Servicing - A/t: Other Dodge Intrepid I

Transaxle

1. With vehicle on level ground, apply parking brake and run engine at curb idle for at least one minute. Move gear selector through all positions, ending in Park.
2. Fluid level should be in crosshatch area of dipstick marked WARM or HOT, depending on fluid temperature. Check condition of fluid for contamination and burned smell. DO NOT overfill. Fully seat dipstick.

Differential (42LE)

Remove fill plug on side of differential cover. Fluid level should be at bottom of fill hole. Add fluid as necessary.

Except Model 42LE

Manufacturer recommends MOPAR ATF Type 7176 when overhaul or fluid change is performed. MOPAR ATF Type 7176 exhibits better anti-foaming qualities than other fluids. Differential portion of transaxle shares fluid reservoir with transmission and is not checked separately. Manufacturer does not recommend using any additives to transmission or differential.

Model 42LE

Manufacturer recommends MOPAR ATF Type 7176 in transmission portion of transaxle assembly. Use 80W-90 gear lubricant in differential.

Models 30TH, 31TH, 41TE & 42LE

1. Raise and support vehicle. Remove oil pan bolts to gradually lower and drain pan at one corner. Remove oil filter screws, and remove filter. Adjustment of rear band can now be made (if required).
2. Install NEW filter and filter gasket or "O" ring (if equipped) on bottom of valve body, and tighten screws to 44 INCH lbs. (5 N.m). Clean pan with solvent, and blow dry using compressed air.
3. Use 3/16" bead of RTV sealant to form pan gasket. Install oil pan. Tighten pan bolts to specification. See «OIL PAN TORQUE SPECIFICATIONS»(ref-48412-S33847220572001011700000) .
4. Lower vehicle, add 4 qts. (3.8L) of ATF and start engine. Allow to idle for at least 2 minutes.
5. With engine at curb idle and parking brake applied, move gear selector lever through all positions, ending in "P" position. Add enough fluid to bring level to 1/8" below ADD mark.
6. Recheck fluid level after transaxle has reached normal operating temperature. Add required amount of fluid. DO NOT overfill. Ensure dipstick is fully seated.

Models F4A22, F4A33 & W4A33

1. Raise and support vehicle. Remove drain plug, and drain fluid. Remove pan, and check filter for clogging and damage. Replace if necessary.
2. Clean inside of pan and 5 magnets. Reinstall magnets in concave part of pan. Clean both gasket surfaces. Install NEW gasket or 3/16" bead of RTV sealant to form gasket. Install pan. Tighten pan bolts to specification. See «OIL PAN TORQUE SPECIFICATIONS»(ref-48412-S33847220572001011700000) . Replace drain plug gasket, and reinstall plug. Fill transaxle with ATF. Recheck fluid level after transaxle has reached normal operating temperature.

OIL PAN TORQUE SPECIFICATIONS

KICKDOWN BAND (FRONT)

Note. Models 41TE and 42LE transaxles do not have any bands. Kickdown band adjustment screw for models 30TH and 31TH is located on left side (top front) of transaxle case.

Models 30TH & 31TH

1. Loosen adjustment screw lock nut (while preventing adjustment screw from turning). Back off 5 turns after ensuring adjustment screw turns freely in case.
2. Tighten adjustment screw to 71 INCH lbs. (8 N.m), and then back off adjustment screw 2 1/2 turns. Hold adjustment screw in this position, and tighten lock nut to 35 ft. lbs. (47 N.m).

1. Raise and support vehicle. Remove servo switch snap ring. Remove servo switch. Attach Restrainer (MD998918) to servo piston and secure to transaxle case with bolts. Tighten bolts only finger tight. Loosen servo piston lock nut.
2. Attach Adjuster (MD998916) outer cylinder to lock nut and inner cylinder to servo adjusting rod. Rotate outer cylinder counterclockwise to ensure adjuster rod is clear. Remove outer cylinder.
3. Rotate inner cylinder clockwise. Using a torque wrench, tighten rod to 89 INCH lbs. (10 N.m). Repeat tightening procedure. Back off adjuster rod. Tighten adjuster rod to 44 INCH lbs. (5 N.m). Back off adjuster rod 2-2 1/2 turns. Engage outer cylinder in lock nut. Taking care not to rotate adjuster rod, tighten lock nut to 18-23 ft. lbs. (24-31 N.m). Install servo switch and snap ring

LOW-REVERSE BAND (REAR)

Note. Low-reverse band adjustment screws are located on rear servo lever. Band adjustment screw is not accessible unless oil pan is removed.

1. Drain transaxle, and remove oil pan. Loosen band adjustment screw lock nut (while preventing adjustment screw from turning), and back off nut 5 turns. Ensure adjustment screw turns freely in case.
2. Tighten adjustment screw to 44 INCH lbs. (5 N.m). Back off adjustment screw 3 1/2 turns. Hold in this position, and tighten lock nut to 10 ft. lbs. (14 N.m).
3. Clean oil pan, and remove all gasket material from pan and case. Install oil pan using NEW pan gasket or 3/16" bead of RTV sealant to form gasket. Add required amount of fluid to fill transaxle. Road test vehicle.

Scheme 62

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 106 INCH lbs. (12 N.m). (Scheme 62)
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.
4. Move transaxle throttle lever counterclockwise. Slowly release it to ensure it will return to full clockwise position.

Model 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 97 INCH lbs. (11 N.m). Ensure linkage backlash is removed by preload spring.

SHIFT LINKAGE

Models 30TH, 31TH & 41TE

1. Place gear selector in "P" position. Loosen lock bolt on cable adjusting bracket on transaxle. (Scheme 63) On column shift models, ensure preload adjustment spring engages fork on transaxle bracket.
2. On all models, pull shift lever by hand fully to front detent position (Park). Tighten lock screw to 97 INCH lbs. (11 N.m).
3. To check adjustment, gearshift lever should be within limits of hand lever gate stops when shifted through gear positions. Vehicle must start only in Park or Neutral.

Scheme 63

Model 42LE (Column Shift)

1. Remove upper steering column shroud. Tilt steering column to full up position. Rotate cable adjuster to unlock position. Ensure transaxle shift lever is in Park (rearmost) position.
2. Place column shift lever in Park position. Remove ignition key. Adjust by rotating adjuster into lock position. Install steering column shroud. Check shifter for smooth operation. Vehicle must start only in Park or Neutral.

Model 42LE (Floor Shift)

Remove shifter handle and console bezel. Loosen nut on shifter cable adjuster. Place column shift lever in Park position. Remove ignition key. Ensure transaxle shift lever is in Park (rearmost) position. Tighten adjuster lock nut. Install shifter handle and console bezel. Check shifter for smooth operation. Vehicle must start only in Park or Neutral.

SHIFT INTERLOCK CABLE

See appropriate STEERING COLUMNS article in STEERING.

NEUTRAL SAFETY SWITCH

Note. On 42LE model transaxle, neutral safety switch and back-up light switch functions are controlled by Manual Valve Lever Position Switch (MVLPS).

Except Laser & Talon

Combination neutral safety and back-up light switch is screwed into side of transmission case. Switch is not adjustable. Switch may be tested for continuity. See TESTING .

Laser & Talon

Place selector lever in Neutral. Place manual control lever in Neutral. To adjust, rotate switch body so manual control lever .20" (5 mm) hole and switch body .20" (5 mm) hole are aligned.