . . . . . . 95 N·m (70 ft. lbs.)
Transmission Differential Bearing Ret. . . . . . . 28 N·m (21 ft. lbs.)
First Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.84 Driveplate To Crank. Bolts . . . . . 95 N·m (70 ft. lbs.)
Second Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57 Driveplate To Torque Conv. . . . . 75 N·m (55 ft. lbs.)
Direct Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 Eight Way Solenoid Conn. . . . . . . 4 N·m (35 in. lbs.)
Overdrive Gear . . . . . . . . . . . . . . . . . . . . . . . . . 0.69 Extension Housing . . . . . . . . . . . 28 N·m (21 ft. lbs.)
Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 Input Speed Sensor . . . . . . . . . . 27 N·m (20 ft. lbs.)
Overall Top Gear Ratio L/R Clutch Retainer . . . . . . . . . . 5 N·m (45 in. lbs.)
2.0 Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.81 Oil Pan To Trans. Case . . . . . . 19 N·m (165 in. lbs.)
2.4 Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.69 Output Gear Bolt . . . . . . . . . . 271 N·m (200 ft. lbs.)
2.5 Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.69 Output Gear Stirrup Ret. . . . . . . 23 N·m (17 ft. lbs.)
Output Speed Sensor . . . . . . . . . 27 N·m (20 ft. lbs.)
Bearing Preload Pressure Taps . . . . . . . . . . . . . . . 5 N·m (45 in. lbs.)
Differential Assembly . . 5 to 18 in. lbs. Drag Torque Pump To Case Bolts . . . . . . . . . . 27 N·m (20 ft. lbs.)
Output Hub . . . . . . . . . . 3 to 8 in. lbs. Drag Torque Reaction Shaft Bolts . . . . . . . . . . 27 N·m (20 ft. lbs.)
Transfer Shaft . . . . . . . . 0.002 to 0.004 in. End Play Rear End Cover . . . . . . . . . . . . 20 N·m (175 in. lbs.)
Overall Drag At Sixty-Way Connector . . . . . . . . . . 4 N·m (35 in. lbs.)
Output Hub . . . . . . 3 to 16 in. lbs. Drag Torque Solenoid Assembly To Case . . . 12 N·m (105 in. lbs.)
Transmission Range Sensor . . . . . 5 N·m (45 in. lbs.)
Clutch Pack Clearances
Transfer Gear Nut . . . . . . . . . 271 N·m (200 ft. lbs.)
Low/Rev Clutch
(Select Reaction Plate) . . . . . . . . . . 0.89-1.04 mm Transfer Plate To Case . . . . . . . 12 N·m (105 in. lbs.)
(0.035-0.042 in.) Valve Body To Case Bolts . . . . 12 N·m (105 in. lbs.)
Two/Four Clutch (No Selection) . . . . . 0.76-2.64 mm Valve Body Bolts . . . . . . . . . . . . . 5 N·m (45 in. lbs.)
(0.030-0.104 in.) Vent Assembly . . . . . . . . . . . . . 12 N·m (105 in. lbs.)
Reverse Clutch (Select Snap Ring) . . . 0.76-1.24 mm
(0.030-0.049 in.)
Overdrive Clutch (No Selection) . . . 1.355–3.188 mm
(0.053-0.125 in.)
Underdrive Clutch
(Select Pressure Plate) . . . . . . . . . . 0.91-1.47 mm
(0.036-0.058 in.)
Input Shaft End
Play . . . . . . . . . . . 0.12-0.63 mm (0.005-0.025 in.)
SPECIAL TOOLS
41TE AUTOMATIC TRANSAXLE
Oil Pump Puller C-3752
Puller C-637
Seal Puller C-3981B
Pressure Gauge (Low) C-3292
Pressure Gauge (High) C-3293SP

Universal Handle C-4171
Dial Indicator C-3339

Seal Installer C-4193A
Adapter C-4996 Gear Checking Plate L-4432
Remover Kit L-4406 Bearing Puller L-4435
Gear Puller L-4407A Differential Tool L-4436A
Bearing Installer L-4410 Special Jaw Set L-4518

Installer L-4520 Remover/Installer 5049-A
Thrust Button L-4539-2 Installer 5050A
Bearing Splitter P-334 Installer 5052
Puller Set 5048 Compressor 5058A

Compressor 5059-A Installer 6053
Installer 5067 Button 6055
Pliers 6051 Plate 6056
Installer 6052 Disk 6057

Installer 6061 Installer 6261
Remover 6062-A Tip 6268
Holder 6259 Remover/Installer 6301
Bolt 6260 Remover/Installer 6302

Installer 6536-A Cooler Flusher 6906A
Puller 7794-A

Eja 21

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JA TRANSAXLE 21 - 1

41TE TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . 42 NV T350 (A-578) MANUAL TRANSAXLE . . . . . . . 1

NV T350 (A-578) MANUAL TRANSAXLE

GENERAL INFORMATION GEARSHIFT MECHANISM REPLACEMENT . . . . . 6

Fig. 3 Bar Code Label

TRANSAXLE IDENTIFICATION INFORMATION

SLIPS OUT OF GEAR

LOW LUBRICANT LEVEL

GEARSHIFT LEVERS CLUTCH PROBLEMS

SERVICE PROCEDURES REMOVAL AND INSTALLATION

Fig. 5 Fill Plug Location Fig. 7 Gearshift Knob

Fig. 6 Drain Plug Location Fig. 8 Knob Removal

Fig. 9 Boot Removal

Fig. 12 Console Rear Screws

Fig. 13 Cable Retaining Clips Fig. 14 Gearshift Mechanism

CAUTION: Gearshift cable bushings must not be

CAUTION: Only the crossover cable is adjustable.

GEARSHIFT MECHANISM REPLACEMENT

VEHICLE SPEED SENSOR DRIVE GEAR

CAUTION: Clean area around speed sensor before

CAUTION: Do not overtighten switch.

(2) Confirm back-up lamps are functioning prop-

CROSSOVER LEVER Fig. 18 Axle Shaft Seal Removal

SHIFT SHAFT SEALS

Fig. 20 Shift Cables

Fig. 23 Accelerator Cable Bracket

Fig. 21 Linkage Bracket Bolts

Fig. 24 Upper Starter Bolt and Bellhousing Stud Nut

Fig. 22 Accelerator Cable Ends

Fig. 26 Left Mount Upper Bolts

Fig. 29 Left Mount Lower Bolts

Fig. 27 Upper Bellhousing Bolts

Fig. 30 Lower Crossbar Front Bolts

Fig. 28 Engine Bridge Fixture

Fig. 34 Rear Transaxle Mount Bracket

Fig. 32 Front Engine Mount Bracket (Aluminum)

Fig. 35 Bracket Removal

Fig. 33 Starter Bolts

Fig. 37 Driveplate to Modular Clutch Bolts

Fig. 39 Case Bolts

Fig. 38 Lower Bellhousing Bolts

DISASSEMBLY AND ASSEMBLY

CAUTION: The transaxle output shaft is serviced as

Fig. 44 Reverse Idler Shaft Bolt Removal

Fig. 42 Bellhousing Case Half Removal

Fig. 45 Reverse Idler Gear Removal

Fig. 43 Differential Assembly Removal

Fig. 46 Screws Retaining Reverse Fork Bracket

Fig. 47 Remove Reverse Fork Bracket Fig. 50 Transaxle Cover Removal

Fig. 51 End Cover

Fig. 52 Snap Rings Retaining Bearings

Fig. 55 Pressing Gears Out of Case

Fig. 53 Bench Fixture

Fig. 56 Transaxle Case Removal

Fig. 54 Bearing Fixture

(15) Install transaxle gear case into shop press.

Fig. 58 Reverse Brake Shim Fig. 61 Reverse Brake Needle Bearing

Fig. 59 Reverse Brake Friction Cone Fig. 62 Reverse Brake Race

Fig. 60 Reverse Brake Blocking Ring Fig. 63 Shift Blocker Removal