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TSB 21-018-05

Superseded by TSB 21-008-06. Left for information only.

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Date: October 4, 2005  Automatic Transmission Diagnostic Teardown Procedure

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-009-03, DATED
AUGUST 29, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS
INCLUDE ADDITIONAL BODIES, MODEL YEARS, NEW REPAIR PROCEDURE, LABOR
TIMES AND SPECIAL TOOLS.  

Models: 1995 - 2002 (BR/BE) Ram Truck, 2002 - 2006 (DR/DH) Ram Truck

1995             (AA) Spirit/Acclaim/LeBaron Sedan
1995 - 2003 (AB) Ram Van/Wagon
1997 - 2004 (AN) Dakota
2005 - 2006 (ND) Dakota
1995            (AJ) LeBaron Coupe/LeBaron Convertible
1995 - 2002 (BR/BE) Ram Truck
2004 - 2006 (CS) Pacifica
1998 - 2003 (DN) Durango
2002 - 2006 (DR/DH) Ram Truck
1995 - 2000 (FJ) Sebring/Avenger/Talon
2004 - 2006 (HB) Durango
1995 - 2000 (JA) Cirrus/Stratus/Breeze
2001- 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan
1996 - 2000 (JX) Sebring Convertible
2002 - 2006 (KJ) Liberty
2002 - 2005 (KJ) Cherokee (International Markets)
1995 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M
2005 - 2006 (LX/LE) 300/Magnum/Charger
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
1995 - 2005 (PL) Neon
2001 - 2006 (PT) PT Cruiser
2002            (PG) PT Cruiser (International Markets)
1997 - 2002 (PR) Prowler
2001 - 2006 (RS) Town & Country/Caravan/Voyager
2001 - 2006 (RG) Chrysler Voyager (International Markets)
1997 - 2006 (TJ) Wrangler
1999 - 2004 (WJ) Grand Cherokee
1999 - 2004 (WG) Grand Cherokee (International Markets)
2005 - 2006 (WK) Grand Cherokee
2005 - 2006 (WH) Grand Cherokee (International Markets)
2006             (XK/XH) Commander
1995             (YJ) Wrangler
1996 - 1998 (ZG) Grand Cherokee (International Markets)
1996 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer

Overview:
This bulletin provides a procedure to determine repair versus replacement of an automatic
transmission assembly. Follow the proper repair procedure based on the transmission type.
This procedure is to be used after the transmission has been removed from the vehicle.

Every replaced transmission assembly returned to DaimlerChrysler must include a
properly completed Diagnostic CheckSheet. This sheet must be attached to the
transmission bellhousing. Refer to Warranty Bulletin D-05-20 for additional information.

Symptom/Condition:
Rear power door locks may not unlock the rear doors when activated with the door lock switch or Remote Keyless Entry. The locks will function normally when operated manually.

Diagnosis:
Operate the power door locks. Iif the rear door lock(s) is lnoperatve, perform the Repair Procedure.

Parts Required:
Qty. Part No. Description
AR 04883971 RTV Sealer

Special Tools/Equipment Required:

C-3339A Set, Dial Indicator
C-3752-A Puller Set
6227 Spring Compressor/Alignment
8257 Support Stand
8261 Plate, Alignment
8266A Fixtures, End Play
8266-12 Adapter, Geartrain End Play
9082 Remover, Bearing

Repair Procedure: 
40TE, 41TE/AE and 42LE/RLE Transmissions
1.     

Remove fluid using approved Team PSE Automatic Transmission Fluid X-changer or equivalent.

2. Remove torque converter (keep with unit).
3.

Measure input shaft end play.

4. Remove input speed sensor.
5. Remove pump assembly.
6. Remove input clutch assembly.
7. Remove front sun gear assembly.
8. Remove front carrier/rear annulus assembly.
9. If transmission is determined to be greater than 70% failed follow steps 10 through 13. If
transmission is determined to be less than 70% failed, refer to the service information
available in TechCONNECT or the appropriate service manual in Section 21 for detailed
repair instructions.
10. Drop #2 thrust bearing into transmission pan.
11. Reassemble transmission by reversing steps 4 through 8.
12. If the transmission is a 40TE, 41TE/AE continue to the next step. If the transmission is a
42LE/RLE, reinstalled old torque converter into the old transmission, and retained using
the shipping strap from the new transmission.
13. Place old torque converter in box new converter was shipped in, and place this box with
transmission in return container.
14. Return any loose items by attaching to bellhousing in plastic bag.
NOTE: All parts must be returned with transmission.
 
30RH, 30TH, 31TH, 32RH, 36RH, 42RE/RH, 44RE/RH, 46RE/RH, 47RE and 48RE Transmissions
Starts with number 15.
15.   

Remove fluid using approved Team PSE Automatic Transmission Fluid X-changer or equivalent.

16. Remove torque converter (keep with unit).
17.

Measure input shaft end play.

18. Remove pump assembly.
19. Loosen front band adjustment screw until link can be removed (keep link with unit).
20. Rotate front band and remove (keep with unit).
21. Remove front clutch retainer and rear clutch retainer assembly.
22. Remove intermediate shaft snap ring (keep with unit).
23. Remove front and rear planetary assemblies and drive shell (keep with unit).
24. Remove low/reverse drum snap rings.
25. Remove low/reverse drum.
26. Remove overdrive unit.
27. Remove overdrive clutch snap ring.
28. Remove overdrive clutch disc and plates.
29. Remove overdrive wave spring.
30. Remove overdrive snap ring.
31. Remove access cover and gasket.
32. Expand output shaft bearing snap-ring with expanding type snap ring pliers. Then push
output shaft forward to release shaft bearing from locating ring.
33. Remove geartrain assembly.
34. If transmission is determined to be greater than 70% failed follow steps 21 through 24. If
transmission is determined to be less than 70% failed, refer to the service information
available in TechCONNECT or the appropriate service manual in Section 21 for detailed
repair instructions.
35. Drop band adjustment link in pan.
36. Reassemble transmission by reversing steps 4 through 19.
37. Place torque converter in box new converter was shipped in, and place this box with
transmission in return container.
38. Return any loose items by attaching to bellhousing in plastic bag.
NOTE: All parts must be returned with transmission.
 
45RFE/545RFE Transmissions
Starts with number 39
39.   

Remove fluid using approved Team PSE Automatic Transmission Fluid X-changer or equivalent.

40. Remove torque converter (keep with unit).
41.

Remove the transmission oil pan from the transmission case.

42. Remove the primary oil filter and the oil cooler return filter.
43. Remove the cooler return filter bypass valve.
44. Remove the valve body from the transmission case.
45. Install Support Stand 8257 onto the transmission case.
46. Measure input shaft end play.
47. Remove input speed sensor.
48. Remove extension/adapter housing from the transmission case.
49. Remove front pump cover.
50. Remove front pump assembly.
51. Remove input clutch assembly.
52. Remove the 4C clutch retainer/bulkhead tapered snap-ring from the transmission case.
53. Remove the 4C clutch retainer/bulkhead from the transmission case.
54. Remove the front 2C clutch pack snap-ring from the transmission case.
55. Remove the 2C clutch pack from the transmission case.
56. Remove the reaction annulus from the reaction planetary carrier.
57. Remove the snap-ring holding the park sprag gear onto the output shaft.
58. Remove the input/reverse planetary assembly.
59. Remove the snap-ring holding the low/reverse clutch retainer into the transmission case.
60. Remove the low/reverse clutch retainer from the transmission case.
61. If transmission is determined to be greater than 70% failed follow steps 24 through 26. If
transmission is determined to be less than 70% failed, refer to the service information
available in TechCONNECT or the appropriate service manual in Section 21 for detailed
repair instructions. Be sure to check input shaft end play during reassembly and (if low)
disassemble the input clutch assembly to check for thrust bearings which may have
fallen out of position.
62. Reassemble transmission by reversing steps 3 through 22.
62. Place torque converter in box new converter was shipped in, and place this box with
transmission in return container.
63. Return any loose items by attaching to bellhousing in plastic bag.
NOTE: All parts must be returned with transmission.
 
NAG1 Transmissions
Starts with number 39
65.   

Remove fluid using approved Team PSE Automatic Transmission Fluid X-changer or
equivalent.

66. Remove torque converter (keep with unit).
67.

Measure input shaft end play.

68. Place Transmission in vertical position with bell housing down.
69. Loosen electrical connector guide bushing and remove from transmission housing.
70. Remove transmission oil pan.
71. Remove oil filter.
72. Unscrew Torx socket bolts and remove electrohydraulic unit.
73. Place the transmission in PARK to prepare for the removal of the output shaft nut.
74. Remove the nut holding the propeller shaft flange to the output shaft and remove the
flange.
75. Remove the transmission rear oil seal with a suitable slide hammer and screw.
76. Remove the transmission output shaft washer. Be sure to tag the washer since it is very
similar to the geartrain end-play shim and they must not be interchanged.
77. Remove the transmission rear output shaft bearing retaining ring.
78. Position Bearing Remover tool 9082 over the inner race of the output shaft bearing.
79. Slide the collar on Bearing Remover tool 9082 downward over the fingers of the too and
remove the output shaft bearing.
80. Remove the geartrain end-play shim from the output shaft. Be sure to tag the shim since
it is very similar to the output shaft washer and they must not be interchanged.
81. Remove the bolts holding the transmission housing to the converter housing from inside
the converter housing.
82. Stand the transmission upright on the converter housing. Be sure to use suitable
spacers between the bench surface and the converter housing since the input shaft may
protrude past the front surface of the housing.
83. Remove the remaining bolts holding the transmission housing to the converter housing.
84. Remove the transmission housing from the converter housing.
85. Remove output shaft with center and rear gear set and clutch K3.
86. Remove thrust needle bearing and thrust washer.
87. Remove input shaft with clutch K2 and front gear set.
88. Remove clutch K1.
89. Unscrew Torx socket bolts and remove oil pump. Screw two opposed bolts into the oil
pump housing and press the oil pump out of the converter housing by applying light
blows with a plastic hammer.
90. If transmission is determined to be greater than 70% failed follow steps 27 through 30. If
transmission is determined to be less than 70% failed, refer to the service information
available in TechCONNECT or the appropriate service manual in Section 21 for detailed
repair instructions.
91. Place rear seal and thrust washer in transmission pan.
92. Reassemble transmission by reversing steps 3 through 25.
93. Install torque converter and hold in place with torque converter retaining bracket from
replacement transmission.
94. Return any loose items by attaching to bellhousing in plastic bag.

Policy:    Reimbursable within the provisions of the warranty.

NOTE: These labor operation numbers are only to be used when repair exceeds 70%
of the cost of transmission assembly replacement.

NOTE: Returned transmissions received missing components are subject to warranty
part return chargebacks. See Global Warranty Administration Manual pages
P19 and P20.

NOTE: Warranty repairs claiming one of the following Labor Operation Numbers must
include a completed diagnostic sheet. Refer to Warranty Bulletin D-05-20 for
additional information. If the diagnostic sheet is not returned with the
transmission assembly, the diagnostic tear down time allowance will be
charged back.

NOTE: The use of a Diagnostic time allowance and/or (00( time in place of one of the
below Labor Operation Numbers does not eliminate the requirement to return a
properly completed Diagnostic Sheet. See Warranty Bulletin D-05-20 for
additional information.

Time Allowance:

Labor Operation No:   Description Models  Amount
21-00-21-94 40TE Transaxle
41TE/AE Transaxle
AA
AJ
CS
FJ
JA
JX
JR
NS
GS
PL
PG
PT
RS
RG
0.8 Hrs.
21-00-21-95 42LE Transmission LH 0.8 Hrs
21-00-21-96 30TH Transmission
31TH Transmission
AA
AJ
NS
GS
RS
RG
PL
PT
0.8 Hrs
21-00-27-91 30RH Transmission
32RH Transmission
36RH Transmission
42LE/RLE Transmission
AB
KJ
PR
HB
TJ
YJ
ND
LX/LE
0.8 Hrs
21-00-27-92 42RE/RH Transmission
44RE/RH Transmission
46RE/RH Transmission
47RE Transmission
48RE Transmission

AB
AN
BE
BR
DN
DR
ZJ
ZG
WJ
WG

1.1 Hrs.
21-00-27-93 45RFE Transmission
545RFE Transmission
AN
DN
DR/DH
HB
KJ
WG
WJ
WK
WH
ND
1.2 Hrs.
21-00-27-94 NAG 1 Transmission WG
WK/WH
XK/XH
LX/LE
1.2 Hrs.

Failure Code:

ZZ       Service Action

I would like to thank Bob Bergevin, Arthur Cantrall, Barry Drodge, David Lovell, Bill Maurits, and Steve for supplying the information for these bulletins. And a big thank you goes to Geno's Garage for making DodgeRam.info possible.

 

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This page was edited on: May 3, 2004