Overhaul - 42LE Automatic Transmission: Specifications Dodge Intrepid I

No Torque Converter Lock-Up

Check for aerated fluid, defective torque converter, engine coolant temperature low, faulty oil pump, hydraulic pressure too low, low fluid level, valve body malfunction or leakage, worn or damaged input shaft seal rings.

TORQUE CONVERTER STALL SPEED TEST

Torque Converter Clutch Pressure Test

1. Remove pressure tap plug and install pressure gauge in torque converter clutch off pressure tap. see scheme 4
2. Place gearshift in "OD" position. Allowing front wheels to rotate, accelerate until vehicle speed indicates 50 MPH. CAUTION: Ensure both front wheels are rotating at the same speed.
3. Torque converter clutch pressure should be less than 5 PSI (.35 kg/cm 2 ). Remove pressure gauge. Install and tighten pressure tap plug to specification. See «TORQUE SPECIFICATIONS»(ref-25345-S39914706182001011700000).
4. Remove pressure tap plug and install pressure gauge in torque converter clutch on pressure tap. see scheme 4 Place gearshift in "OD" position.
5. Allowing front wheels to rotate, accelerate until vehicle speed indicates 50 MPH. Ensure torque converter clutch is applied. NOTE: It may be necessary to use DRB scan tool to monitor engine RPM to verify when torque converter clutch is applied. If DRB usage is required, connect DRB to Blue data link connector. Use proper cartridge and DRB manufacturer's instructions for monitoring torque converter clutch operation.
6. Torque converter clutch on pressure should be 60-90 PSI (4.2-6.3 kg/cm 2 ). This pressure test checks torque converter clutch hydraulic circuit. Remove pressure gauge. Install and tighten pressure tap plug to specification. See «TORQUE SPECIFICATIONS»(ref-25345-S39914706182001011700000).

TORQUE CONVERTER LEAK TEST

Note. Transaxle contains a separate oil sump for the differential. Transmission uses ATF and differential uses hypoid gear oil. Transaxle contains oil seals for each individual sump. A fluid leakage weep hole is located on side of transaxle case. (Scheme 1) Before performing torque converter fluid leakage test, check for fluid leakage at fluid leakage weep hole. If fluid leakage exists, note if fluid is ATF or differential gear oil. This indicates which oil seal is leaking and must be replaced.

Note. Fluid around torque converter may originate from engine oil or the transaxle. Ensure transaxle fluid level is correct. Fluid leakage at torque converter may result if fluid level is too high. Transaxle can be checked for torque converter leaks using following method.

1. Remove torque converter dust shield. Using solvent and compressed air, clean inside area of torque converter housing. Ensure area is clean and dry.
2. Fabricate leakage test probe using 1/32" sheet metal, 6" (152 mm) long and 1 1/2" (38.1 mm) wide. (Scheme 2) Start and operate engine until transaxle is at normal operating temperature. Shut engine off.
3. Install leakage test probe using dust shield bolt so leakage test probe is near torque converter. Ensure leakage test probe does not contact torque converter.
4. Start engine. Place gearshift in Neutral. Operate engine at 2500 RPM for 2 minutes. Stop engine. Remove leakage test probe.
5. If upper surface of leakage test probe is dry, torque converter is not leaking. If upper surface of leakage test probe is wet with transaxle ATF fluid, torque converter is leaking. If lower area below leakage test probe is wet with transaxle ATF fluid, fluid is coming from the transaxle.
6. Possible causes of ATF fluid leaks at torque converter areas are: Torque converter hub. Defective seal (check torque converter hub finish). Mispositioned or worn bushing. Oil pump housing oil return hole restricted. Defective oil pump housing or "O" ring. Oil pump-to-transaxle case bolts.
7. If torque converter is leaking, check for defective welds on outside diameter of torque converter and torque converter hub. Torque converter hub weld is welded on the inside and is not visible. Replace torque converter if a leak exists. DO NOT attempt to repair torque converter.

Scheme 1

Scheme 2

TORQUE CONVERTER

DIFFERENTIAL BEARING ROTATING TORQUE

Note. Differential bearing rotating torque must be checked when any of the following components are replaced: transaxle case, differential bearings, inner and outer bearing adjusters with bearing races, differential bearing support or differential case. Differential bearing rotating torque should be performed only with NEW differential bearings. Inner and outer bearing adjusters and transfer shaft bearings must be replaced if differential bearings are replaced. DO NOT use this procedure with used differential bearings. Manufacturer does not list differential bearing rotating torque with used differential bearings. Differential bearing torque must be checked with transfer shaft removed from transaxle case.

1. Press oil seal from inner and outer bearing adjusters. Press NEW oil seals into inner and outer bearing adjusters. Install NEW "O" ring on inner and outer bearing adjusters. Lubricate threads on inner and outer bearing adjusters and lip of oil seals with gear oil.
2. Using Socket (6502-B), screw inner bearing adjuster into transaxle case. Inner bearing adjuster should be positioned so it is below the transaxle case surface when viewed from differential side of transaxle case.
3. Install differential assembly and differential cover. Install and tighten differential cover bolts to specification. See «TORQUE SPECIFICATIONS»(ref-25345-S39914706182001011700000).
4. Install Seal Protector (6591) on short stub shaft. Lubricate seal protector with gear oil. Install outer bearing adjuster. Screw outer bearing adjuster into differential cover until it is finger tight. Rotate differential back and forth in both directions several times to seat bearings.
5. Install foot-lb. torque wrench and Socket (6503) on outer bearing adjuster. (Scheme 3) Install Adapter (6548) into differential assembly.
6. Install 1/4" extension and INCH-lb. torque wrench on adapter. (Scheme 3) Using INCH-lb. torque wrench, rotate differential and note amount of torque required to rotate the differential assembly. This is the differential bearing rotating torque. Tighten outer bearing adjuster until differential bearing rotating torque is 19-23 INCH lbs. (2.1-2.6 N.m).
7. Record torque reading required on the outer bearing adjuster to obtain correct differential bearing rotating torque. This reading will be required during transaxle reassembly. Remove socket, adapter, differential cover and differential assembly from transaxle case.

Scheme 3

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

TRANSAXLE SPECIFICATIONS

TRANSAXLE SPECIFICATIONS