Servicing - A/t Dodge Caravan II

IDENTIFICATION

TRANSAXLE APPLICATION

SERVICE INTERVALS

Light duty service requires no transaxle servicing. Vehicles subjected to severe heavy-duty conditions should have transaxle serviced (fluid drained and refilled, bands adjusted) every 15,000 miles.

CHECKING FLUID LEVEL

1. Check fluid level with vehicle parked on level surface, engine idling at normal operating temperature for a minimum of 60 seconds and parking brake applied. Move selector lever through all gear ranges, ending in "P".
2. Fluid level should be in WARM crosshatched area of dipstick with transaxle fluid temperature about 100°F (38°C) and in HOT crosshatched area of dipstick with transaxle temperature about 180°F (82°C). Check condition of fluid for contamination or burnt smell.

RECOMMENDED FLUID

It is important that proper lubricant be used in transaxle. Mopar ATF Plus automatic transaxle fluid Type 7176 should be used, except for PTU units, to aid in assuring optimum transaxle performance. Fluids of the type labeled Dexron-II should be used only if recommended fluid is not available.

For AWD models, power transfer unit (PTU) requires 85W-90 SAE API GL-5 gear oil.

FLUID CAPACITIES

Note. Transaxle total refill capacities listed in table should only be used as a guide. Correct fluid level should always be determined by marks on dipstick. See DRAINING & REFILLING when performing regular servicing.

TRANSMISSION REFILL CAPACITIES

DRAINING & REFILLING

Note. Torque converter is not equipped with a drain.

Scheme 94

Scheme 95

1. Loosen oil pan bolts. Break pan loose by tapping lightly on one corner of pan and allow fluid to drain. Remove pan. Install new filter on bottom of valve body and tighten retaining screws to 40 INCH lbs. (5 N.m). Clean oil pan. Clean magnet (if equipped), and place over boss in right rear corner of pan. Install pan with new gasket. (Scheme 94)and (Scheme 95). Tighten pan bolts to 165 INCH lbs. (19 N.m). (Scheme 94): 30TH & 31TH Oil Pan Gasket ID (Scheme 95): 41TE Oil Pan Gasket ID
2. Add 4 qts. (3.8L) ATF to transaxle. Start engine and run at idle for at least one minute. Apply parking brake and move shift selector lever through all ranges, ending in "P". Add fluid to 1/8" below middle hole on dipstick. DO NOT overfill. Recheck fluid level when transaxle reaches normal operating temperature.

ADJUSTMENTS

Note. 41TE transaxle does not have any bands. Kickdown band adjusting screw is located on left side (top front) of transaxle case.

30TH & 31TH Transaxle

1. Locate kickdown band adjusting screw on left side (top front) of transaxle case. Loosen adjusting screw lock nut and back off screw 5 turns. Ensure adjusting screw turns freely in case.
2. Using Wrench (C-3380-A) with Adapter (C-3705), tighten adjusting screw to 48 INCH lbs. (5 N.m). If adapter is not used, tighten adjusting screw to 72 INCH lbs. (8 N.m).
3. Back off front adjusting screw 2 1/2 turns. Hold adjusting screw and tighten lock nut to 35 ft. lbs. (47 N.m).

1. Drain transaxle fluid and remove oil pan. Apply 30 psi (2.1 kg/cm 2 ) air pressure to low-reverse servo and measure gap between band ends. If gap is less than .080" (2.0 mm), band is excessively worn and should be replaced.
2. To adjust band, loosen lock nut approximately 5 turns and tighten adjusting screw to 44 INCH lbs. (5 N.m). Back off adjusting screw 3 1/2 turns. Hold screw in position and tighten lock nut to 120 INCH lbs. (14 N.m).

30TH

1. Ensure engine idle speed is correct and engine is at normal operating temperature. Loosen adjustment bracket lock screw. Bracket must have both bracket alignment tabs touching transaxle cast surface. Tighten lock screw to 105 INCH lbs. (12 N.m).
2. Release cross-lock on cable assembly by pulling upward. Ensure adjustment is correct. Cable must be free to slide toward engine, against its stop, after cross-lock is released.
3. Move transaxle throttle control lever fully clockwise against its internal stop. Press cross-lock downward into locked position. Move transaxle throttle lever counterclockwise. Slowly release it to ensure it will return to full clockwise position.

31TH

1. Ensure engine idle speed is correct and engine is at normal operating temperature. Loosen adjustment swivel lock screw. Ensure swivel is free to slide along throttle rod. Disassemble and repair if necessary.
2. Move transaxle throttle pressure lever toward engine until it contacts internal stop. Tighten swivel lock screw to 100 INCH lbs.(11 N.m). Ensure linkage backlash is removed by preload spring.

Column Shift

1. Place shift selector in "P" position. Loosen lock bolt on cable adjusting bracket on transaxle. Ensure preload adjustment spring engages fork on transaxle bracket. Pull shift lever by hand all the way to front detent position (Park).
2. Tighten lock screw to 100 INCH lbs. (11 N.m). To check adjustment, gearshift lever should be within limits of hand lever gate stops when shifted through gear positions. Vehicle must only start in Park or Neutral.

NEUTRAL SAFETY SWITCH

A combination neutral safety and back-up light switch is screwed into side of transaxle case. Switch is nonadjustable. Switch may be tested for continuity using the following method.

Note. Before replacing a switch that fails test, ensure gearshift linkage is properly adjusted.

Testing

1. With transaxle linkage properly adjusted, switch should allow starter operation in "P" and "N" only. To test switch, remove wire connector and test for continuity between switch center pin and transaxle case. Continuity should exist only when transaxle is in "P" or "N".
2. Check for continuity between 2 outer pins. Continuity should exist with transaxle in "R" position only. There should be no continuity between either outside pin and the transaxle case.
3. To replace neutral safety switch, remove switch from case and allow fluid to drain. Move selector lever to "P" and "N" positions and ensure switch operating fingers are centered in switch opening. Install new switch and seal. Tighten to 25 ft. lbs. (34 N.m). Retest switch for continuity and add transaxle fluid as required.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• DRAINING & REFILLING