Servicing - A/t Dodge Shadow I

IDENTIFICATION

AUTOMATIC TRANSAXLE APPLICATIONS

LUBRICATION - SERVICE INTERVALS

Check fluid level whenever performing other underhood services. Draining, refilling and band adjustments are not required under normal driving conditions. Under heavy duty (severe service) conditions, change fluid, replace filter, and adjust bands (if applicable) every 15,000 miles. On ZF 4HP-18 units, the transaxle fluid and filter screen should be changed every 30,000 miles but, while the differential must be checked, the fluid need not be replaced.

ALL EXCEPT ZF 4HP-18

1. With vehicle on level ground, apply parking brake and run engine at curb idle for at least 60 seconds. 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 or burned smell. Do not overfill. Fully seat dipstick.

ZF 4HP-18

1. Place vehicle on level surface. Start and run engine at idle speed. Move gear selector through all positions ending in Park.
2. If transaxle is cold, fluid level should be at FULL COLD mark on dipstick. If transaxle is at normal operating temperature, fluid level should be at FULL HOT mark on other side of dipstick. About 1/4 quart is needed to increase level from ADD to FULL mark.

Differential

With vehicle on level surface, fluid level should be at the bottom of fill plug hole. (Scheme 59)

Scheme 59

RECOMMENDED FLUID

Use only Dexron II ATF or Mopar 7176 ATF Plus on all except ZF 4HP-18. On ZF 4HP-18 use only Mopar Mercon type fluid in the transaxle and SAE 75W-140 synthetic gear oil (Part No. 89982 200 945) in the differential. Chrysler Motors does not recommend the use of any additives to transmission or differential.

Note. In the ZF 4HP-18 unit, the transaxle and differential are separate and require different lubricants.

FLUID CAPACITY

Note. Transmission and converter assembly capacities given below are approximate. Correct fluid level should be determined by mark on dipstick.

TRANSMISSION REFILL CAPACITIES

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 be made at this time (if required).
2. Install new filter and filter gasket or "O" ring (if equipped) on bottom of valve body and tighten screws to 40 INCH lbs. (5 N.m). Clean pan with solvent and blow dry with compressed air.
3. Install pan using new RTV sealant to form gasket. Tighten pan bolts to specification.
4. Lower vehicle, add 4 qts. (3.8L) of ATV 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 the "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.

1. Raise and support the vehicle. Remove the splash shield. Loosen nut attaching filler tube to transmission oil pan. Slide filler tube out and allow fluid to drain.
2. Remove oil pan and discard gasket. Remove 10 filter screen cover bolts and remove cover. Remove oil filter screen (noting position of each bolt for installation purposes) and remove screen gasket.
3. Clean oil pan and magnet. Replace all parts using new gaskets and oil filter screen "O" ring. Ensure oil filter screen bolts are installed in correct position and tightened to correct torque. (Scheme 60)Fill transaxle with ATF.

Note. ZF 4HP-18 oil filter screen bolts are different lengths and must be replaced in their original positions.

OIL PAN TORQUE SPECIFICATIONS

Scheme 60

ADJUSTMENTS - KICKDOWN BAND (FRONT)

Note. The A-604 transaxle does not have any bands. Kickdown band adjustment screw for A-413 is located on left side (top front) of transaxle case.

1. Loosen adjustment screw lock nut (while preventing adjustment screw from turning). Back off 5 turns after making sure adjustment screw turns freely in case.
2. Tighten adjustment screw to 72 INCH lbs. (8 N.m), 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).

ADJUSTMENTS - 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 41 INCH lbs. (5 N.m).
3. On all models, back off adjustment screw the specified number of turns given in «LOW-REVERSE BAND ADJUSTMENT»(/dodge/shadow/i-1986-1994/remont/automatic-trans/#servicing-at) . Hold in this position and tighten lock nut to 10 ft. lbs. (14 N.m).
4. Clean oil pan and remove all gasket material from pan and case. Install oil pan using new pan gasket (or new RTV sealant) and add the required amount of fluid to fill transaxle. Road test vehicle.

LOW-REVERSE BAND ADJUSTMENT

Note. The ZF 4HP-18 is non-serviceable. If clutches and/or brakes are damaged or worn, the transmission must be replaced.

Scheme 61

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). (Scheme 61)
2. Release cross-lock on cable assembly by pulling upward. To ensure correct adjustment, 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.

SHIFT LINKAGE

Scheme 62

1. Place gear selector in the "P" position. Loosen lock bolt on cable adjusting bracket on transaxle. (Scheme 62) On column shift models, ensure preload adjustment spring engages fork on transaxle bracket.
2. On all models, pull shift lever by hand all the way to front detent position (Park). Tighten lock screw to 100 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 only start in Park or Neutral.

NEUTRAL SAFETY SWITCH

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

TESTING

1. Center terminal of 3 terminal neutral safety and back-up light switch provides ground for starter solenoid circuit through shift lever in Park or Neutral positions only.
2. To test, remove wiring connector from switch and check for continuity between center pin of switch and case. Continuity should exist only when transmission is in Park or Neutral. NOTE: Check shift linkage adjustment before replacing a switch that tests bad.
3. The back-up light switch circuit is through the 2 outside terminals of the switch. Continuity should exist between the 2 terminals only when transmission is in reverse. No continuity should exist from either terminal to case.
4. To replace, unscrew switch from case (some fluid will escape). Move gear selector lever to Park, and then to Neutral position. Check to see that switch operating fingers are centered in switch opening in case.
5. Install switch with new seal into case and tighten. Check transmission fluid level.

Scheme 63

Scheme 64

1. Loosen cable lock nuts and lift threaded shank out of engine bracket. (Scheme 63) Ensure throttle valve lever is in the idle position.
2. Pull cable wire forward. Place a fabricated 1.55" (39.5 mm) gauge block between cable connector and cable end. Vernier calipers can be used to measure cable distance. (Scheme 64)
3. Pull cable shank rearward to detent position, but NOT to wide open throttle position. Detent position will have a definite feel, similar to stop, when reached.
4. Hold shank at detent position and place it in engine bracket. Tighten lock nuts to lock shank in position. Remove gauge block. Detent position should be reached when cable travel is 1.52-1.59" (38.5-40.5 mm).

Scheme 65

Scheme 66

Scheme 67

See also:
• LOW-REVERSE BAND ADJUSTMENT