Professional Documents
Culture Documents
J
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . 1
COMPONENT IDENTIFICATION . 5
Transaxle Controller . 6
Relays 0 0 o 0 0 0 I I o 6
Solenoid Assembly . . . 7
Case 0 I I 0 I 0 I I I I 8
Valve Body Assembly . 8
Torque Converter . . . . 9
Oil Pump . . . . . . . . 9
Input Clutch Assembly . 10
2-4 and Low/Reverse Clutch Assemblies . 12
Planetary Geartrain . 13
) Transfer Gears . . . . 16
Final Drive Geartrain . 17
Planetary Geartrain
0 I I o I 45
50
\ Transfer Gears . . . 55
Final Drive Gears & Differential . 56
1
OPERATING THE TRANSAXLE
GENERAL INFORMATION assembly. When the pawl is engaged with the
park gear (lugs) of the carrier it will, in effect, lock
The purpose of this section "OPERATING THE the output shaft to the transaxle case.
TRANSAXLE" is to inform the reader of how the
transaxle should operate under normal driving NOTE: Before road testing the engine should
conditions. Malfunctions in the transaxle will not be thoroughly warmed-up.
be discussed in this section. The verification of
any malfunctions will be left to the driver during
road testing procedures. It is from the knowledge
of normal operation that an abnormal condition
can be detected and corrected.
OVERDRIVE "OD"
When the vehicle is stationary and gear selector
lever is placed in the "00" quadrant position, with
engine running the transaxle automatically shifts
NEUTRAL and PARK to 1st gear. This speed range is referred to as drive
launch or low. The driver accelerates and when
The engine can be started only in the Neutral or the vehicle has reached a predetermined point
Park shift quadrant positions. When the gear (engine load and vehicle speed), the transaxle
selector lever is in either of these two positions, will automatically shift into 2nd gear. The driver
there will be no power flow through the clutches should be concerned with the "feel" of the shift,
or gear train of the transaxle . The low/reverse or the shift quality. Was the shift smooth? Was
clutch is applied to anticipate shifting the transaxle there any delay in the shift? Was the shift point
into gear, for smooth engagement. correct?
When in the Neutral quadrant position, the vehicle Now, the transaxle is in 2nd gear stage of opera-
can roll down an incline. The rear carrier assem- tion and the vehicle is building up speed as
bly, which has park locking lugs, is free to turn. acceleration continues. The vehicle then reaches
a point at which engine load and speed conditions
On the other hand, when the gear selector lever are just right for another shift. At this time the
is placed in the Park position, a park rod assembly transaxle will make another shift, from 2nd to 3rd .)
operated through cable and manual lever, will (direct) gear. Again, the same questions should
engage the park pawl into lugs on the rear carrier be asked by the driver as to the quality of the shift.
2
OPERATING THE TRANSAXLE
With the transaxle in 3rd gear stage of operation
the vehicle will continue to build up speed as
acceleration continues . The vehicle will again
reach a point where engine load and speed condi-
tions are just right for another shift. Now the
transaxle will shift from 3rd to 4th (overdrive) gear.
Again the same questions of shift quality should
be asked by the driver.
LOW "L"
With gear selector in the "L" position on the shift
quadrant, vehicle stationary, the transaxle is
)
automatically in first gear, identical to what it was
in "OD" and "D" selections. Unlike Chrysler's
previous transaxles, this transaxle will upshift to
2nd gear and even to 3rd gear. The determining
factor here is engine speed. The transaxle will
upshift at certain engine speeds to protect the
engine from being damaged from overspeed. REVERSE "R"
The only difference between the transaxle's op- When shifting the transaxle to Reyerse it is advis-
eration in "D" and "L", then, is the point at which able to have the vehicle at a complete stop. The
the shifts occur. The upshifts that occur in "L" are shift into reverse should be smooth and without
more delayed. For example, 1-2 upshift occurs at delay.
NOTES
4
I COMPONENT IDENTIFICATION
This section of the book is aimed at familiarizing Transaxle controller I sensors
you with the main components of the transaxle. Relays (2)
This will be done by showing a picture or drawing Solenoid and pressure switch assembly
of the component, where it's located, and a brief Case
description of what the component does. Valve body
Torque converter
The component descriptions will be in the follow- Oil pump
ing order: Input clutch assembly
2-4 and low/reverse clutch assemblies
Planetary gear train
Transfer and final drive gears
NOTES
5
COMPONENT IDENTIFICATION
TRANSAXLE CONTROLLER connection is through a 60-way sealed connector.
The unit is located underhood on the dash panel
of the S-body, and on the inner fender shield of
the A and C bodies.
RELAYS
S-BODV
REVERSE
LAMP
TRANSAXLE CONTROLLER - The controller is RELAY
the brains of the transaxle. It receives information THE SOLENOID SHUTDOWN RELAY AND THE REVERSE
from several inputs to make decisions on just how LAMP RELAY ARE LOCATED NEXT TO ONE ANOTHER.
the transaxle should be controlled . The informa- C ANDA BODY
tion the controller uses comes from :
PRNDL switch
Neutral safety switch
Turbine speed sensor
Output speed sensor
Pressure switches (three, located in solenoid assy.)
Throttle position sensor
Coolant temperature sensor
Engine speed
Battery temperature
Brake switch
6
COMPONENT IDENTIFICATION
RELAYS - Two externally mounted relays are SOLENOID ASSEMBLY- The solenoids are com-
used in the operation of the A-604 transaxle. Both pletely controlled by the transaxle controller through
of the relays are identical and are interchange- the shutdown relay. The assembly consists of four
able. One relay is used in operation of the rear solenoids that control hydraulic pressure to four
back-up lights. The second relay is used to supply of the transaxle's five clutches, and the lockup
power into the transaxle controller for operation clutch in the torque converter. The solenoid as-
of the solenoid assembly. It is called the Solenoid sembly is mounted outside, on the front of the
Shutdown Relay. transaxle case. The electrical connection is an
8-way sealed connector on top of the solenoid
The relays will be mounted to the transaxle con- assembly and is secured using a bolt.
troller on A and C bodies, and on the right inner
fender shield of S bodies. The solenoid has three pressure switches built
into it that feed information to the transaxle control-
ler. The solenoid assembly must be replaced as
an assembly if any of the solenoids or pressure
SOLENOID ASSEMBLY switches fail.
GASKETS (2)
~
)
"
,
I
I
SOLENOID
ASSEMBLY
SOLENOID ASSEMBLY
NOTES
' STEEL
PLATE
.J
7
COMPONENT IDENTIFICATION
CASE
STRENGTHENING RIBS
SOLENOID
SOUND
SHIELD
ACCUMULAT~
valves. Unlike other transaxles, there is no gover-
nor pressure or throttle pressure used to operate
this valve body. These two pressure signals are
now replaced by electronic signals sent to the
transaxle controller by the throttle position sensor
and output speed sensor. All shift valves have
also been eliminated and replaced by the sole-
noids in the solenoid assembly .
.
The primary responsibility of the valve body is to
control line pressure and .torque converter pres-
sure, and to direct pressurized transmission fluid
to the clutches, torque converter, and solenoids
via the manual valve and switch valves.
8
COMPONENTIDENTIRCATION
TORQUE CONVERTER TORQUE CONVERTER - The torque converter
is not much different, in design or function, from
what Chrysler has been using in their previous
PISTON TURBINE domestic transaxles. It is a lockup torque con-
verter and it is controlled electronically through the
solenoid assembly, and hydraulically applied. The
IMPELLER torque converter is used to transmit power from
the engine to the input shaft.
) OIL PUMP
REACTION SHAFT
SUPPORT
S AL RINGS (3)
9
COMPONENT IDENTIFICATION
INPUT CLUTCH ASSEMBL V
10
COMPONENT IDENTIFICATION
INPUT SPRING
SHAFT
INPUT
HUB
I OVERDRIVE/REVERSE
PISTON SNAP
RING
OVERDRIVE REVERSE
REACTION CLUTCH SNAP CLUTCH REACTION
PLATE DISCS DISCS rlATE
SEPARATOR
RING PRESSURE PLATE RING
PLATE
) INPUT CLUTCHES
COMPONENTIDENTIACATION
OVERDRIVE
UNDERDRIVE
HUB
J
THRUST
PLA\ T
THRUST
WASHER THRUST
PLATE
UNDERDRIVE AND OVERDRIVE HUBS
SNAP RING
CLUTCH DISCS
PISTON
2-4 CLUTCH
2-4 CLUTCH - Directly rearward of the input clutch are held into place in the case with snap rings.
retainer assembly is the 2-4 clutch. This clutch The 2-4 clutch sits around the outside of the
consists of a stamped steel clutch piston retainer, planetary geartrain and when this clutch is ap-
piston, belleville return spring, clutch plates, steel plied, it will hold a geartrain component from
separator plates, and reaction plate. These parts turning.
12
COMPONENTIDENTIRCATION
SEPARATOR BELLEVILLE
PLATES SPRING
~GASKET
BELLEVILLE
CLUTCH SNAP
DISCS RING
LOW REVERSE CLUTCH
LOW/REVERSE CLUTCH - The Low/Reverse retainer that is secured to the back of the case
(UR) clutch is located in the rearmost part of the with screws. Like the 2-4 clutch, the L-R clutch sits
case, directly behind the 2-4 clutch. As a matter around the outside of the planetary geartrain, and
of fact, it shares the reaction plate of the 2-4 clutch. when this clutch is applied, it will hold a geartrain
It consists of steel plates and clutch discs, belleville component from turning.
return spring, piston, and a stamped steel piston
PLANETARY GEARTRAIN
FRONT THRUST
SUN GEAR ASSEMBLY BEARINGS
FRONT
,.
REAR CARRIER
CARRIER ASSEMBLY ASSEMBLY
PLANETARY GEARTRAIN
) PLANETARY GEARTRAIN - The entire planetary clutch assemblies. The planetary geartrain con-
geartrain is located rearward of the input clutch sists of two sun gears, two planetary carriers, two
retainer assembly, and inside the 2-4 and L-R annulus gears, and one output shaft.
13
COMPONENTIDENTIRCATION
FRONT
ANNULUS
GEAR
/
LUGSFOR ~
SPLINED
TO UNDERDRIVE
PARKING PAWL REAR HUB
& OUTPUT SPEED
SENSOR
REAR CARRIER ASSEMBLY REAR SUN GEAR
REAR CARRIER ASSEMBL V - The rear plane- REAR SUN GEAR- The rear sun gear is located
tary carrier, front annulus gear, and output shaft in the center of the rear carrier assembly. The
come as a single welded assembly. All output rear sun gear is driven by the underdrive clutch, )
power must go through this assembly. The lugs when applied, through the underdrive hub
around the outside of this assembly serve a dual assembly.
purpose; first, the parking pawl will engage the
lugs for park, and second, the output speed pickup
uses th~ lugs to generate an output speed signal
that is sent to the transaxle control module. No
clutches are splined or connected to this
assembly.
NOTES
).
14
COMPONENT IDENTIFICATION
LOW-REVERSE
CLUTCH LOCATION
GEAR \
PLANETARY
FRONT CARRIER ASSEMBLY FRONTSUNGEARASSEMBLY
FRONT CARRIER AND REAR ANNULUS AS- FRONT SUN GEAR ASSEMBLY - The front sun
SEMBLY -The front planetary carrier and rear gear rides in the center of the front carrier and is
) annulus gear are splined together and operate as welded to the center of two hubs that are arranged
a single unit. The overdrive clutch, when engaged, back to back. Each of the hubs are splined to a
will drive this assembly through the overdrive hub clutch. The front hub is splined to the reverse
assembly. The low/reverse clutch, when applied, clutch that will turn the sun gear when applied.
will hold this assembly from turning . The rear hub is splined to the 2-4 clutch that when
applied will hold the sun gear from turning.
NOTES
15
COMPONENT IDENTIFICATION
TRANSFER AND FINAL DRIVE GEARTRAIN
TRANSFER GEARS
TRANSFER GEARS - There are two transfer output transfer gear. The second transfer gear is
gears and their only purpose is to transfer power splined to the transfer shaft and retained with a
from the output shaft to the transfer shaft. One large nut and is referred to as the transfer shaft
transfer gear is splined to the output shaft and gear.
retained with a large bolt and is referred to as the
NOTES
16
COMPONENT IDENTIFICATION
SPLINE FOR
TRANSFER GEAR
TRANSFER SHAFT
!
!
DIFFERENTIAL
CASE
TRANSFER SHAFT AND RING GEAR - The DIFFERENTIAL CASE ASSEMBLY - This as-
transfer shaft transfers power from the transfer sembly consists of the differential case, two differ-
) gears to the differential ring gear. The forward end ential pinion gears, differential pinion shaft, and
of the transfer shaft has an integral pinion gear two differential side gears. The transfer case
that is in constant mesh with the ring gear. The assembly takes input power from the ring gear
transfer shaft pinion is a helical gear which means and transfers it to the axle shafts. The pinion and
there is no depth of mesh adjustment. side gears inside the differential case allow the
axle shafts to rotate at different speeds for turning.
The ring gear is bolted to the differential case and
drives the differential case for all forward or re-
verse gears.
NOTES
17
TRANSAXLE FUNCTION OF OPERATION
This section of the book will explain how all the The systems will be divided and explained, in the
different parts function, and contribute to the over- following order;
all operation of the transaxle. To do this in an
understandable order, the transaxle will be divided Transaxle controller and sensors
into subsystems. Each subsystem operation will Solenoid assembly and valve body
be explained as well as how it affects the adjoining Torque converter
subsystem. Clutches
Planetary geartrain
Transfer gears
Differential
Another feature of the transaxle controller is that When the transaxle goes into the default mode it
it will help the technician find a problem in a will automatically shift to 2nd gear (in any forward-
malfunctioning transaxle. It can do this through drive selection) and stay there. When the ignition
what is called self-diagnostics. When something key is turned "off" and then back "on" again, the
goes wrong with any of the major electronic controller will reset itself to operate normally, until
circuits in the controller, sensors, or solenoid it senses the fault and again goes into 2nd gear.
assembly, a two digit numeric fault code will be No matter what forward gear is selected it will stay
put into memory. In addition to being able to sense in 2nd gear. All other gear selections (P,R,N) will
electrical malfunctions the controller can also detect operate as usual except for harsh shifts. The idea
some hydraulic and mechanical malfunctions that behind this is to prevent the customer from being
will also produce fault codes. Each code repre- stranded and to provide them the ability to drive
sents a different malfunction. In order to read the the vehicle in for service. This capability could
fault codes, the technician must hook-up a special potentially save our customers large repair costs
diagnostic tool, called a ORB II (Diagnostic Readout and provide higher levels of customer satisfaction.
Box, 2nd version), to a diagnostic connector lo- As mentioned previously in the Component Identifica-
cated under the instrument panel. To retrieve fault tion section, the controller has the job of controlling
codes it will be necessary to follow the procedures four solenoids in the solenoid assembly. To do
outlined in the POWERTRAIN DIAGNOSTIC PRO- this the controller uses information from 12 differ-
CEDURES, A604-ULTRADRIVE AUTOMATIC ent sensors.
TRANSAXLE book. The transaxle controller will
retain up to seven fault codes in memory.
18
TRANSAXLE FUNCTION OF OPERATION
Some of the sensors are wired directly to the
controller and other sensor signals come through
..___ ;------;
; - - THROlTLE POSITION SEN . COOLANT SEN. I what is called Chrysler's Multiplexing CCD circuit.
r- BATTERY - ~ AMBIENT SEN. J
>-- DISTRIBUTOR -
-
I BRAKE SWITCH I The CCD circuit is used to allow different control-
>-- IGNITION SWITCH lers in the vehicle to share information with each
ENGINE CONTROL
MODULE
ll OTHER VEHICLE
CONTROLLERS
J other through two wires. The benefit of this is the
2
c o "' amount of wiring that is saved.
LINK""
"""'l ORB II I
:J TRANSAXLE CONTROL I.
MODULE 1&.
HNEUTRAL SAFETY SWITCH J.
>--; PRNDL SWITCH
TRANSAXLE FOUR SOLENOIDSE~
--1 TURBINE SPEED SEN. ~PREssuRE' sWiiC"HEs
Dr
'---1 OUTPUT SPE ED SEN.
0
..l.__
At this time the controller also performs a self test THROTTLE BODY
to determine if the controller, solenoid shutdown
relay, and solenoid assembly is performing as it THROTTLE POSITION SENSOR - The A-604
should at this point. If the self check is good then does not use throttle pressure to control shift
the controller sends battery voltage to the solenoid points like Chrysler's previous transaxles did.
shutdown relay. The relay will close its internal Instead, an electronic signal from the throttle
contacts and send battery voltage to the solenoid position sensor is used by the controller to help
assembly to power the solenoids and pressure determine shift points and shift quality.
19
TRANSAXLE FUNCTION OF OPERATION
the sensor is actually taking the reading off the
input clutch hub. It can be done this way because
the turbine and hub are connected directly to-
gether through the input shaft.
CONNECTOR
20
TRANSAXLE FUNCTION OF OPERATION
PRNDL
SWITCH THREE PRESSURE SWITCHES ARE BUILT-
IN TO THE SOLENOID ASSEMBLY.
SWITCH LOCATION SOLENOID ASSEMBLY
These switches also operate the starter relay and NOTE: ALL THE SENSORS MENTIONED UP
the backup light relay, and prevent starter engage- TO THIS POINT ARE WIRED DIRECTLY TO
ment in all positions except "P" or "N". THE CONTROLLER. THE REMAINING SENSOR
INPUTS WILL BE SUPPLIED THROUGH THE
CCD CIRCUIT.
NOTES
21
TRANSAXLE FUNCTION OF OPERATION
ENGINE CONTROLLER
COOLANT TEMPERATURE SENSOR (AMBIENT TEMPERATURE SENSOR)
NOTES
22
TRANSAXLE FUNCTION OF OPERATION
BRAKE SWITCH
BRAKE SWITCH SIGNAL - The brake switch SOLENOID SHUTDOWN RELAY - The instant
signal is used for one reason, to disengage the the ignition is turned on, the transaxle controller
torque converter lockup clutch when the brakes performs a quick check to determine that its
are applied. internal electronic circuits are all working properly.
The sensor's circuits are all checked, and the relay
The controller takes the information from the contact points are checked to make sure they are
sensors, evaluates it, then uses it to control open. If everything checks good the controller will
the solenoid shutdown relay, then the sole- send electrical current through the shutdown relay,
noid assembly, in that order. Let's take a look causing the contact points in the relay to close.
at what the transaxle controller output When the shutdown relay points close, electrical
operates. current is fed into the controller and to four sole-
noids in the solenoid assembly.
NOTES
If the controller sees a fault in the system it can
turn off the power feed to the shutdown relay
causing the points to open and put a fault code
into memory. Remember, not all fault codes will
cause the controller to open the shutdown relay;
only certain faults will.
23
TRANSAXLE FUNCTION OF OPERATION
SOLENOID ASSEMBLY - Once the shutdown
relay has closed its contact points the controller
now has electrical power to operate the solenoid
assembly. The relay sends power to all four
solenoids through a single wire. This means that
all the solenoids will have voltage supplied to them
whenever the shutdown relay is closed. The sole-
noids, however, do not energize until the negative
wires are grounded.
NOTES
24
TRANSAXLE FUNCTION OF OPERATION
SOLENOID ASSEMBLY AND VALVE BODY
The solenoid assembly and valve body work filter, through the valve body housing, and into the
together to operate five transaxle clutches, lockup pump. The pump pressurizes oil and sends it back
torque converter, and provide oil for lubrication. through the valve body to the regulator valve.
The source of pressurized oil for the solenoid
assembly and valve body is the transaxle oil The valve body uses only five valves in conjunc-
pump. The pump is a positive displacement, gear tion with four solenoids in the solenoid assembly
type pump that is driven by the engine through the to perform all functions necessary to operate the
torque converter housing . transaxle. A brief description of how each valve
and solenoid works will make it easier to under-
Oil for the pump is drawn through the transaxle stand the operation of the transaxle.
TORQUE CONVERTER
CONTROL VALVE
t OVERDRIVE CLUTCH
CIRCUIT
SOLENOID SWITCH &
LOCKUP SWITCH VALVES
r.===MANUALt
VALVE
-u::t
:u-<
) SPRING_
mo
(I):IJ
(/)}>
TENSION cc
:ur
mo
. . . . . .~. .~. . . . . . . . . . . . . .~. . . . . . . . __.MANUALVALVE
PUMP FILTER
REGULATOR VALVE - The regulator valve has A system of sleeves and ports allows this regulator
one function, to control hydraulic pressure in the valve to work at three different predetermined
transaxle. The pump supplies unregulated pres- pressure levels, depending on which gear ratio is
sure to the regulator valve. The regulator valve engaged. Looking at the illustration you can see
will control this pressure which will then be re- that if oil pressure increases it will push the valve
ferred to as line pressure. The regulator valve to the left causing the valve to dump oil and lower
uses a spring on one end that pushes the valve pressure. If oil pressure were to drop off, the
over to the right and closes a dump, which causes spring would push the valve to the right , closing
oil pressure to increase. Oil pressure is used on the dump and allow oil pressure to build up again.
the opposite end of the valve to push the valve to The oil that is dumped by the regulator valve will
the left, opening the dump and lowering oil pres- be directed back to the oil pump pick-up circuit.
sure. The result is spring tension working against
oil pressure to keep the oil at a certain pressure.
25
TRANSAXLE FUNCTION OF OPERATION
LOCKUP SWITCH LOCKUP SWITCH SOLENOID LU
VALVE VALVE SWITCH VALVE
+ t
TIC
~~.tzzzz~
t~2~~:; -+- TO
DRIBBLERS
SOLENOID
SWITCH
..,.. VALVE
REGULATOR
. . . . . ..,_VALVE
TORQUE CONVERTER CONTROL VALVE -The LOCKUP SWITCH VALVE - The lockup switch
main responsibility of the torque converter control valve does the job of switching the lockup torque
valve is to control hydraulic pressure fed to the converter on and off. In the unlocked position oil
torque converter. Line pressure from the regulator is fed to the lockup valve from the torque converter
valve is fed to the torque converter control valve control valve. The lockup valve will let oil pass
where it passes through the valve and pressure through it to disengage the torque converter piston,
is reduced . This reduced pressure is directed and oil coming out of the torque converter will
through the lockup switch valve and to the front again pass through it on its way back to the torque
side of the torque converter lockup piston. This converter valve which becomes the lube feed
pressure that is being fed to the front of the piston circuit.
will push the piston rearward, disengaging the
lockup clutch. The oil will then pass around the When the transaxle controller energizes the sole-
outside of the piston, flow out the torque converter, noid assembly to lock up the torque converter, the
through the lockup switch valve and back to the lockup switch valve will be positioned hydraulically
torque converter control valve. The oil will then to the left. When that happens the oil that was
flow on through the transaxle oil cooler and return being fed to the torque converter is now blocked,
to transaxle as lube oil pressure. while the front side of the lockup piston is vented.
Oil is now fed to the back side of the lockup piston
to apply the torque converter lockup clutch.
NOTES
26
TRANSAXLE FUNCTION OF OPERATION
PRESSURE
PRESSURE
UNDERDRIVE
. ._ _ _ _ _ ..,CLUTCH UNDERDRIVE
. ._ _ _ _ .-CLUTCH
t
LINE
CIRCUIT L1 CIRCUIT
PRESSU
PRESSURE
..__SOLENOID SOLENOID
ENERGIZED ....,.. DE-ENERGIZED
REGULATOR VALVE
)
SOLENOID SWITCH VALVE SHIFTED SOLENOID SWITCH VALVE SHIFTED
LEFT FOR OPERATION OF TORQUE RIGHT AND IN POSITION TO
CONVERTER LOCKUP CLUTCH OPERATE LOW/REVERSE CLUTCH
SOLENOID SWITCH VALVE - The switch valve The valve will be shifted to the right in all positions
is used to control line pressure from the low except 2nd, 3rd, or 4th gear. When the transaxle
reverse/lockup solenoid. When the valve is shifted upshifts to 2nd gear the valve will shift to the left
to the right it will allow the low/reverse clutch to to anticipate torque converter lockup. The valve
be pressurized and when it's shifted to the left it must be allowed to return to the right before a
will direct line pressure to the end of the lockup downshift to 1st gear can occur.
switch valve to operate the lockup torque
converter.
NOTES
27
TRANSAXLE FUNCTION OF OPERATION
LOW/REVERSE
CLUTCH
REGULATOR TORQUE CONVERTER CONTROL VALVE
2-4 CLUTCH VALVE
t ~ 1 LOW-REVERSE/LOCKUP SOLENOID
REGULATOR._..=====
l REVERSE
CLUTCH
VALVE
REGULATOR~IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
VALVE
MANUAL VALVE - The manual valve is operated sending line pressure to the appropriate circuits
by the shifter linkage and has the responsibility of and solenoids, for the different gear selections.
NOTES
28
TRANSAXLE FUNCTION OF OPERATION
OVERDRIVE
SOLENOID
(ENERGIZED)
LOW-REVERSE/LOCKUP
SOLENOID
(DE-ENERGIZED)
VALVE
) LOW REVERSE/LOCKUP and OVERDRIVE When cycled (turned "on" and "off") at high fre-
SOLENOIDS - When these two solenoids are not quency, these solenoids will modulate the element
energized, the check valves will seat on passage pressure to any value between zero and line
orifices and not allow hydraulic pressure to pass pressure, depending on the pulse duty cycle
through the circuit. At the same time, the element (percent "on" time). In the case of the lockup
circuit is free to vent through the solenoid valve, solenoid, this mndulation in turn can be used to
thus being called a NORMALLY VENTED valve. modulate the loljkup switch valve such that the
When the solenoid is energized it will unseat the torque converter can operate nearly, but not quite,
check valve allowing hydraulic oil pressure to flow locked up ... called "partial" lock.
past the check valve and on through the circuit,
at the same time closing the vent port, thus
directing pressure to the element.
NOTES
_)
29
TRANSAXLE FUNCTION OF OPERATION
UNDERDRIVE
CLUTCH
LINE
PRESSURE
2-4/LOW-REVERSE
SOLENOID
(ENERGIZED)
UNDERDRIVE
SOLENOID
(DE-ENERGIZED)
2-4/LOW REVERSE and UNDERDRIVE SOLE- ment being controlled, and at the same time vent
NOIDS - When these two solenoids are not ener- the element. Like the NORMALLY VENTED valves,
gized their ball checks prevent oil flow out of the these NORMALLY APPLIED valves can also be
element while allowing line pressure in, thus being cycled to modulate the element pressure to any
NORMALLY APPLIED. When energized, these level between line pressure and zero.
valves stop line pressure from reaching the ele-
30
TRANSAXLE FUNCTION OF OPERATION
U1
U1
COLD-OPEN
HOT-CLOSED
THERMAL VALVE - The thermal valve is a open to assist in venting oil past the U1 orifice. At
bi-metallic shutter valve that helps control the temperatures above 20 degrees the valve will start
) venting rate of oil pressure in the underdrive clutch to close and be fully closed at approximately 140
passage during release of the clutch. When the degrees fahrenheit. The thermal valve is located
transaxle oil temperature is at approximately 20 in the transfer plate of the valve body.
degrees fahrenheit or less, the valve will be fully
)
LR(R-N-1) 24(2-4)
PARK/NEUTRAL
SPEED UNDER 8 MPH
LR=LOW REVERSE 24 =2-4 CLUTCH
UD=UNDERDRIVE OD =DYE RDR lYE l...--=lt~-----==!1-F-'
R =REVERSE SW=SWITCH
AC= ACCUMULATOR LU =LOCKUP
PT=PRESSURE TAP D =DRIBBLER
S =SOLENOID
V =VENT
LUBE
PRESSURE(PS I)
AT 1500 RPM
PARK/NEUTRAL - In either of these gear selec- Note that this internal transaxle condition is identi-
tions the transaxle has lube pressure. The low/ cal for the two different (PARK, NEUTRAL) posi-
reverse clutch is pressurized to prepare for the tions of the external manual lever. These different
transaxle shifting to a forward or reverse gear for positions do provide different codes from the
a smoother engagement. The low/reverse lockup PRNDL and Neutral Safety switches to the con-
solenoid is energized to allow line pressure to the troller. Also, in "Park" only, the Park Pawl is
low/reverse clutch . The 2-4/low reverse solenoid engaged to prevent the vehicle from moving.
is energized to close the circuit to the manual
valve .
NOTES
32
TRANSAXLE FUNCTION OF OPERATION
NEUTRAL
SPEED OYER 8 MPH
LR=LOIV REVERSE 24 =2-4 CLUTCH
UD=UNDERDR IVE OD =OVERDRIVE '---t+--.. - - -- ---tt---7...,....
R =REVERSE SIV =SIV ITCH
AC= ACCUMULATOR LU =LOCKUP
PT=PRESSURE TAP D =DRIBBLER
S =SOLENOID
V =VENT
PRESSURE(PS I)
AT 1500 RPM
ROLLING NEUTRAL- SPEED GREATER THAN engage any forward ratio, depending on vehicle
8 MPH. - In this neutral selection, all elements are speed and throttle position, if the driver selects a
disengaged to minimize drag and avoid excessive forward drive mode.
element speeds. This configuration is ready to
NOTES
33
TRANSAXLE FUNCTION OF OPERATION
REVERSE
LR=LOW REVERSE 24 =2-4 CLUTCH
UD=UNDERDR IVE OD =OVERDRIVE
R =REVERSE SW=SWITCH
AC= ACCUMULATOR LU =LOCKUP
PT=PRESSURE TAP D =DRIBBLER
S =SOLENOID
V =VENT
REVERSE - With the manual valve moved to the valve. With only the smaller valve working against
reverse position the line pressure is fed directly the regulator valve the regulator valve spring will
to the reverse clutch and through the 2-4/LR close down the dump causing the line pressure
solenoid to the low/reverse clutch. The regulator to increase.
valve is regulating line pressure to a higher pres-
sure to increase clutch capacity. Notice the line Also notice that there are no solenoids energized
pressure that is fed between the two valves on the in reverse gear. However, the 2-4/LR solenoid is
end of the regulator valve. This pressure neutral- cycled during initial engagement of reverse to
izes the effects of the larger valve on the regulator smooth the torque transition.
NOTES
34
TRANSAXLE FUNCTION OF OPERATION
REVERSE BLOCK
SH 1FT TO REV_ "'I/SPEED OYER 8 MPH
LR=LOW REVERSE 24 =2-4 CLUTCH
UD=UNDERDR IVE OD =OVERDRIVE
R =REVERSE SW=SWITCH
AC=ACCUMULATOR LU =LOCKUP
PT=PRESSURE TAP D =DRIBBLER
S =SOLENOID
V =VENT
PRESSURE(PSI)
~==t!:::!~~...:...::.,~ r7;;:;~r.7;~~~';7-i~~-;t---;::,-,.,;.:'---t.::;-;;;:;=l AT 1500 RPM
REVERSE BLOCK - When reverse is blocked When the transaxle controller goes into reverse
from engaging it is done through a command from block it does it by energizing the 2-4/low reverse
the transaxle controller. This will happen if the solenoid. This will prevent line pressure from
output speed sensor detects the output shaft is applying the low/reverse clutch. In this situation,
spinning at a speed equal to 8 miles per hour or the transmission is effectively in NEUTRAL.
greater. This is done to protect the transaxle from
a situation that could potentially cause damage
to the transaxle.
NOTES
35
TRANSAXLE FUNCTION OF OPERATION
HOLDING CLUTCHES
FIRST GEAR
LR=LOW REVERSE 24 =2-4 CLUTCH
UD=UNDERDR IVE OD =OVERDRIVE L-==if=-:-- - - - = = t ' F-'
R =REVERSE SW=SWITCH
AC= ACCUMULATOR LU =LOCKUP
PT=PRESSURE TAP D =DRIBBLER
S =SOLENOID
V =VENT
LUBE
PRESSURE(PS I)
AT 1500 RPM
FIRST GEAR - When any of the forward gear Notice that the forward gear selection made has
selections are made line pressure is fed to all four no effect on the manual valve, its location will be
solenoids. In first gear the controller will energize the same. The selection difference will be de-
the low/reverse lockup and 2-4/low reverse sole- tected by the controller through the PRNDL and
noids. This configuration will apply the low reverse neutral safety switches. The two switches will give
and underdrive clutches. the controller the information needed to determine
what shift pattern and schedule is to be used.
NOTES
36
TRANSAXLE FUNCTION OF OPERATION
SECOND GEAR
LR=LO'tr' REVERSE 24 =2-4 CLUTCH
UD=UNDERDRIVE OD =OVERDRIVE '----lh.------+-:-:---1
R =REVERSE S'tr'=S'tr'ITCH
AC= ACCUMULATOR LU =LOCKUP
PT=PRESSURE TAP D =DRIBBLER
S =SOLENOID
V =VENT
PRESSURE(PSI)
2::z:=:!!:!::!t!:::!~:.,:::::::.,:::l f!'":"l':,-;IN:::-'E~~~...:.;=:;-;~t=';-;-;-t-';7;;~-b,-;;~ AT 1500 RPM
SECOND GEAR - In second gear none of the the low reverse/lockup solenoid will feed for torque
solenoids are energized. With the solenoids de- converter lockup. When the transaxle goes into
energized, line pressure is fed to the 2-4 and default the solenoids and valve body will shift to,
underdrive clutches. Line pressure from the 2-4 and stay in, this configuration for any forward gear
clutch circuit is fed to the solenoid switch valve, selection by the driver.
moving the valve to the left, and switching circuits
NOTES
.)
37
TRANSAXLE FUNCTION OF OPERATION
SECOND GEAR
PARTIAL LOCKUP
LR=LOW REVERSE 24 =2-4 CLUTCH
UD=UNDERDRIVE OD =OVERDRIVE L-...-=J-1=:--,.-- -....:::=:tt=-=--'
R =REVERSE SW=SWITCH
AC= ACCUMULATOR LU =LOCKUP
PT=PRESSURE TAP D =DRIBBLER
S =SOLENOID
V =VENT
SECOND GEAR (PARTIAL LOCKUP) - When When these two valves move it will cause the
conditions allow for it, the controller will modulate lockup switch valve to start venting the torque
the low reverse/lockup solenoid. By modulating converter release pressure on the front side of the
the solenoid it can lower the line pressure that torque converter clutch piston. At the same time
passes through it before it reaches the lockup the lockup switch valve will increase the apply
switch and torque converter control valves. When pressure on the back side of the torque converter
the modulated pressure reaches the two valves it piston. This will not cause the torque converter to
will fully shift the torque converter control valve to fully lock up but simply reduce the amount of
the left, but only partially shift the lockup switch slippage.
valve.
NOTES
38
TRANSAXLE FUNCTION OF OPERATION
HOLDING CLUTCHES
DIRECT GEAR
LR=LOW REVERSE 24 =2-4 CLUTCH
UD=UNDERDR IVE OD =OVERDRIVE L...--H-.,----+f--~
R =REVERSE SW=SWITCH
AC= ACCUMULATOR LU =LOCKUP
PT=PRESSURE TAP D =DRIBBLER
S =SOLENOID
V =VENT
)
VENT
RESERVOIR
PRESSURE(PSI)
AT 1500 RPM
DIRECT GEAR - To shift to direct gear the Notice that the line pressure is reduced. This was
transaxle controller will energize the 2-4/low re- accomplished by using line pressure from the
verse and overdrive solenoids. This solenoid con- overdrive circuit also. This line pressure is fed to
figuration will feed line pressure to the underdrive an area between the regulator valve and the
and overdrive clutches. Line pressure from the smaller of the two valves on the end. This pressure
overdrive clutch circuit will be fed to an area helps move the regulator valve to the left, dumping
between two plugs at the end of the solenoid additional oil, resulting in lower line pressure.
switch valve. This is done to keep the solenoid
switch valve shifted to the left since 2nd gear line
pressure that was holding the valve, has been
vented off.
NOTES
39
TRANSAXLE FUNCTION OF OPERATION
DIRECT GEAR
PARTIAL LOCKUP
LR=LOW REVERSE 24 =2-4 CLUTCH L--=t-F..,------=t-f--:--'
UD=UNDERDR IVE OD =OVERDRIVE
R =REVERSE SW =SWITCH
AC=ACCUMULATOR LU =LOCKUP
PT=PRESSURE TAP D =DRIBBLER
S =SOLENOID
V =VENT
PRESSURE(PS I)
AT 1500 RPM
DIRECT GEAR (PARTIAL LOCKUP) - Partial reason . For a review of partial lockup operation
lockup in direct gear is accomplished the same see the "SECOND GEAR (PARTIAL LOCKUP)"
way it was done for second gear, and for the same write-up .
NOTES
40
TRANSAXLE FUNCTION OF OPERATION
DIRECT GEAR
FULL LOCKUP
LR=LOW REVERSE 24 =2-4 CLUTCH
UD=UNDERDRIVE OD =OVERDRIVE L...-----tj~----+t--;-:-1
.R =REVERSE SW=SWITCH
AC= ACCU~1Ul ATOR LU =LOCKUP
PT=PRESSURE TAP D =DRIBBLER
S =SOLENOID
V =VENT
PUMP PRESSURE(PSI)
AT 1500 RPM
DIRECT GEAR (FULL LOCKUP)- The solenoid When the low reverse/lockup solenoid is ener-
and valve configuration for direct gear full lockup gized it will send full line pressure to the ends of
is the same as direct gear except for the addition the lockup switch and torque converter control
of the low reverse/lockup solenoid being valves. Both the valves will fully shift to the left.
energized. This will allow the lockup switch valve to fully vent
the pressure on the front side of the torque
converter lockup piston causing full lockup.
NOTES
41
TRANSAXLE FUNCTION OF OPERATION
OVERDRIVE LR~J
1)) V d 2~)
LU ~ LR=LOW REVERSE 24 =2-4 CLUTCH l __r. --
~
UD=UNDERDR IVE OD =OVERDRIVE L.-=J.1F-- - --=IF=-----.J
R =REVERSE
AC=ACCUMULATOR SW=SWITCH
LU =LOCKUP ~~l~ _! ~
PT~ PT=PRESSURE TAP D =DRIBBLER PT AC
S =SOLENOID
V =VENT rr==;-r==:-&2J(1);:::::::::::====1===;-,
OFF ON
LR/LU
-!
v uo
~1
'C OOLER )'~
.M, I
LUBE
~-----,------------~
..
._ ~~--_.--------~~
~ VENT
T
RESER VOIR
I
I
OVERDRIVE - The controller will energize the 2-4 clutch to engage. This will shift the transaxle
underdrive solenoid which will shut off line pres- into overdrive by allowing only the 2-4 and over-
sure to the underdrive clutch. The controller will drive clutches to be applied.
also de-energize the 2-4 solenoid and allow the
NOTES
42
TRANSAXLE FUNCTION OF OPERATION
OVERDRIVE
FULL LOCKUP
LR=LOYI REVERSE 24 =2-4 CLUTCH
UD=UNDERDR lYE OD =OVE RDR lYE
R =REVERSE SYI =SWITCH
AC= ACCUMULATOR LU =LOCKUP
PT=PRESSURE TAP D =DRIBBLER
S =SOLENOID
Y =VENT
PRESSURE(PSI)
AT 1500 RPM
OVERDRIVE (FULL LOCKUP) - To go into full that take place for full lockup, review the write-up
lockup the controller must energize the low reverse/ on "DIRECT GEAR (FULL LOCKUP)".
lockup solenoid. To review the sequence of events
NOTES
_)
43
TRANSAXLE FUNCTION OF OPERATION
TORQUE CONVERTER clutch operation is controlled by the transaxle
controller through the solenoid assembly and valve
The torque converter used in the A604 transaxle body. Benefits of the torque converter when in
is relatively the same in design and operating lockup are improved fuel economy, reduced
characteristics as other lockup torque converters engine noise and reduced transaxle operating
Chrysler has used in the past. Torque converter temperature.
)
VENTED
When the torque converter is unlocked, pressure is vented. The pressure on the back side of the
is fed through the center of the input shaft to the torque converter piston will push the piston for-
front side of the torque converter piston. This ward and lock the turbine to the torque converter
pressure will push the piston rearward and flow housing.
around the outer edge of the piston. The oil will
then exit the torque converter between the input Notice that the torque converter piston has no
shaft and reaction shaft. outer piston seal. Sealing of the outer piston is
done when piston comes into contact with the
When the torque converter goes into lockup, the friction disc. The friction disc is free-floating since
pressure that was fed to the front side of the piston it is not bonded to either the torque converter
through the input shaft is shut off and the circuit piston or housing.
44
TRANSAXLE FUNCTION OF OPERATION
CLUTCHES coil spring. Three of the clutches supply input
power to the planetary geartrain while the other
All clutches in the A604 transaxle are applied two clutches hold components of the planetary
hydraulically. Four of the clutches are released geartrain, to furnish reaction torque.
with belleville springs and one is released with a
INPUT SHAFT
-,
...:
UNDERDRIVE CLUTCH - Of the three input gear and will turn it when clutch is engaged.
clutches that are located in the input clutch re-
tainer, the one that sits in the most forward When the clutch line pressure is released the
position is the underdrive clutch. When line pres- clutch piston will return with tension from the coil
sure is applied to the underdrive clutch it will be spring located between the piston and spring
supplied from the valve body, through passages retainer.
in the transaxle case, oil pump housing and
reaction shaft support. The pressure will then pass Notice that the piston has a vent in it, and the
through a drilled passage in the input clutch spring retainer has a seal on it. These two items
r8tainer hub and to the front side of the underdrive are used to keep oil on the back side of the piston
clutch piston. The piston will move rearward com- to counteract a centrifugal head condition that
pressing the clutch and locking it to the underdrive could cause the piston to move slightly and cause
hub. The underdrive hub is splined to the rear sun the clutch to drag when it's not applied.
NOTES
_)
45
TRANSAXLE FUNCTION OF OPERATION
FRONT PLANETARY
CARRIER
CLUTCH RETAINER
OVERDRIVE CLUTCH - The overdrive clutch is The line pressure will push the piston forward and
the center clutch of the three located in the input apply the overdrive clutch. The clutch pack is
clutch assembly. The clutch pack is retained in the compressed against the same reaction plate that
clutch retainer and the piston that applies the the underdrive clutch used.
clutch is located around the outside of the retainer.
Attached to the rear of the clutch piston is a With the overdrive clutch applied it will lock to the
pressure plate that will compress the overdrive overdrive hub. The overdrive hub is splined to the
clutch pack to apply the clutch. front planetary carrier and will turn it when over-
drive clutch is engaged.
To apply the overdrive clutch, line pressure from
the valve body will be fed through passages in the When line pressure to clutch is released the
transaxle case, oil pump housing and reaction belleville spring on the front side of the overdrive/
shaft support. The line pressure will then be fed reverse piston will return piston to its released
through the input hub and input clutch retainer to position.
the back side of overdrive/reverse clutch piston.
NOTES
46
TRANSAXLE FUNCTION OF OPERATION
FRONT SUN
GEAR HUB
CLUTCH RETAINER
)
REVERSE CLUTCH - The reverse clutch is lo- pressure will move the piston rearward to com-
cated in the rearmost position of the three input press the reverse clutch pack. When the clutch is
clutches. The reverse clutch is operated by the applied it will turn the front sun gear hub assembly.
same piston , pressure plate and belleville spring
that operate the overdrive clutch. When line pressure to the reverse clutch is re-
leased the belleville spring will pull the piston
Line pressure to apply the reverse clutch will come forward to its released position . The overdrive/
from the valve body, fed through passages in the reverse clutch piston belleville spring is positioned
case, oil pump housing and reaction shaft support. so it will center the piston to prevent either the
The line pressure then goes through the input hub overdrive or reverse clutches from dragging when
to the front side of overdrive/reverse piston. The they are not applied.
NOTES
47
TRANSAXLE FUNCTION OF OPERATION
2-4 CLUTCH
2-4 CLUTCH - The 2-4 clutch is one of two To apply the 2-4 clutch, line pressure is sent from
clutches located in the rear portion of the transaxle the valve body straight into the piston retainer.
case. It is the clutch that sits more towards the Located on top of the valve body is a rubber seal
front of the transaxle. Starting from the front of the that seals the valve body directly to the piston
clutch is the 2-4 piston retainer, 2-4 piston, belleville retainer.
spring, clutch pack, and reaction plate. When the
clutch is applied it will lock the front sun gear hub When line pressure is released the belleville spring
assembly to the case so it will not turn. will return piston into piston retainer. The piston
retainer is held to the transaxle case using a snap
ring .
NOTES
48
TRANSAXLE FUNCTION OF OPERATION
LOW/REVERSE CLUTCH - Of the two clutches The clutch is applied with line pressure from the
located in the rear of the transaxle case the valve body that is fed through the transaxle case
rearmost of the two is the low/reverse clutch. The to the piston retainer and pushes the piston for-
low/reverse clutch shares the reaction plate with ward, applying the clutch. When the clutch is
the 2-4 clutch. Moving rearward from the reaction applied it will lock the front planetary carrier to the
plate is the clutch pack, belleville spring, low/ transaxle case so it will not rotate. When line
reverse piston, and the piston retainer. The piston pressure is released the belleville spring will push
retainer is secured to the case with three screws piston back into piston retainer and release the
and sealed with a gasket. clutch.
NOTES
49
TRANSAXLE FUNCTION OF OPERATION
PLANETARY GEARTRAIN When going through the following power flows
keep in mind that the geartrain must somehow
The planetary geartrain is driven by input clutches. complete it's power flow by turning the rear carrier
One of the input clutches must be applied before assembly. The reason for this is that the output
the vehicle can move. A variety of gear ratios are shaft is part of the rear carrier assembly. If the
accomplished by using input clutches to turn output shaft does not turn, the vehicle will not
different planetary components and two clutches move.
in the rear of the case to hold different planetary
components.
FIRST GEAR -Torque input is through the under- planetary pinion gears around the stationary rear
drive clutch, to the underdrive hub assembly which annulus causing the rear carrier assembly to
turns the rear sun gear. The low/reverse clutch is rotate which provides output torque. In this gear,
applied to hold the front carrier/rear annulus as- the rest of the planetary is freewheeling. The gear
sembly. The rear sun gear will drive the rear ratio is 2.84:1.
NOTES
50
TRANSAXLE FUNCTION OF OPERATION
\
POWER FLOW IN SECOND GEAR
SECOND GEAR - Second gear ratio is achieved pinions rotate the rear annulus/front carrier as-
by having both planetary gear sets contribute to sembly. The pinions of the front carrier will "walk
torque multiplication. As in 1st gear, torque input around" the stationary front sun gear. This will
is through the underdrive clutch to the rear sun transmit torque to the front annulus/rear carrier
gear. The 2-4 clutch is applied to hold the front assembly which provides output torque. The gear
sun gear stationary. The rotating rear sun gear ratio is 1.57:1.
turns the rear planetary pinions. The rotating rear
NOTES
51
TRANSAXLE FUNCTION OF OPERATION
UNDERDRIVE CLUTCH
APPLIED
THIRD GEAR- In third gear two input clutches are rotates the front carrier/rear annulus assembly. In
applied, the underdrive clutch and overdrive clutch, effect, this locks the entire planetary gear set so
to provide input torque. The underdrive clutch it rotates as a unit. The gear ratio is 1:1.
rotates the rear sun gear while the overdrive clutch
NOTES
52
TRANSAXLE FUNCTION OF OPERATION
2-4CLUTCH
OVERDRIVE CLUTCH APPLIED
APPLIED
\
) POWER FLOW IN FOURTH GEAR
FOURTH GEAR - In fourth gear input torque is will cause the front carrier pinions to turn the front
through the overdrive clutch while the 2-4 clutch annulus/rear carrier assembly which will provide
is applied to hold the front sun gear. As the output torque. In fourth gear transaxle output
overdrive clutch rotates the front carrier, it causes speed is more than input speed, which is over-
the pinions of the front carrier to "walk around" the drive. Fourth gear ratio is 0.69:1.
front sun gear which is being held stationary. This
NOTES
53
TRANSAXLE FUNCTION OF OPERATION
REVERSE CLUTCH
APPLIED
POWERFLOWINREVERSEGEAR
)
REVERSE GEAR - In reverse input power is carrier assem91y. The pinions will then rotate the
through the reverse clutch which drives the front front annulus/r'ear carrier assembly in the reverse
sun gear. The low/reverse clutch is applied to hold direction providing output torque . The gear ratio
the front carrier/rear annulus assembly stationary. in reverse is- 2.21:1.
The front sun gear will rotate pinions of the front
NOTES
54
TRANSAXLE FUNCTION OF OPERATION
OUTPUT SHAFT
GEAR
SPUNEDTO
TRANSFER SHAFT
TRANSFER GEARS
TRANSFER GEARS
The purpose of the transfer gears is to transfer to the transfer shaft. The gears are helical cut for
output power from the output shaft of the rear quieter operation.
carrier assembly to the transfer shaft. The gear
that is splined and bolted to the output shaft of the The overall gear ratio of the transaxle is, in part,
rear carrier is called the output shaft transfer gear. determined by the ratio between the output shaft
It supplies input power to the transfer shaft transfer gear and transfer shaft gear.
gear that is splined, and retained with a large nut
NOTES
55
TRANSAXLE FUNCTION OF OPERATION
RING GEAR
SPLINE FOR
FINAL DRIVE GEARS The final drive gears The differential is a typical design having two
include the transfer shaft which ha~ a piniqn gear differential pinion gears and two differential side
on the front end of the sh-a ft :The ~ot_h~r fin-al drive gears. Sure grip differentials are not available on
gear is the ring gear which is driven by the transfer front wheel drive transaxles because of possible
shaft pinion. The ring geai'is boltecno, and turns loss of directional control.
the differential case. The differential case Will send
driving torque to the front wheel$ tlirough _axle
shafts.
NOTES
56
ULTRADRIVE AUTOMATIC TRANSAXLE
TRANSAXLE SERVICE
A604 ULTRADRIVE 4-SPEED ELECTRONIC AUTOMATIC TRANSAXLE
SECTIONS INDEX
Page Page
BEARING ADJUSTMENT PROCEDURES . . . . . 112 SERVICE IN VEHICLE . . . . . . . . . . . . . . . . . . . 70
DIAGNOSIS AND TESTS . . . . . . . . . . . . . . . . . 58 SERVICE OUT OF VEHICLE . . . . . . . . . . . . . . . 71
MAINTENANCE AND ADJUSTMENTS . . . . . . . 69 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . 116
TIGHTENING REFERENCE . . . . . . . . . . . . . . . . 117
NOTES
57
ULTRADRIVE AUTOMATIC TRANSAXLE
A-604 ULTRADAIVE DIAGNOSIS AND TESTS
INDEX
Page Page
Clutch Air Pressure Tests . . . . . . . . . . . . . . . . . . . . . . 63 Diagnosis-General . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Torque Converter Stall Test. . . . . . . . . . . . . . . . . . . . . . . 63 Fluid Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Diagnosis Chart "B" . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Hydraulic Pressure Tests . . . . . . . . . . . . . . . . . . . . . . 59
Default Code Chart "A" . . . . . . . . . . . . . . . . . . . . . . . 32 Shift Quality Quick-Learn Procedure . . . . . . . . . . . . 59
58
ULTRADRIVE AUTOMATIC TRANSAXLE
ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER
Shift 1- - - - - - - - - - CLUTCHES - - - - - - - - : - - - - ,
Lever Start Park 1 1 1 1 Low/ 1
Position Safety Sprag I Underdrive I Overdrive I Reverse I 2/4 Reverse 1
P - PARK X X X
R - REVERSE X X
N - NEUTRAL X X
OD - OVERDRIVE
First X X
Second X X
Direct X X
Overdrive X X
D -- DRIVE*
First X X
Second X X
Direct X X
L -- LOW*
First X X
Second X X
Direct X X
*Vehicle upshift and downshift speeds are increased when in these selector positions .
teet any unit which slips and to confirm proper Kickdown l.earn Procedure
operation of good units. However, although road (1) With vehicle speed below 25 mph, make 5
test analysis can usually diagnose slipping units, to 8 wide-open-throttle kickdowns to 1st gear from
the actual cause of the malfunction usually can- either 2nd or 3rd gear. Allow for 5 seconds or
not be decided. Practically any condition can be more of operation in 2nd or 3rd prior to the
caused by leaking hydraulic circuits or sticking kickdown.
valves. (2) With vehicle speed greater than 25 mph,
make 5 to 8 part throttle to wide-open throttle
SHIFT QUALITY QUICK-LEARN PROCEDURE kickdowns to either 3rd or 2nd gear from 4th
This procedure will quickly optimize shift quality gear (for example, 4-3 or 4-2 kickdowns). Allow
after battery disconnect. for 5 seconds or more of operation in 4th, prefer-
The transaxle operating temperature must be ably at road-load throttle, prior to performing
warm before learning is allowed. To warm up the kickdown.
transaxle fluid, observe the following chart:
HYDRAULIC PRESSURE TESTS
AMBIENT ENGINE IDLE
TEMP. (F) TIME (MINUTES) Pressure testing is a very important step in the
0 8 diagnostic procedure. These tests usually reveal
20 6 the cause of most transaxle problems.
Before performing pressure tests, be certain
40 4 that fluid level and condition, and shift cable
60 2 adjustments have been checked and approved.
80 0 Fluid must be at operating temperature (150 to
200 degrees F.).
Upshift l.earn Procedure Install an engine tachometer, raise vehicle on
(1) Maintain constant throttle opening during hoist which allows front wheels to turn, and po-
shifts. sition tachometer so it can be read.
CAUTION: Do not move accelerator pedal during the Attach 150 psi gauges to ports required for test
upshifts. being conducted. A 300 psi gauge (C-3293) is re-
(2) Accelerate vehicle with throttle opening quired for reverse pressure test.
angle in range of 10 to 50 degrees Test port locations are shown in (Figure 1).
(3) Make 15 to 20 1-2, 2-3, and 3-4 upshifts. Ac-
celerating from stop to approximately 45 mph each
time at moderate throttle angle (20-25) is sufficient.
59
ULTRADRIVE AUTOMATIC TRANSAXLE
Test Four (Selector in CircleD-overdrive gearJ
(1) Attach ga uge to the 2/4 clutch tap.
(2) Move selector lever to the circleD position.
(3) Allow vehicle front wheels to turn and in-
crease throttle opening to achieve an indicated
vehicle speed of 30 mph.
(4) The 2/4 clutch pressure should read 75 to
95 psi.
(5) This test checks the 2/4 clutch hydraulic
circuit.
NOTES
61
ULTRADRIVE AUTOMATIC TRANSAXLE
DEFAULT CODE CHART "A"
E E
~
I E
~
I ~
I lQ)
~
Vl
c
0
~
::J
~
::J
0 0
.s .8
0
.s .8 .8 ~ .8 Q Vl
=i:i
Vl Vl
Vl
0
0:;:
Vl
Vl
0
0:;: (';J :;: 0:: :;: :::J .8 u Vl "'> c
0
::J
c
Vl
~
n...
Q)
tt 1:) -
0 Q)
tt 1:) -
0
1:) -
0 ~
_J-
0 Vl
Vl
Q)
~
-~
Vl
~ e ~
.8
u "'
w
0 c 0 c 0 c 0 1:) 0
Q) ::J u~ Q 1:)
u a. ~-=
I I "'.S I ~
"'.S "'
~
0
~
c
ro~
0
"'
~
:::J
0
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62
ULTRADRIVE AUTOMATIC TRANSAXLE
TORQUE CONVERTER STALL TEST Noise
A whining or siren-like noise due to fluid flow
WARNING: Do not let anyone stand in front of vehi-
is normal during stall operation with some torque
cle during test.
converters; however, loud metallic noises from
The stall test consists of determining the en-
loose parts or interference within the assembly
gine speed obtained at full throttle in "D" pos_i-
indicate a defective torque converter. To con-
tion only, with the front wheels blocked. Th1s
firm that the noise originates with the torque
test checks the torque converted stator clutch
converter, operate the vehicle at light throttle in
operation, and the holding ability of the transaxle
D and N on a hoist and listen under the transaxle
clutch. The transaxle oil level should be checked
bell housing.
and the engine brought to normal operating tem-
perature before stall operation. Both the parking
and service brakes must be fully applied and front
CLUTCH AIR PRESSURE TESTS
wheels blocked while making this test.
Clutch Air Pressure Checks
Do not hold the throttle open any longer than
Inoperative clutches can be located using a
is necessary to obtain a maximum engine speed
series of tests by substituting air pressure for
reading, and never longer than five seconds at a
fluid pressure (Figs. 2 and 3). The clutches m~y
time. If more than one stall check is required,
be tested by applying air pressure to thetr
operate the engine at approximately 1,000 q~m
respective passages after the valve body has
in neutral for 20 seconds to cool the transmis-
been removed and Tool 6056 has been installed.
sion fluid between runs. If engine speeds ex-
To make air pressure tests, proceed as follows:
ceeds the maximum limits shown, release the
The compressed air supply must be free of all dirt
accelerator immediately since transaxle clutch
and moisture. Use a pressure of 30 PSI.
slippage is indicated.
Remove oil pan and valve body. (See Valve body
removal.)
Stall Speed Above Specification
If stall speeds exceeds the maximum specified engine
speed of 2240 to 2440 rpm by more than 200 rpm,
transaxle clutch slippage is indicated. Follow the tran-
saxle oil pressure and air presure checks outlined in this
section to determine the cause of slippage.
63
ULTRADRIVE AUTOMATIC TRANSAXLE
TOOL 6056 AIR NOZZLE
FLUID LEAKAGE-TRANSAXLE
TORQUE CONVERTER HOUSING AREA
(1) Check for source of leakage.
Since fluid leakage at or around the torque
converter area may originate from an engine oil
leak, the area should be examined closely. Fac-
tory fill fluid is dyed red and , therefore, can be
distinguished from engine oil.
(2) Prior to removing the transaxle, perform
the following checks:
When leakage is determined to originate from
the transaxle, check fluid level prior to removal
of the transaxle and torque converter.
High oil level can result in oil leakage out the
vent in the manual shaft. If the fluid level is
Fig. 3-Testing Reverse Clutch high, adjust to proper level.
After performing this operation, inspect for
Reverse Clutch leakage. If a leak persists, perform the following
Apply air pressure to the reverse clutch apply operation on the vehicle to determine if it is the
passage and watch for the push/pull piston to torque converter or transaxle that is leaking.
move rearward. The piston should return to its
starting position when the air pressure is removed.
2/4 Clutch
Apply air pressure to the feed hole located on
the 2/4 clutch retainer. Look in the area where )
the 2/4 piston contacts the first separator plate
and watch carefully for the 2/4 piston to move
rearward. The piston should return to its origi-
nal position after the air pressure is removed.
Low/Reverse Clutch
Apply air pressure to the low/reverse clutch MATERIAL: 5" X 1-1 /2" X
SHIELD 1/32" SHEET METAL
feed hole (rear of case, between 2 bolt holes). BOLT RY287
Then, look in the area where the low/reverse
piston contacts the first separator plate and watch Fig. 4-Leak Locating Test Probe Tool
carefully for the piston to move forward. The
piston should return to its original position after Leakage Test Probe
the air pressure is removed. (1) Remove torque converter housing dust
shield.
Underdrive Clutch (2) Clean the inside of torque converter hous-
Because this clutch piston cannot be seen, its ing (lower area) as dry as possible. A solvent
operation is checked by function. Air pressure is spray followed by compressed air drying is pref-
applied to the low/reverse and the 2/4 clutches. erable.
This locks the output shaft. Use a piece of rub- (3) Fabricate and fasten test probe (Fig. 4) se-
ber hose wrapped around the input shaft and a curely to convenient dust shield bolt hole. Make
pair of clamp-on pliers to turn the input shaft. certain torque converter is cleared by test probe.
Next apply air pressure to the underdrive clutch. Tool must be clean and dry.
The input shaft should not rotate with hand (4) Run engine at approximately 2,500 rpm with
torque. Release the air pressure and confirm transaxle in neutral, for about 2 minutes. Trans-
that the input shaft will rotate. axle must be at operating temperature.
(5) Stop engine and carefully remove tool.
64
ULTRADRIVE AUTOMATIC TRANSAXLE
(6) If upper surface of test probe is dry, there 15/32" DRILL 2 HOLES
is no torque converter leak. A path of fluid across
probe indicates a torque converter leak. Oil leak-
ing under the probe is coming from the transaxle
torque converter area.
(7) Remove transaxle and torque converter as-
sembly from vehicle for further investigation. The
fluid should be drained from the transaxle. Re-
install oil pan (with RTV sealant) at specified 1-------13-5/16" - - - - - . - J
torque. ,_ _ _ _ _ _ 15-1/4" ------~
65
ULTRADRIVE AUTOMATIC TRANSAXLE
DIAGNOSIS GUIDE-ABNORMAL NOISE
INSPECT AND CORRECT THE
TRANSAXLE FLUID LEVEL.
ROAD TEST TO VERIFY THAT AN
ABNORMAL NOISE EXISTS. IDENTIFY
THE TYPE OF NOISE, DRIVING
RANGES, AND CONDITIONS
WHEN THE NOISE OCCURS.
NOTES
66
ULTRADRIVE AUTOMATIC TRANSAXLE
DIAGNOSIS GUIDE-VEHICLE WILL NOT MOVE
CHECK THE TRANSAXLE FLUID
LEVEL BEFORE STARTING THE
ENGINE. IF NO FLUID IS VISIBLE
ON THE DIPSTICK, ADD FLUID
TO THE " ADD" MARK BEFORE
STARTING THE ENGINE. THEN
START THE ENGINE WITH THE ABNORMAL NOISE,
TRANSAXLE IN NEUTRAL AND STOP ENGINE IMMEDIATELY,
LISTEN FOR NOISE. REMOVE THE TRANSAXLE AND
CONVERTER AS AN ASSEMBLY.
DISASSEMBLE, CLEAN AND
NO ABNORMAL NOISE,
INSPECT ALL PARTS. CLEAN
MOVE THE SELECTOR TO A
VALVE BODY; INSTALL ALL NEW
FORWARD DRIVE RANGE AND
SEALS, RINGS AND GASKETS;
OBSERVE THE FRONT WHEELS
REPLACE WORN OR DEFECTIVE
FOR TURNIN G
PARTS.
THE FOLLOWING LEAKS MAY BE CORRECTED THE FOLLOWING LEAKS REQUIRE REMOVAL
WITHOUT REMOVING THE TRANSAXLE: OF THE TRANSAXLE AND TORQUE
MANUAL LEVER SHAFT OIL SEAL CONVERTER FOR CORRECTION.
PRESSURE GAUGE PLUGS TRANSAXLE FLUID LEAKING FROM THE
NEUTRAL START SWITCH LOWER EDGE OF THE CONVERTER HOUSING;
OIL PAN RTV CAUSED BY FRONT PUMP SEAL, PUMP TO
OIL COOLER FITTINGS CASE SEAL, OR TORQUE CONVERTER WELD.
EXTENSION HOUSING TO CASE BOLTS
CRACKED OR POROUS
SPEEDOMETER ADAPTER " 0 " RING
TRANSAXLE CASE.
FRONT BAND ADJUSTING SCREW
EXTENSION HOUSING AXLE SEAL
DIFFERENTIAL BEARING RETAINER AXLE SEAL
REAR END COVER RTV
DIFFERENTIAL COVER RTV
EXTENSION HOUSING " 0 " RING
DIFFERENTIAL BEARING RETAINER RTV
PU294B
67
ULTRADRIVE AUTOMATIC TRANSAXLE
PO~~IRI F r.AIISF DIAGNOSIS CHART "B"
Engine Performance X X X X X
Worn or faulty clutch(es) X X X X X X X X X X
-Underdrive clutch X X X X X X
-Overdrive clutch X X X X X
-Reverse clutch X X X X
-2/4 clutch X X X X
-Low/reverse clutch X X X X X
Clutch(es) dragging X
Insufficient clutch plate clearance X X
Damaged clutch seals X X X
Worn or damaged accumulator seal ring(s) X X X X X
Faulty cooling system X
Engine coolant temp. too low X X
Incorrect gearsh itt control
linkage adjustment X X X X X
Shift linkage damaged X
Chipped or damaged gear teeth X X
Planetary gear sets broken or seized X X
Bearings worn or damaged X X
Driveshaft(s) bushing(s) worn or damaged X
Worn or broken reaction shaft
X X X X X
support seal rings
Worn or damaged input shaft seal rings X X X
Valve body malfunction or leakage X X X X X X X X X X X
Hydraulic pressures too low X X X X X X X
Hydraulic pressures too high X X X X
Faulty oil pump X X X X X
Oil filter clogged X X X X X
Low fluid level X X X X X X X X
High fluid level X X
Aerated fluid X X X X X X X X X
Engine idle speed too low X X
Engine idle speed too high X X X X
Normal solenoid operation X
Solenoid sound cover loose X
Sticking lockup piston X
w
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68
ULTRADRIVE AUTOMATIC TRANSAXLE
MAINTENANCE AND ADJUSTMENTS
INDEX
Page Page
Gearshift Linkage Adjustments . . . . . . . . . . . . . . . . . 69 Lubrication 69
LUBRICATION
AUTOMATIC TRANSAXLE
Inspect fluid level on indicator every six months FLUID LEVEL INDICATOR
(Fig. 1) with engine idling and transaxle in park (DIPSTICK)
or neutral position. Allow the engine to idle for at
least one minute with vehicle on level ground. This
SEE SELECTION OF LUBRICANT
will assure complete oil level stabilization between FOR RECOMMENDED FLUID TYPE
differential and transmission. A properly filled
transaxle will read near the "add" mark when B900-4
fluid temperature is 21 degrees Celsius (70 de-
grees Fahrenheit) and in the "HOT" region at 82 Fig. 2-0il Level Indicator
degrees Celsius (180 degrees Fahrenheit) (average
operating temperature). If the transaxle is disassembled for any reason, the
fluid and filter should be changed.
Fluid and Filter Changes
Fluid and filter changes are not required for Drain and Refill
average passenger vehicle usage. (1) Raise vehicle on a hoist (See Lubrication,
Severe usage as defined below, requires that "Group 0"). Place a drain container with a large
fluid and filter be changed, the magnet (on the opening, under transaxle oil pan.
inside of the oil pan) should be cleaned with a (2) Loosen pan bolts and tap the pan at one
clean, dry cloth every 24 000 km (15,000 miles). corner to break it loose allowing fluid to drain,
) (a) More than 50% operation in heavy city traf- then remove the oil pan.
fic during hot weather above 32C (90F.). (3) Install a new filter and 0-ring on bottom of
(b) Police, Taxi, Commercial Type Operation, the valve body.
and Trailer Towing. (4) Clean the oil pan and magnet. Reinstall pan
When the factory fill fluid is changed as recommended using new RTV sealant. Tighten oil pan bolts to
above, only fluids of the type labeled MOPAR ATF 19 Nm (165 in. lbs.).
PLUS (Automatic Transmission fluid) Type 7176, (5) Pour four quarts of MOPAR ATF PLUS
or DEXRON II, should be used. A filter change should (Automatic Transmission Fluid) Type 7176, or
be made at the time of the oil change and the mag- DEXRON II, through the fill tube.
net (on the inside of the oil pan) should be cleaned (6) Start engine and allow to idle for at least
with a clean, dry cloth. one minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Add sufficient fluid to bring level to 118
inch below the "ADD" mark.
Recheck fluid level after transaxle is at nor-
mal operating temperature. The level should be
in the "HOT" region (Fig. 1).
To prevent dirt from entering transaxle, make
certain that dipstick is seated into the dipstick
fill tube.
69
ULTRADRIVE AUTOMATIC TRANSAXLE
new grommet into lever and rod into grommet. (5) Check adjustment as follows:
CAUTION: Set parking brake. (a) Detent position for neutral and drive
(1) Place gearshift lever in "P" (PARK) position. should be within limits of hand lever gate stops.
(2) Loosen clamp bolt on gearshift cable bracket. (b) Key start must occur only when shift lev-
(3) Column shift: Insure that preload adjustment er is in park or neutral positions.
spring engages fork on transaxle bracket. (6) To remove button assembly, completely re-
(4) Pull the shift lever by hand all the way to move knob attaching fasteners. Pull knob "up"
the front detent position (PARK) and tighten lock sharply. Proceed as outlined in console removal,
screw to 11 Nm (100 in. lbs.). Gearshift linkage "Group 23."
should now be properly adjusted. After console is back in place, install knob
and button by reversing the above procedure.
SERVICE IN VEHICLE
INDEX
Page Page
Aluminum Thread Repair . . . . . . . . . . . . . . . . . . . . . . 70 Speedometer Pinion Gear ..................... . 70
General Information ... .. . . . . . . . . . . . . . . . . . . . . . . 70 Valve Body Recondition ..... . .... .... ....... . . 75
GENERAL INFORMATION (5) If transmission fluid is found leaking be-
tween the cable and adapter, replace the small
Various transaxle components can be removed 0-ring on the cable. Remove the adapter from
for repairs without removing the transaxle from the cable. Replace the 0-ring.
the vehicle. The removal, reconditioning, and in- (6) Install the adapter on the cable.
stallation procedures for some of these compo- (7) Install the pinion on adapter with a new
nents are covered here. large 0-ring and install retainer on pinion and
The valve body (see service out of vehicle) may be adapter. Be sure the retainer is properly seated.
serviced in the vehicle, as can the parking sprag, Before installing pinion, adapter, and cable
solenoid assembly, PRNDL Switch, Neutral/Safety assembly make sure adapter flange and its mat-
switch, and extension housing oil seal. ing areas on extension housing are clean. Dirt or
sand will cause misalignment resulting in speed-
SPEEDOMETER PINION GEAR ometer pinion gear damage.
(8) Install bolt and washer. Tighten retainer
When the speedometer pinion adapter Is removed bolt to 7 Nm (60 in. lbs.).
for any reason, a NEW 0-ring must be Installed on
the outside diameter of the adapter. ALUMINUM THREAD REPAIR
Remove and Install Damaged or worn threads in the aluminum
(1) Remove bolt and washer assembly securing transaxle case and valve body can be repaired by
speedometer pinion adapter in the extension the use of Heli-Coils, or equivalent. Essentially,
housing. this repair consists of drilling out the worn-out
(2) With cable housing connected, carefully work damaged threads, tapping the hole with a special
adapter and pinion out of the extension housing. Heli-Coil tap, or equivalent, and installing a Heli-
(3) Remove the retainer and remove the pin- Coil insert, or equivalent, into the tapped hole.
ion from the adapter. This brings the hole back to its original thread
(4) lftransmission fluid is found in cable hous- size.
ing, install a new speedometer pinion and seal Heli-Coil, or equivalent, tools and inserts are
assembly. readily available from most automotive parts
suppliers.
70
ULTRADRIVE AUTOMATIC TRANSAXLE
SERVICE OUT OF VEHICLE
INDEX
Page Page
Assembl y- Subassembly Installation . . . . . . . . . . . . 91 Grounded Clutches . . . . . . . . . . . . . . . . . . . . . . . . . 81
Bearing Adjustment Procedures . . . . . . . . . . . . . . . . 112 Input Clutches Assembly . . . . . . . . . . . . . . . . . . . . 94
Checking Input Shaft End Play . . . . . . . . . . . . . . . . . 79 Oil Pump and Reaction Shaft Support . . . . . . . . . 79
Differential Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Transfer Shaft Repair . . . . . . . . . . . . . . . . . . . . . . . 86
Disassembly- Subassembly Recon dition . . . . . . . . . 94 Valve Body Installation . . . . . . . . . . . . . . . . . . . . . . 76
Input Shaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Valve Body Removal . . . . . . . . . . . . . . . . . . . . . . . . 75
Metric Con version- Inches to Mi ll imeters . . . . . . . . 115 Valve Body Recondition . . . . . . . . . . . . . . . . . . . . . 76
Oil Cooler and Tubes Reverse Flushing . . . . . . . . . . 71 Solenoid Assembly-Replace . . . . . . . . . . . . . . . . . . . . 72
Pump Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Recondition Subassemblies: Tightening Reference . . . . . . . . . . . . . . . . . . . . . . . . . 117
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Transaxle Removal and Installation . . . . . . . . . . . . . 71
OIL COOLERS AND TUBES REVERSE FLUSHING
When a transaxle failure has contaminated the
fluid , the oil cooler(s) should be flushed and the
torque converter replaced with an exchange unit
to insure that metal particles or sludged oil are
not later transferred back into the reconditioned
(or replaced) transaxle.
(1) Place a 'length of flush hose' over the end
of the lower (to cooler) oil cooler hose. Insert
flush hose securely into a waste oil container.
(2) Apply compressed air to the upper oil cooler
hose in very short, sharp blasts.
) (3) Pump approximately one pint of MOPAR
ATF PLUS (automatic transmission fluid) type
7176 into the upper (from cooler) oil cooler hose.
(4) Repeat step (2). Remove 'length of flush hose.'
TRANSAXLE REMOVAL AND INSTALLATION
See Group 7-Cooling to drain engine cooling system
and remove coolant return extension.
8921-16
SOLENOID
ASSEMBLY
8921-24
72
ULTRADRIVE AUTOMATIC TRANSAXLE
PRNDL SWITCH OUTPUT SPEED SENSOR
PRESSURE
TAP PLUGS
73
DIFFERENTIAL UNDERDRIVE CLUTCH OVERDRIVE CLUTCH REVERSE CLUTCH 24 CLUTCH
c:
q
:0
LOW/REVERSE
:t=..
II t:J
CLUTCH
:0
.....
~
:t=..
c:
.....
-...,J
+:> (~ \--\\ __j.j ~\\\'6\ \ Jr b\UJ I ~\1 \\ '1~~~\~~ ff!T~~l\ 1 0
~
:::!
0
~
:t=..
:z:
(/)
:t=..
\~
\' J" ~~~
.. .,~
8921-15
-
ULTRADRIVE AUTOMATIC TRANSAXLE
VALVE BODY
Prior to removing any transaxle subassemblies, plug
all openings and thoroughly clean exterior of the unit,
preferably by steam. Cleanliness through entire disassem-
bly and assembly cannot be overemphasized. When
disassembling , each part should be washed in a suitable
solvent, then dried by compressed air. Do not wipe parts
with shop towels. All mating surfaces in the transaxles
are accurately machined; therefore, careful handling of
all parts must be exercised to avoid nicks or burrs. Tag
all springs as they are removed, for reassembly
identification.
OIL PAN
BOLTS
(USE RTV UNDER
Fig. 3-0i/ Filter
BOLT HEADS)
8921-28
75
ULTRADRIVE AUTOMATIC TRANSAXLE
----- 8921-33
OIL 1-37
Fig. 7-Valve Body Removed Fig. 10-Transfer Plate and Separator Plate
SCREW
8921-35
76
ULTRADRIVE AUTOMATIC TRANSAXLE
NOTES
BALL CHECK
SEAL ~VENT
ROOSTER COMB
cQ]..______ _ --r------"~L------------11~
\
MANUAL SHAFT
d ~
INSULATOR
) ~
D
PARKING SPRAG ROD
RETAINER
24ACCUMULATOR~ ~
(]O([JD~
REGULATOR VALVE ~RETAINER
MANUALVA~E~ ~
RETAINER
LOCKUP
SWITCH VALVE
)
8921-39 VALVES REMOVED VALVES INSTALLED
77
ULTRADRIVE AUTOMATIC TRANSAXLE
LOCKUP SWITCH VALVE ACCUMULATOR RETURN
SPRING PLUG PISTON SPRING
(OVERDRIVE OR
UNDERDRIVEJ
SEAL RING
8921-40 8921-43
Fig. 14-Remove or Install Dual Retainer Plate
8921-41
Fig. 15-Remove or Install Retainer Plate
Fig. 3-Low/Reverse Accumulator Snap Ring
When installing valve body assembly onto trans-
axle, observe Figure 5 and guide park rod rollers
into guide bracket, while shifting manual lever
assembly out of the installation position.
ACCUMULATORS
UNDERDRIVE CLUTCH
ACCUMULATOR
Fig. 1-Accumulators 78
ULTRADRIVE AUTOMATIC TRANSAXLE
TRANSAXLE RECONDITION
Tag all clutch pack assemblies, as they are removed,
for reassembly identification.
Fig. 1-Remove Oil Pump Seal Fig. 1-Measure Input Shaft End Play
79
ULTRADRIVE AUTOMATIC TRANSAXLE
80
ULTRADRIVE AUTOMATIC TRANSAXLE
I
)
Fig. 9-Front Sun Gear Assembly Fig. 12-214 Clutch Retainer Snap Ring
Fig. 10-Front Carrier and Rear Annulus Assembly Fig. 13-Remove 214 Clutch Retainer
._)
81
ULTRADRIVE AUTOMATIC TRANSAXLE
0
CAUTION:
TAG AND IDENTIFY
CLUTCH PACKS
TO ASSURE
24 CLUTCH ORIGINAL \1\
RETURN SPRING PLACEMENT \\1
LOW/REVERSE CLUTCH
REACTION
-....;;::LOW/REVERSE TAPERED
SNAP RING
(TAPERED SIDE UP)
u
NOTES
I
82
ULTRADRIVE AUTOMATIC TRANSAXLE
SNAP RING ENDS
LOCATED IN CASE
~-~~-~..... (NOT BY REACTION
PLATE LUGS)
ACROSS FROM
OIL PAN FACE.
SEQUENCE
(DTHRU@ = REMOVE
A THRU H - INSTALl DO NOT REUSE SNAP RING
TAPERED
SNAP RING
(INSTALL
AS SHOWN)
J
8921-72
8921-70
NOTES
83
ULTRADRIVE AUTOMATIC TRANSAXLE
Fig. 24-Low/Reverse Clutch Pack Fig. 27-Remove Transfer Shaft Gear Nut
REAR COVER
BOLTS
84
ULTRADRIVE AUTOMATIC TRANSAXLE
TRANSFER
SHAFT
8921-81 GEAR 8921-84
Fig. 31-Tighten Nut to 271 Nm (200Ft. Lbs.) Fig. 34-Remove Transfer Shaft Bearing Cone
ARBOR PRESS RAM --10-1 HANDLE C-4171
TOOL5052
Fig. 32-Transfer Shaft Gear and (Select) Shim Fig. 35-lnsta/1 Transfer Shaft Bearing Cone
85
ULTRADRIVE AUTOMATIC TRANSAXLE
WRENCHES 6062
TRANSFER SHAFT
BEARING CUP
RETAINER 8921-86
TOOL6061
ARBOR PRESS RAM
TOOL P-334
USE REMOVED BEARING
CUP TO SUPPORT RETAINER )
8921-87 8921-90
Fig. 37-/nsta/1 New Bearing Cup Fig. 40--Remove Transfer Shaft Bearing Cone
SNAP RING PLIERS TOOL 6052
TOOL6051
'e
)
Fig. 38-Transfer Shaft Bearing Snap Ring Fig. 41-/nsta/1 Bearing Cone
86
ULTRADRIVE AUTOMATIC TRANSAXLE
BEARING CUP BEARING CONE
BOLTS
TOOL L-4407-6 ~~~-~--:::;;;J
8921-95
\.) Fig. 44-0utput Gear Bolt and Washer Fig. 47-Tighten Output Gear to 271 Nm (200Ft. Lbs.)
87
ULTRADRIVE AUTOMATIC TRANSAXLE
Fig. 48-0utput Gear and (Select) Shim Fig. 51-Rear Carrier Assembly
TOOL5048
WITH JAWS
5048-5 AND
BUTION l-4539-2
OUTPUT 8921-99
Fig. 49-Remove Bearing Cone Fig. 52-Remove Rear Carrier Bearing Cone
ARBOR PRESS RAM ----~ HANDLE C-4171
TOOL5052
REAR
CARRIER
OUTPUT GEAR 8921-100 8921 -103
ASSEMBLY
Fig. 50-Install New Bearing Cone Fig. 53-Install Rear Carrier Bearing Cone
88
ULTRADRIVE AUTOMATIC TRANSAXLE
B921-107
lj&
0
Q
89
ULTRADRIVE AUTOMATIC TRANSAXLE
GUIDE BRACKET PAWL
SPLIT SLEEVE
ANTIRATCHET
SPRING
STEPPED
Pl1En 8921-110 8921-113
SPACER SPACER
Fig. 61-Pivot Shaft and Guide Bracket Fig. 64-Low/Reverse Clutch Piston
PA GUIDE
BRACKET
ANTIRATCHET
SPRING
(MUST BE ASSEMBLED
AS SHOWN)
8921-112
90
ULTRADRIVE AUTOMATIC TRANSAXLE
OUTPUT GEAR
,
- /
~IAL
SPE~Ol SCREWS
6260 8921-120
Fig. 7Q-Checking Output Gear Bearings End Play
OUTPUT GEAR
Fig. 71-Checking Output Gear Bearings Turning Torque
91
ULTRADRIVE AUTOMATIC TRANSAXLE
USE HOOK TOOL TO Press down clutch pack with finger and zero dial
RAISE ONE CLUTCH indicator. The 2/4 clutch pack clearance is 0.76 to
DISC
2.64mm (.030 to .104 inch). If not within specifications,
the clutch is not assembled properly. There is no
adjustment for the 2/4 clutch clearance.
Fig. 73-Check 214 Clutch Clearance CAUTION: If view through input speed sensor hole
is not as shown above, the input clutches assembly
is not seated properly.
92
ULTRADRIVE AUTOMATIC TRANSAXLE
Fig. 76--Remove Oil Pump 0-Ring Fig. 77-Measure Input Shaft End Play
By removing the oil pump 0-ring, you will be Input shaft end play must be .012 to .030 inch.
able to install and remove the oil pump very For example , if end play reading is .055 inch,
easily to select the proper #4 thrust plate. select #4 Thrust Plate PN 4431666 which is .071
CAUTION: Be sure to reinstall 0-ring on oil pump to .074 thick. This should provide an input shaft
after selecting the proper #4 thrust plate. end play reading of .020 inch which is within
specifications.
NOTES See chart below to select the proper #4 thrust
plate.
93
ULTRADRIVE AUTOMATIC TRANSAXLE
SUBASSEMBLY RECONDITION
Input Shaft Clutches Retainer Assembly
Disassembly
AP DOWN
REVERSE CLUTCH
REACTION PLATE
TO REMOVE OR
INSTALL SNAP RING Fig. 3-Pry Reverse Clutch Reaction Plate
REVERSE CLUTCH
REACTION PLATE
(INSTALL FLAT
8921-122 SIDE DOWN)
8921-123
CAUTION: TAG
NOTES AND IDENTIFY
CLUTCH PACKS
TO ASSURE
ORIGINAL
PLACEMENT
94
ULTRADRIVE AUTOMATIC TRANSAXLE
OVERDRIVE
SHAFT
ASSEMBLY
AND CD
CLUTCH
PACK
UNDERDRIVE
SHAFT
ASSEMBLY 8921 -130
Fig. 6-0D/Reverse Pressure Plate Snap Ring Fig. 9-Remove OD Clutch Pack
CD/REVERSE
PRESSURE
PLATE
(STEP SIDE
DOWN)
CAUTION: TAG
AND IDENTIFY
CLUTCH PACKS TO
ASSURE ORIGINAL
PLACEMENT 8921-131
#3 THRUST #4 THRUST
PLATE PLATE
(3 TABS) (3 SLOTS)
8921-129
95
ULTRADRIVE AUTOMATIC TRANSAXLE
OD/UD CLUTCH
REACTION
PLATE
(STEP SIDE
DOWN)
8921-134
CAUTION :
DO NOT
REUSE
TAPERED
SNAP RING 8921-135
96
ULTRADRIVE AUTOMATIC TRANSAXLE
Fig. 16-Remove One UD Clutch Disc Fig. 19-UD Spring Retainer Snap Ring
UNDERDRIVE CLUTCH UNDERDRIVE SNAP RING
\
REACTION PLATE SPRING
FLAT SNAP RING RETAINER
PISTON
8921 -138 RETURN
SPRING 8921-141
Fig. 17 -UD Clutch Flat Snap Ring Fig. 20-UD Return Spring and Retainer
CLUTCH PISTON
PLATE (NOTE 2
ANTI SPIN
TABS)
CAUTION : TAG
AND IDENTIFY
CLUTCH PACKS
TO ASSURE
ORIGINAL
REPLACEMENT
8921-139
97
ULTRADRIVE AUTOMATIC TRANSAXLE
INPUT HUB SNAP RING OVERDRIVE/REVERSE /
(TAPERED SIDE UP PISTON /
WITH TABS IN
CAVITY)
SNAP
RING
::/ PLIERS
/ 8921-143 8921-146
Fig. 22-lnput Hub Tapered Snap Ring Fig. 25-Pull Retainer from Piston
ARBOR PRESS RAM
(COMPRESS \
RETURN SPRING
JUST ENOUGH
TO REMOVE OR INSTALL
SNAP RING)
8921-147
OVERDRIVE/REVERSE PISTON
Fig. 24-lnput Hub Removed Fig. 27 -Snap Ring and Return Spring
98
ULTRADRIVE AUTOMATIC TRANSAXLE
SCREWDRIVER
(DO NOT SCRATCH
BEARING SURFACE)
LIP
8921-152
Fig. 28-Remove Input Shaft Snap Ring Fig. 2-lnsta/llnput Shaft Snap Ring
ARBOR PRESS liAM SOCKET CD/REVERSE RETURN SNAP RING
PISTON SPRING
LIP SEAL
8921-150
Fig. 29-Remove Input Shaft Fig. 3-Return Spring and Snap Ring
8921-147
INPUT
CLUTCHES
RETAINER
8921-153
PISTON
RETURN
8921-154 SPRING 8921-141
Fig. 6-lnsta//lnput Shaft Hub Assembly Fig. 9-UD Return Spring and Retainer
INPUT HUB SNAP RING TOOL5067
,...,....-""""'- (TAPERED SIDE UP
WITH TABS IN
CAVITY)
SNAP
RING
~ PLIERS
/ 8921-143 8921-195
Fig. 7-lnput Hub Tapered Snap Ring Fig. 10-Seal Compressor Tool 5067
100
ULTRADRIVE AUTOMATIC TRANSAXLE
Fig. 11-lnsta/1 UD Spring Retainer and Snap Ring Fig. 14-lnsta/1 Last UD Clutch Disc
CAUTION: TAG
AND IDENTIFY
CLUTCH PACKS
TO ASSURE
ORIGINAL
REPLACEMENT
8921-139
CAUTION:
DO NOT
REUSE
TAPERED
SNAP RING 8921-135
Fig. 13-UD Clutch Flat Snap Ring Fig. 16--Tapered Snap Ring
_)
101
ULTRADRIVE AUTOMATIC TRANSAXLE
Snap ring ends must be located within one finger of STEEL
the input clutch hub. Be sure that snap ring is fully BAR
seated, by pushing with screwdriver, into snap ring
groove all the way around.
OVERDRIVE/UNDERDRIVE CLUTCHES
REACTION PLATE TAPERED SNAP RING
COMPRESS
CLUTCH PACK
WITH FINGER
TO ZERO
DIAL INDICATOR 8921-157 .
NOTES
102
ULTRADRIVE AUTOMATIC TRANSAXLE
OVERDRIVE OVERDRIVE/
CLUTCH REVERSE
PACK PRESSURE
PLATE
8921-159 8921-162
CAUTION:
PRESS
) DOWN
JUST
ENOUGH
TO
EXPOSE
SNAP
RING
8921-160 GROOVE 8921-163
Fig. 21-lnsta/1 Waved Snap Ring Fig. 24-lnsta/1 Flat Snap Ring
OVERDRIVE/REVERSE OVERDRIVE/REVERSE
PRESSURE PRESSURE PLATE
PLATE
(STEP SIDE
DOWN)
8921-161
MUST
RAISE
REVERSE
REACTION
PLATE TO
RAISE
8921-165 SNAP RING 8921-168
Fig. 26-lnsta/1 Reverse Clutch Pack Fig. 29-Seating Snap Ring to Determine
Reverse Clutch Clearance
REVERSE
CLUTCH COMPRESS CLUTCH PACK WITH
REACTION FINGER TO ZERO INDICATOR
PLATE
(FLAT
SIDE DOWN)
8921-169
Fig. 27 -Install Reaction Plate
Fig. 30-Check Reverse Clutch Pack Clearance
#3 THRUST
WASHER 8921-174
Fig. 35 -Install Overdrive Shaft Assembly
Fig. 32-lnsta/1 Underdrive Shaft Assembly
Now that both shaft assemblies and thrust washers are
properly installed, reinstall overdrive clutch and reverse
clutch as shown in Figures 20 thru 28. Rechecking these
clutch clearances is not necessary, as they were set
and approved previously.
OVERDRIVE SHAFT
ASSEMBLY
8921-175
105
Fig. 36-lnput Shaft Clutches Assembly
ULTRADRIVE AUTOMATIC TRANSAXLE
DIFFERENTIAL REPAIR
The transfer shaft should be removed for dif-
ferential repair and bearing turning torque check-
ing.
PR2307A.
SPECIAL TOOL
ADAPTER C-293-45
(USE 4 PIECES)
RP453
DIFFERENTIAL
ASSEMBLY
BEARING CONE
RP454
107
ULTRADRIVE AUTOMATIC TRANSAXLE
Fig. 13-Remove Differential Bearing Cone Fig. 16---Remove Pinion Shaft Roll Pin
TOOL C-4171
TOOL L-4410
8921-194
Fig. 15-Torque New Ring Gear Bolts to Fig. 18-Remove or Install Pinion Gears, Side Gears,
95 Nm (70 Ft. Lbs.) and Tabbed Thrust Washers, by Rotating Pinion Gears
to Opening in Differential Case
CAUTION: Always install NEW ring gear bolts. Bolts
must be properly torqued.
108
ULTRADRIVE AUTOMATIC TRANSAXLE
SPECIAL TOOL C-4996
SIDE GEAR THRUST (NOTE POSITION)
WASHER {2)
[SELECT THICKNESS]
n PINION GEAR
~----- "iJ THRUST WASHER
~ ~
~ ~PINION
'V' SHAFT
DIFFERENTIAL /
RP461 RP463
ASSEMBLY
MOVE
SIDE GEAR
UP AND DOWN
n .042, and .047 inch.
SIDE GEAR
RP462
DIFFERENTIAL
BEARING - - --1--1
Fig. 20-Checking Side Gear End Play RETAINER
SPECIAL TOOL
HANDLE C-4171 _ __
RB758
HANDLE C-4171
DIFFERENTIAL
BEARING
RETAINER --~
PR2328
PR2330A
BEARING CUP
LUBRICATION HOLE
(SELECT) SHIM
TO DETERMINE
DIFFERENTIAL
BEARING PRELOAD
(
DIFFERENTIAL
BEARING RETAINER PR2329A
RY296A
Fig. 25-Differentia/ Bearing Retainer
Fig. 27-Checking Differential End Play
_)
110
ULTRADRIVE AUTOMATIC TRANSAXLE
') NOTES
111
ULTRADRIVE AUTOMATIC TRANSAXLE
BEARING ADJUSTMENT PROCEDURE
GENERAL RULES ON SERVICING BEARINGS
(1) Take extreme care when removing and in- (5) Use Tool 6259 to remove the retaining nut
stalling bearing cups and cones. Use only an ar- and washer. To remove the output gear, use Tool
bor press for installation, as a hammer may not L-4407.
properly align the bearing cup or cone. Burrs or (6) Remove the gauging shim and install the
nicks on the bearing seat will give a false end proper shim. Use grease to hold the shim in place.
play reading, while gauging for proper shims. Install the output gear and bearing assembly.
Improperly seated bearing cup and cones are (7) Install the retaining nut and washer and
subject to low-mileage failure. torque to 271 Nm (200 ft. lbs.).
(2) Bearing cups and cones should be replaced (8) Using an inch-pound torque wrench, check
if they show signs of pitting or heat distress. the turning torque. The torque should be between
If distress is seen on either the cup or bearing 3 and 8 inch-pounds.
rollers, both cup and cone must be replaced. If the turning torque is too high, install a .04 mm (.0016
Bearing end play and drag torque specifications must inch) thicker shim. If the turning torque is too low,
be maintained to avoid premature bearing failures. install a .04 mm (.0016 inch) thinner shim. Repeat
Used (original) bearing may lose up to 50% of until the proper turning torque is 3 to 8 inch pounds.
the original drag torque after break-in.
All bearing adjustments must be made with no OUTPUT GEAR BEARING SHIM CHART
other component interference or gear inter-mesh, ex-
cept the transfer gear bearing. End Play End Play
Oil all bearings before checking turning torque. (with 4.50 mm Required (with 4.5 mm Required
Gauging Shim Shim Gauging Shim Shim
OUTPUT GEAR BEARING Installed) Installed)
mm Inch mm mm Inch mm
With output gear removed: .05 .002 4.42 .53 .021 3.94
(1) Install a 4.50 mm (0.177 inch) gauging shim .08 .003 4 .38 .56 .022 3 .90
on the rear carrier assembly hub, using grease .10 .004 4.38 .58 .023 3 .90
to hold the shim in place. .13 .005 4.34 .61 .024 3 .86
. 15 .006 4.30 .64 .025 3.82
(2) Install output gear and bearing assembly. . 18 .007 4.30 .66 .026 3 .82
Torque to 271 Nm (200 ft. lbs.). .20 .008 4.26 .69 .027 3 .78
(3) To measure bearing end play: .23 .009 4.22 .71 .028 3 .74
(a) Attach Tool L-4432 to the gear. .25 .010 4.22 .74 .029 3.74
(b) Push and pull the gear while rotating back .28 .011 4.18 .76 .030 3.70
.30 .012 4.14 .79 .031 3.66
and forth to insure seating of the bearing rollers. .33 .013 4.14 .81 .032 3.66
(c) Using a dial indicator, mounted to the .36 .014 4.10 .84 .033 3.62
transaxle case, measure output gear end play. .38 .015 4.10 .86. .034 3.62
(4) Once bearing end play has been determined, .41 .016 4 .06 .89 .035 3 .58
refer to the output gear bearing shim chart for .43 .017 4 .02 .91 .036 3.54
.46 .018 4.02 .94 .037 3 .54
the required shim to obtain proper bearing .48 .019 3.98 .97 .038 3.50
setting. .51 .020 3.94
Average Conversion .04mm = .0016 1nch
NOTES
_)
112
ULTRADRIVE AUTOMATIC TRANSAXLE
DIFFERENTIAL BEARING (8) When the end play has been determined,
refer to the Differential Bearing Shim Chart for
(1) Remove the bearing cup from the differen- the correct shim combination to obtain the proper
tial bearing retainer using Tool L-4518, and re- bearing setting.
move the existing shim from under the cup. (9) Remove the differential bearing retainer.
(2) Install a .50 mm (.020 inch) gauging shim Remove the bearing cup and the .50 mm (.020
and reinstall the bearing cup into the retainer. inch) gauging shim.
Use an arbor press to install the cup. (10) Install the proper shim combination un-
Oil Baffle is not required when making shim selection. der the bearing cup. Make sure the oil baffle is
(3) Install the bearing retainer into the case installed properly in the bearing retainer, below
and torque bolts to 28 Nm (250 in. lbs.). the bearing shim and cup.
(4) Position the transaxle assembly vertically (11) Install the differential bearing retainer.
on the support stand and install Tool C-4995 into Make sure to seal the retainer to the housing
side gear. with RTV Sealant and torque bolts to 28 Nm (250
(5) Rotate the differential at least one full revo- in. lbs.).
lution to ensure the tapered roller bearings are (12) Using Tool C-4995 and an inch-pound torque
fully seated. wrench, check the turning torque of the differ-
(6) Attach a dial indicator to the case and zero ential. The turning torque should be between 5 and
the dial indicator. Place the indicator tip on the 18 inch-pounds.
end of Tool L-4436. If the turning torque is too high, install a .05 mm
(7) Place a large screwdriver to each side of (.002 inch) thinner shim. If the turning torque is too
the ring gear and lift. Check the dial indicator low, install a .05 mm (.002 inch) thicker shim. Repeat
for the amount of end play. until 5 to 18 inch-pounds turning torque is obtained.
CAUTION: Do not damage the transaxle case and/or
differential cover sealing surface. TRANSFER SHAFT BEARING
) DIFFERENTIAL BEARING SHIM CHART (1) Use Tool 6259 to remove the retaining nut
End Play and washer. Remove the transfer shaft gear using
(with .50 mm Required Tool L-4407.
gauging shim Shim Total (2) Install a 4.66 mm (.184 inch) gauging shim
Installed) Combination Thickness on the transfer shaft.
mm Inch mm mm Inch (3) Install transfer shaft gear and bearing as-
.0 .0 .50 .50 .020 sembly and torque the nut to 271 Nm (200 ft.
.05 .002 .75 .75 .030 lbs.) .
.10 .004 .80 .80 .032 (4) To measure bearing end play:
.15 .006 .85 .85 .034 (a) Attach Tool L-4432 to the transfer gear .
.20 .008 .90 .90 .035
.25 .010 .95 .95 .037 (b) Mount a steel ball with grease into the
.30 .012 1.00 1.00 .039 end of the transfer shaft.
.35 .014 1.05 1.05 .041 (c) Push and pull the gear while rotating back
.40 .016 . 50 + .60 1.10 .043 and forth to insure seating of the bearing rollers .
.45 .018 .50+ .65 1.15 .045 (d) Using a dial indicator, measure transfer
.50 .020 .50+ .70 1.20 .047
.55 .022 .50 + .75 1.25 . 049 shaft end play .
.60 .024 .50+ .80 1.30 .051 NOTES
.65 .026 .50+ .85 1.35 .053
.70 .027 .50 + .90 1.40 .055
.75 .029 .50+ .95 1.45 .057
.80 .031 .50 + 1.00 1.50 .059
.85 .033 .50 + 1.05 1.55 .061
.90 .035 1.00 + .60 1.60 .063
.95 .037 1.00 + .65 1.65 .065
1.00 .039 1.00 + .70 1.70 .067
1.05 .041 1.00 + .75 1. 75 .069
1.10 .043 1.00 + .80 1.80 .071
1.15 .045 1.00 + .85 1.85 .073
1.20 .047 1.00 + .90 1.90 .075
1.25 .049 1.00 + .95 1.95 .077
1.30 .051 1.00 + 1.00 2.00 .079
1.35 .053 1.00 + 1.05 2.05 .081
1.40 .055 1.05 + 1.05 2.10 .083
113
ULTRADRIVE AUTOMATIC TRANSAXLE
TRANSFER BEARING SHIM CHART BEARING SHIM CHART
(6) Use Tool 6259 to remove the retaining nut 0.50 .020 4207134 - - X*
0.55 .022 4207135 - - X
and washer. Remove the transfer shaft gear us- 0.60 .024 4207136 - - X
ing Tool L-4407. 0.65 .026 4207137 - - X
(7) Remove the gauging shim and install the 0.70 .027 4207138 - - X
correct shim. Install the transfer gear and bear- 0.75 .029 4207139 - - X
ing assembly. 0.80 .031 4207140 - - X
0.85 .033 4207141 - - X
(8) Install the retaining nut and washer and 0.90 .035 4207142 - - X
torque to 271 Nm (200 ft. lbs.). Measure transfer 0.95 .037 4207143 - - X
shaft end play, end play should be .05 to .10 mm 1.00 .039 4207144 - - X
(.002 to .004 inch). 1.05 .041 4207145 - - X
(9) Measure bearing end play as outlined in *Also used as gauging shims
Step (4). End play should be between .05 mm and
.10 mm (.002 to .004 inch).
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 combination. Repeat until
.05 to .1 0 mm (.002 to .004 inch) end play is obtained.
114
METRIC CONVERSION CHART
INCHES TO MILLIMETERS
All values in this table are exact
inches 0.000 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009
millimeters
0.000 0.0254 0.0508 0.0762 0.1016 0.1270 0.1524 0.1778 0.2032 0.2286
0.010 0.2540 0.2794 0.3048 0.3302 0.3556 0.3810 0.4064 0.4318 0.4572 0.4826
0.020 0.5080 0.5334 0.5588 0.5842 0.6096 0.6350 0.6604 0.6858 0.7112 0.7366
0.030 0.7620 0.7874 0.8128 0.8382 0.8636 0.8890 0.9144 0.9398 0.9652 0.9906
0.040 1.0160 1.0414 1.0668 1.0922 1.1176 1.1430 1.1684 1.1938 1.2192 1.2446
0.050 1.2700 1.2954 1.3208 1.3462 1.3716 1.3970 1.4224 1.4478 1.4732 1.4986
0.060 1.5240 1.5494 1.5748 1.6002 1.6256 1.6510 1.6764 1.7018 1. 7272 1.7526
0.070 1. 7780 1.8034 1.8288 1.8542 1.8796 1.9050 1.9304 1.9558 1.9812 2.0066
0.080 2.0320 2.0574 2.0828 2.1082 2.1336 2.1590 2.1844 2.2098 2.2352 2.2606
0.090 2.2860 2.3114 2.3368 2.3622 2.3876 2.4130 2.4384 2.4638 2.4892 2.5146
0.100 2.5400 2.5654 2.5908 2.6162 2.6416 2.6670 2.6924 2. 7178 2.7432 2.7686
0.110 2.7940 2.8194 2.8448 2.8702 2.8956 2.9210 2.9464 2.9718 2.9972 3.0226
0.120 3.0480 3.0734 3.0988 3.1242 3.1496 3.1750 3.2004 3.2258 3.2512 3.2766
0 .130 3.3020 3.3274 3.3528 3.3782 3.4036 3.4290 3.4544 3.4798 3.5052 3.5306
0.140 3.5560 3.5814 3.6068 3.6322 3.6576 3.6830 3. 7084 3.7338 3.7592 3.7846
0.150 3.8100 3.8354 3.8608 3.8862 3.9116 3.9370 3.9624 3.9878 4.0132 4.0386
0.160 4.0640 4.0894 4.1148 4.1402 4.1656 4.1910 4.2164 4.2418 4.2672 4.2926
0.170 4.3180 4.3434 4 .3688 4.3942 4.4196 4 .4450 4.4704 4.4958 4.5212 4.5466
0.180 4.5720 4.5974 4.6228 4.6482 4.6736 4.6990 4.7244 4.7498 4.7752 4.8006
0.190 4.8260 4.8514 4.8768 4.9022 4.9276 4.9530 4.9784 5.0038 5.0292 5.0546
0.200 5.0800 5.1054 5.1308 5.1562 5.1816 5.2070 5.2324 5.2578 5.2832 5.3086
0.210 5.3340 5.3594 5.3848 5.4102 5.4356 5.4610 5.4864 5.5118 5.5372 5.5626
0.220 5.5880 5.6134 5.6388 5.6642 5.6896 5.7150 5.7404 5.7658 5.7912 5.8166
) 0.230 5.8420 5.8674 5.8928 5.9182 5.9436 5.9690 5.9944 6.0198 6.0452 6.0706
0.240 6 .0960 6.1214 6.1468 6.1722 6.1976 6.2230 6.2484 6.2738 6.2992 6.3246
0.250 6.3500 6.3754 6.4008 6.4262 6.4516 6.4770 6.5024 6.5278 6.5532 6.5786
0 .260 6.6040 6.6294 6.6548 6.6802 6.7056 6.7310 6.7564 6.7818 6.8072 6.8326
0.270 6.8580 6.8834 6.9088 6.9342 6.9596 6.9850 7.0104 7.0358 7.0612 7.0866
0.280 7.1120 7.1374 7.1628 7.1882 7.2136 7.2390 7.2644 7.2989 7.3152 7.3406
0.290 7.3660 7.3914 7.4168 7.4422 7.4676 7.4930 7.5184 7.5438 7.5692 7.5946
0.300 7.6200 7.6454 7.6708 7.6962 7.7216 7.7470 7.7724 7.7978 7.8232 7.8486
0.310 7.8740 7.8994 7.9248 7.9502 7.9756 8.0010 8.0264 8.0518 8.0772 8.1026
0.320 8.1280 8.1534 8.1788 8.2042 8.2296 8.2550 8.2804 8.3058 8.3312 8.3566
0.330 8.3820 8.4074 8.4328 8.4582 8.4836 8.5090 8.5344 8.5598 8.5852 8.6106
0.340 8.6360 8.6614 8.6868 8.7122 8.7376 8.7630 8.7884 8.8138 8.8392 8.8646
0.350 8.8900 8.9154 8.9408 8.9662 8.9916 9.0170 9.0424 9.0678 9.0932 9.1186
0.360 9.1440 9.1694 9.1948 9.2202 9.2456 9.2710 9.2964 9.3218 9.3472 9.3726
0.370 9.3980 9.4234 9.4488 9.4742 9.4996 9.5250 9.5504 9.5758 9.6012 9.6266
0.380 9.6520 9.6774 9.7028 9.7282 9.7536 9.7790 9.8044 9.8298 9.8552 9.8806
0.390 9.9060 9.9314 9.9568 9.9822 10.0076 10.0330 10.0584 10 .0838 10.1092 10.1346
0.400 10.1600 10.1854 10.2108 10.2362 10.2616 10.2870 10.3124 10.3378 10.3632 10.3886
0.410 10.4140 10.4394 10.4648 10.4902 10.5156 10.5410 10.5664 10.5918 10.6172 10.6426
0.420 10.6680 10.6934 10.7188 10.7442 10.7696 10.7950 10.8204 10.8458 10.8712 10.8966
O.tl-30 10.9220 10.9474 10.9728 10.9982 11.0236 11.0490 11.0744 11.0998 11.1252 11.1506
I 0.440
0.450
0.460
0.470
0.480
11.1760
11.4300
11.6840
11.9380
12.1920
11.2014
11.4554
11.7094
11 .9634
12.2174
11.2268
11.4808
11.7348
11.9888
12.2428
11.2522
11.5062
11.7602
12.0142
12.2682
11.2776
11.5316
11.7856
12.0396
12.2936
11.3030
11.5570
11.8110
12.0650
12.3190
11.3284
11.5824
11.8364
12.0904
12.3444
11.3538
11.6078
11.8618
12.1158
12.3698
11.3792
11.6332
11.8872
12,1412
12.3952
11.4046
11.6586
11.9126
12.1666
12.4206
0.490 12.4460 12.4714 12.4968 12.5222 12.5476 12.5730 12.5984 12.6238 12.6492 12.6746
inches 0.000 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009
115
TRANSAXLE SPECIFICATIONS
SPECIFICATIONS
A604 UL TRADRIVE 4SPEED ELECTRONIC AUTOMATIC TRANSAXLE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fully-adaptive, electronically-controlled, four-speed
automatic with torque converter and integral differential
T~rque C~nverter Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 millim~ters (9.48 inc.hes)
011 Capac1ty-Transaxle and Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6 L1ters (18.25 p1nts)
Oil Type. .. . . .. ... .. ... . . .. ... . .. ...... ...... .. ......... ... ... ..... MOPAR ATF Typ~ 7176 (or DEXRON II)
Cooling Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water heat exchanger and/or a1r-to-oll heat exchanger
Lubrication . ..... .. ........... . ......... . .. ..... . . .. . ... ................. Pump (internal-external gear type)
Gear Ratios:
Transmission portion:
First . .. .... .. ......... .. ...... . .. ..... . ....... .... ........ . .. .... ............ . ............. 2 .84
Second .. . .. ............... . . .. .. ......... .... ... ..... . . ... .. ... .......... . ........ .. ....... . 1.57
Direct ..... . ...... .. ... .. ... . ..... .......... ... ...... . ... ..... . . . ... . ..... ...... ....... . .. .. . 1.00
Overdrive .. . ................ . .... . .. .. .. .................. . .... .... ..... . .. . ............ . ... . .69
Reverse .... ... ... .... .. .... . ........ . . .... .. ... ..... .. . . .......... ..... .. ... . .. ... . ... . . .. . . . 2.21
Overall Top Gear Ratio:
(in overdrive). ... .... .. ........ . ...... . . . ... . ..... . .... ... .. ... .... ... ... .......... . ........... . 2.36
Pump Clearances: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(same as A-413 automatic transaxle)
Tapered Roller Bearing Settings: (Millimeter) (Inch)
Output Gear............ ... ... . . .. . ..... . .... .02-.05 Preload .0008-.002 Preload
Transfer Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05- .10 End Play .002-.004 End play
Differential.. . .... ... .. .. .......... ....... . . . .15- .29 Preload .006-.012 Preload
NOTES
116
TRANSAXLE - TIGHTENING REFERENCE
TIGHTENING REFERENCE
A604 ULTRADRIVE 4SPEED AUTOMATIC TRANSAXLE
Torque
Newton- Inch- Foot-
Item Thread Size meters Pounds Pounds
Cooler Line Fitti ngs ... . ......... . ......... . 1/8 x 27 NPT 12 110
Differe ntial Cover ..... .. .. . .......... . .. . . . M8 X 1. 25 19 165
Differential Ring Gear ... .......... ... . ... . . M10 X 1.0 X 25 95 70
Differential Bearing Retainer . . . . . ...... ... . . M8 X 1.25 X 23 28 21
Rear End Cover .................. . ....... . M8 X 1.25 19 14
Extension Housing .... .. ............. . .... . M8 X 1.25 X 33 28 21
Input Speed Sensor .......... .. .... . ...... . M22 X 1.5 27 20
UR Cl utch Retainer . . ... . ................. . M5 X 0.8 5 40
Neutral Safety Switch . ............. . ... .. . . 3/4 IN. x 16 34 25
Oil Pan to Case .. .. .......... . .. . ..... . .. . M8 X 1.25 19 14
Output Gear Bolt ( 1. 5 inch hex} ........ . ... . M18 X 1.75 271 200
Output Speed Sensor . .................... . M24 X 2 27 20
Pressure Taps ...... . ........... . .... . . ... . 1/16 - 27 NPTF 5 45
PRNDL Switch .. . ............. .... ....... . M22 X 2.5 34 25
Pump to Case ............ .. . ......... ... . . M8 X 1.25 22 23
Reaction Shaft to Pump ... . ............... . M8 X 1. 25 22 23
Solenoid Assy. to Case .......... .. ... .. ... . M6 X 1.0 X 93 .5 12 105
Transfer Plate to Case . . .. . .... . ..... .. . ... . M6 X 1.0 12 105
Transfer Gear Nut (1.25 inch hex) ........ . . . M22 X 1. 5 271 200
Valve Body & Transfer Plate ....... ... . . . . .. . M5 X 0.8 5 40
Vent Assembly . .. .............. . ........ . . 1/8 PIPE 12 110
8-Way Solenoid Connector .... . . . . . .. .. .. . . . M6 X 1.0 4 38
60-Way EATX Connector .. . ...... . ........ . . M6 X 1.0 4 38
NOTES
117