Chrysler Full-Size Vans 1989-1998 Repair Guide

Manual Transmission

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The manual transmission oil should be replaced at 37,500 miles (60,000 km) intervals.

FLUID RECOMMENDATIONS



The use of 10W-30 weight engine oil meeting API service specification SH is recommended for use in all manual transmissions.

ATF+3II or equivalent automatic transmission fluid can be used as a substitute for the transmission's engine oil if high shift effort is experienced during warm-up in cold weather.

LEVEL CHECK



See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: NP-2500 transmission's fill and drain plug locations



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Fig. Fig. 2: AX-15 transmission's fill and drain plug locations

  1. Park the vehicle on a level surface, turn the engine OFF , firmly apply the parking brake and block the drive wheels.
  2.  

Ground clearance may make access to the transmission filler plug impossible without raising and supporting the vehicle. If the vehicle must be raised, it must be supported at four corners and level. If only the front or rear is supported, an improper fluid level will be indicated.

  1. Remove the filler plug from the side of the transmission. The fluid level should be even with the bottom of the filler hole.
  2.  
  3. If additional fluid is necessary, add it through the filler hole using a siphon pump or squeeze bottle.
  4.  
  5. Carefully install the filler plug and tighten to 27 ft. lbs. (37 Nm).
  6.  

DO NOT overtighten the filler plug, as this can damage the transmission.

  1. Lower the vehicle.
  2.  

DRAIN & REFILL



It is a good idea to warm the oil first so it will flow better. This can be accomplished by 15-20 miles (24-32 km) of highway driving. Oil which is warmed to normal operating temperature will flow faster, drain more completely and remove more contaminants from the transmission.


CAUTION
The EPA warns that prolonged contact with used gear oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used gear oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used gear oil. Soap and water, or waterless hand cleaner, should be used.

  1. Raise and support the vehicle safely. Remember that the vehicle must be supported level (at four points) so the proper oil level can be determined.
  2.  
  3. Before you crawl under the vehicle, take a look at where you will be working and gather all the necessary tools, such as a few wrenches or a strip of sockets, the drain pan and some clean rags.
  4.  
  5. Position the drain pan beneath the transmission drain plug. Keep in mind that the fast flowing oil, which will spill out as you pull the plug from the transmission, will flow with enough force that it could miss the pan. Position the drain pan accordingly and be ready to move the pan more directly beneath the plug as the oil flow lessens to a trickle.
  6.  
  7. Loosen the filler plug with a wrench (or socket and driver), then carefully unscrew the plug with your fingers. This step is performed first to ensure the transmission can be filled with fresh oil after the used oil is drained.
  8.  
  9. Loosen the drain plug with a wrench (or socket and driver), then carefully unscrew the plug with your fingers. Use a rag to shield your fingers from the heat. Push in on the plug as you unscrew it so you can feel when all of the screw threads are out of the hole, (and so you will keep the oil from seeping past the threads until you are ready to remove the plug). You can then remove the plug quickly to avoid having hot oil run down your arm. This will also help assure that you have the plug in your hand, not in the bottom of a pan of hot oil.
  10.  


CAUTION
Be careful of the oil; when at operating temperature, it is hot enough to cause a severe burn.

  1. Allow the oil to drain until nothing but a few drops come out of the drain hole. Check the drain plug to make sure the threads and sealing surface are not damaged. Carefully thread the plug into position and tighten it with a torque wrench to 27 ft. lbs. (37 Nm). If a torque wrench is not available, snug the drain plug and give it a slight additional turn. You don't want the plug to fall out (as you would quickly become stranded), but the threads are easily stripped from overtightening (and this can be time consuming and/or costly to fix).
  2.  


WARNING
Never operate the transmission without oil, otherwise severe damage will result.

  1. Refill the transmission slowly, checking the level often with your finger, as illustrated. Due to the positioning of the filler hole, it is very difficult to see the level of oil in the transmission. This makes overfilling and spilling the gear oil a good possibility. When the gear oil level reaches the bottom of the filler hole, the gear oil is at the proper level.
  2.  
  3. Check the filler plug to make sure the threads and sealing surface are not damaged. Carefully thread the plug into position and tighten it with a torque wrench to 27 ft. lbs. (37 Nm).
  4.  
  5. Remove the jackstands and carefully lower the vehicle.
  6.  
  7. Empty your used oil into a suitable container for recycling.
  8.  

 
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