Chrysler Caravan/Voyager/Town n Country 1984-1995

Transaxle Assembly

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REMOVAL & INSTALLATION



If the vehicle is going to be rolled while the transaxle is out of the vehicle, obtain 2 outer CV-joints to install to the hubs. If the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will be destroyed.

  1. Disconnect the negative battery cable. If equipped with a 3.0L, 3.3L or 3.8L engine, drain the coolant.
  2.  
  3. Remove the dipstick.
  4.  
  5. Install an engine support fixture.
  6.  
  7. Remove the air cleaner assembly if it is preventing access to the upper bell housing bolts.
  8.  
  9. Remove the upper bell housing bolts and water tube, where applicable. Disengage all electrical connectors from the transaxle.
  10.  
  11. If equipped with a 2.2L or 2.5L engine, remove the starter attaching nut and bolt at the top of the bell housing.
  12.  
  13. Raise the vehicle and support safely. Remove the tire and wheel assemblies.
  14.  
  15. Remove the axle end cotter pins, nut locks, spring washers and axle nuts.
  16.  
  17. Remove the ball joint retaining bolts and pry the control arm from the steering knuckle.
  18.  
  19. Position a drain pan under the transaxle where the axles enter the differential or extension housing.
  20.  
  21. Remove the axles from the transaxle or center bearing.
  22.  
  23. Unbolt the center bearing and remove the intermediate axle from the transaxle, if equipped.
  24.  
  25. Drain the transaxle. Disconnect and plug the fluid cooler hoses.
  26.  
  27. Disconnect the shifter and kickdown linkage from the transaxle, if equipped.
  28.  
  29. Unfasten the speedometer cable adaptor bolt and remove the adaptor from the transaxle.
  30.  
  31. Remove the starter.
  32.  
  33. Remove the torque converter inspection cover, matchmark the torque converter to the flexplate and remove the torque converter bolts.
  34.  
  35. Using the proper equipment, support the weight of the engine.
  36.  
  37. Remove the front motor mount and bracket.
  38.  
  39. On vehicles equipped with DIS ignition system, remove the crankshaft position sensor from the bell housing.
  40.  
  41. Position a suitable jack under the transaxle.
  42.  
  43. Remove the lower bell housing bolts.
  44.  
  45. Remove the left side splash shield.
  46.  
  47. Remove the transaxle mount bolts.
  48.  
  49. Carefully pry the engine from the transaxle.
  50.  
  51. Slide the transaxle rearward until the locating dowels disengage from the mating holes in the transaxle.
  52.  

Attach a small C-clamp to the edge of the bell housing. This will hold the torque converter in place during transaxle removal.

  1. Pull the transaxle completely away from the engine and remove it from the vehicle.
  2.  
  3. To prepare the vehicle for rolling, support the engine with a suitable support or reinstall the front motor mount to the engine. Then reinstall the ball joints to the steering knuckle and install the retaining bolt. Install the obtained outer CV-joints to the hubs, install the washers and tighten the axle nuts to 180 ft. lbs. (244 Nm). The vehicle may now be safely rolled.
  4.  

To install:
  1. Install the transaxle securely on the jack. Rotate the converter so it will align with the positioning of the flexplate.
  2.  


WARNING
If equipped with a 41TE Transaxle, and the torque converter has been replaced, a Torque Clutch Break-in Procedure must be performed. This procedure will reset the transaxle control module break-in status. Failure to perform this procedure may cause transaxle shutter. To properly do this a DRB scan tool is required to read or reset the break-in status.

  1. Apply a coating of high temperature grease to the torque converter pilot hub.
  2.  
  3. Raise the transaxle into place and push it forward until the dowels engage and the bell housing is flush with the block.
  4.  
  5. Install the transaxle to bell housing bolts.
  6.  
  7. Raise the transaxle up (using the jack) and fasten the left side mount bolts. Install the torque converter bolts and tighten to 55 ft. lbs. (74 Nm).
  8.  
  9. Install the front motor mount and bracket. Remove the engine and transaxle support fixtures.
  10.  
  11. Install the starter to the transaxle. Fasten the bolt finger-tight if equipped with a 2.2L or 2.5L engine.
  12.  
  13. Install a new O-ring to the speedometer cable adaptor and engage it to the extension housing, make sure it snaps in place. Tighten the retaining bolt.
  14.  
  15. Connect the shifter and kickdown linkage to the transaxle, if equipped.
  16.  
  17. Install the axles and center bearing, if equipped.
  18.  
  19. Install the ball joints to the steering knuckles. Tighten the axle nuts to 180 ft. lbs. (244 Nm) and install new cotter pins.
  20.  
  21. Install the splash shield and the wheels.
  22.  
  23. Lower the vehicle and install the dipstick.
  24.  
  25. Install the upper bell housing bolts and water pipe, if removed.
  26.  
  27. If equipped with 2.2L or 2.5L engine, install the starter attaching nut and bolt at the top of the bell housing.
  28.  
  29. Raise the vehicle again and tighten the starter bolt from underneath the vehicle. Lower the vehicle.
  30.  
  31. Engage all electrical wiring disconnected from the transaxle.
  32.  
  33. Install the air cleaner assembly, if it was removed. Fill the transaxle with the proper amount of ATF+3.
  34.  
  35. Connect the negative battery cable and check the transaxle for proper operation. On the A-604 transaxle perform the upshift and kickdown learn procedure found earlier in this section.
  36.  

 
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