Chrysler Full-Size Vans 1989-1998 Repair Guide

Automatic Transmission Assembly

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REMOVAL & INSTALLATION



See Figure 1



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Fig. Fig. 1: The speedometer's electrical harness is connected to the driver's side of the transmission


WARNING
The transmission and torque converter must be removed as an assembly to avoid component damage. The converter drive plate, pump bushing, or oil seal can be damaged if the converter is left attached to the driveplate during removal. Be sure to remove the transmission and converter as an assembly.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle securely on jackstands.
  4.  
  5. Remove engine-to-transmission struts.
  6.  
  7. Remove starter motor and cooler line bracket.
  8.  


WARNING
The crankshaft position sensor can be damaged if the transmission is removed (or installed) with the sensor still bolted to the engine block. To avoid damage, remove the sensor before removing the transmission.

  1. Disconnect and remove the crankshaft position sensor. Retain the sensor attaching bolts.
  2.  
  3. Remove the torque converter access cover.
  4.  
  5. Remove the transmission oil pan and drain the fluid. Temporarily install the pan after the fluid has drained.
  6.  
  7. Remove transmission fluid fill tube. Discard fill tube O-ring it should not be reused.
  8.  
  9. Mark the torque converter and drive plate for assembly alignment. Use a scriber or paint for this purpose.
  10.  
  11. Rotate the crankshaft in a clockwise direction until the converter bolts are accessible. Then, remove the bolts one at a time. Rotate the crankshaft with a socket wrench on the damper bolt.
  12.  
  13. Matchmark propeller shaft and axle yokes for assembly alignment. Then, disconnect and remove the propeller shaft.
  14.  
  15. Disconnect wires from the park/neutral position switch, transmission solenoid, and vehicle speed sensor.
  16.  
  17. Disconnect gearshift cable from transmission shift lever.
  18.  
  19. Disconnect throttle valve cable from transmission throttle lever.
  20.  
  21. Disconnect overdrive connector wires from the plug on the driver's side of the transmission.
  22.  
  23. Remove transmission wire harnesses from clips on transmission. Also, disconnect the oxygen sensor wire if necessary.
  24.  
  25. Support the rear of the engine using jackstands.
  26.  
  27. Raise transmission slightly with floor jack to relieve load on supports.
  28.  
  29. Remove bolts securing transmission mount to crossmember and crossmember to frame and crossmember.
  30.  
  31. Remove engine oil filter.
  32.  
  33. Remove all converter housing bolts.
  34.  
  35. Disconnect fluid cooler lines at transmission.
  36.  


CAUTION
Do not dip the front of transmission downward during removal process, since the torque converter can fall out, causing damage or injury.

  1. Carefully work the transmission and torque converter assembly rearward off the engine block dowels and disengage the torque converter hub from the end of the crankshaft. If necessary, attach a small C-clamp to edge of bell housing to hold torque converter in place during transmission removal.
  2.  
  3. Lower transmission and remove assembly from under the vehicle.
  4.  

To install:
  1. Installation is the reverse of the removal procedure. However, please keep in mind these important steps.
  2.  

It is important that the correct length bolts be used to attach the converter to the driveplate. Bolts that are too long will damage the lockup surface within the converter. If new bolts are required, use the bolt specified by the manufacturer .

  1. Tighten the transmission bell housing-to-engine bolts as illustrated.
  2.  
  3. Verify the torque converter bolts length as follows:

    9.5 in. 3 lug converter-0.46 in. (11.7mm)
     
    9.5 in. 4 lug converter-0.52 in. (13.2mm)
     
    10.0 in. 4 lug converter-0.52 in. (13.2mm)
     
    10.75 in. 4 lug converter-0.44 in. (11.2mm)
     

  4.  
  5. Tighten the torque converter bolts to the following specification:

    9.5 in. 3 lug converter-40 ft. lbs. (54 Nm)
     
    9.5 in. 4 lug converter-55 ft. lbs. (74 Nm)
     
    10.0 in. 4 lug converter-55 ft. lbs. (74 Nm)
     
    10.75 in. 4 lug converter-23 ft. lbs. (31 Nm)
     

  6.  

ADJUSTMENTS



Throttle Linkage

To insure proper adjustment, it is suggested that new linkage grommets be installed. Do not attempt to adjust the linkage if any of the parts are excessively worn. If any rods are removed from the plastic grommets, new grommets should be installed. Pry only where the grommet and rod attach, not on the rod itself. Use pliers to snap the rod into the new grommet.

  1. Shift the transmission into PARK.
  2.  
  3. Raise and safely support the vehicle securely on jackstands.
  4.  
  5. Loosen the shift rod adjusting swivel lock screw. Make sure the swivel turns freely on the rod.
  6.  
  7. Make sure the valve body is in the PARK position by moving it all the way rearward.
  8.  
  9. Adjust the swivel position on the shift rod to obtain a free pin fit in the torque shaft lever. Tighten the lock screw.
  10.  
  11. If the vehicle starts in any gear other than PARK or NEUTRAL, or does not start in both P and N , either the adjustment is wrong or another problem exists.
  12.  

 
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