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Chrysler PT Cruiser. Manual - part 801

(2) Move selector lever to the (R) position.
(3) Read reverse clutch pressure with output sta-

tionary (foot on brake) and throttle opened to achieve
1500 rpm.

(4) Reverse and LR clutch pressure should read

165 to 235 psi.

(5) This test checks the reverse clutch hydraulic

circuit.

TEST RESULT INDICATIONS

(1) If proper line pressure is found in any one test,

the pump and pressure regulator are working prop-
erly.

(2) Low pressure in all positions indicates a defec-

tive pump, a clogged filter, or a stuck pressure regu-
lator valve.

(3) Clutch circuit leaks are indicated if pressures

do not fall within the specified pressure range.

(4) If the overdrive clutch pressure is greater than

5 psi in Step 4 of Test Three, a worn reaction shaft
seal ring or a defective solenoid assembly is indi-
cated.

(5) If the underdrive clutch pressure is greater

than 5 psi in Step 4 of Test Two A, a defective sole-
noid assembly or PCM/TCM is the cause.

PRESSURE CHECK SPECIFICATIONS

Gear Selector

Position

Actual Gear

Pressure Taps

Underdrive

Clutch

Overdrive

Clutch

Reverse

Clutch

Torque

Converter

Clutch

Off

2/4 Clutch

Low/

Reverse

Clutch

Park

PARK

0-2

0-5

0-2

60-110

0-2

115-145

0 mph

REVERSE

0-2

0-7

165-235

50-100

0-2

165-235

0 mph

NEUTRAL

0-2

0-5

0-2

60-110

0-2

115-145

0 mph

FIRST

110-145

0-5

0-2

60-110

0-2

115-145

20 mph

SECOND

110-145

0-5

0-2

60-110

115-145

0-2

30 mph

DIRECT

75-95

0-2

60-90

0-2

45 mph

OVERDRIVE

0-2

75-95

0-2

60-90

75-95

0-2

30 mph

OVERDRIVE

WITH TCC

0-2

75-95

0-2

0-5

75-95

0-2

50 mph

* Engine speed at 1500 rpm

# CAUTION: Both front wheels must be turning at the same speed.

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40TE AUTOMATIC TRANSAXLE (Continued)

DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS

Inoperative clutches can be located using a series

of tests by substituting air pressure for fluid pressure
(Fig. 5) (Fig. 6). The clutches may be tested by apply-
ing air pressure to their respective passages. The
valve body must be removed and Tool 6056 installed.
To make air pressure tests, proceed as follows:

NOTE: The compressed air supply must be free of
all dirt and moisture. Use a pressure of 30 psi.

Remove oil pan and valve body. See Valve body

removal.

OVERDRIVE CLUTCH

Apply air pressure to the overdrive clutch apply

passage and watch for the push/pull piston to move
forward. The piston should return to its starting
position when the air pressure is removed.

REVERSE CLUTCH

Apply air pressure to the reverse clutch apply pas-

sage and watch for the push/pull piston to move rear-
ward. The piston should return to its starting
position when the air pressure is removed.

2/4 CLUTCH

Apply air pressure to the feed hole located on the

2/4 clutch retainer. Look in the area where the 2/4

piston contacts the first separator plate and watch
carefully for the 2/4 piston to move rearward. The
piston should return to its original position after the
air pressure is removed.

LOW/REVERSE CLUTCH

Apply air pressure to the low/reverse clutch feed

hole (rear of case, between 2 bolt holes). Then, look
in the area where the low/reverse piston contacts the
first separator plate. Watch carefully for the piston to
move forward. The piston should return to its origi-
nal position after the air pressure is removed.

UNDERDRIVE CLUTCH

Because this clutch piston cannot be seen, its oper-

ation is checked by function. Air pressure is applied
to the low/reverse and the 2/4 clutches. This locks the
output shaft. Use a piece of rubber hose wrapped
around the input shaft and a pair of clamp-on pliers
to turn the input shaft. Next apply air pressure to
the underdrive clutch. The input shaft should not
rotate with hand torque. Release the air pressure
and confirm that the input shaft will rotate.

Fig. 5 Air Pressure Test Plate

1 - TOOL 6056
2 - ACCUMULATORS

Fig. 6 Testing Reverse Clutch

1 - TOOL 6056
2 - AIR NOZZLE

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40TE AUTOMATIC TRANSAXLE (Continued)

DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE

When diagnosing converter housing fluid leaks,

three actions must be taken before repair:

(1) Verify proper transmission fluid level.
(2) Verify that the leak originates from the con-

verter housing area and is transmission fluid.

(3) Determine the true source of the leak.
Fluid leakage at or around the torque converter

area may originate from an engine oil leak (Fig. 7).
The area should be examined closely. Factory fill
fluid is red and, therefore, can be distinguished from
engine oil.

Some suspected converter housing fluid leaks may

not be leaks at all. They may only be the result of
residual fluid in the converter housing, or excess
fluid spilled during factory fill, or fill after repair.
Converter

housing

leaks

have

several

potential

sources. Through careful observation, a leak source
can be identified before removing the transmission
for repair.

Pump seal leaks tend to move along the drive hub

and onto the rear of the converter (Fig. 7). Pump
o-ring or pump body leaks follow the same path as a
seal leak. Pump attaching bolt leaks are generally
deposited on the inside of the converter housing and
not on the converter itself. Pump seal or gasket leaks
usually travel down the inside of the converter hous-
ing (Fig. 7).

TORQUE CONVERTER LEAKAGE

Possible sources of torque converter leakage are:
• Torque converter weld leaks at the outside diam-

eter weld (Fig. 8).

• Torque converter hub weld (Fig. 8).

REMOVAL

(1) Disconnect battery cables.
(2) Remove air cleaner assembly (Fig. 9).

(3) Remove battery (Fig. 10).
(4) Remove battery tray (Fig. 11).

Fig. 7 Converter Housing Leak Paths

1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK

Fig. 8 Converter Leak Points - Typical

1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG

Fig. 9 Air Cleaner Assembly Removal/Installation

1 - AIR CLEANER ASSEMBLY

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40TE AUTOMATIC TRANSAXLE (Continued)

(5) Remove uppermost starter-to-transaxle bell-

housing bolt and remove transaxle dipstick & tube.
Plug hole to prevent debris from entering transaxle.

(6) Disconnect gearshift cable from manual valve

lever. Remove gearshift cable from trans mount
bracket and position cable out of the way.

(7) Using Tool 8875A, disconnect transaxle oil

cooler lines. (Refer to 7 - COOLING/TRANSMISSION
- STANDARD PROCEDURE)

(8) Disconnect input speed sensor connector (Fig.

12).

(9) Disconnect output speed sensor connector (Fig.

12).

(10) Disconnect transmission range sensor connec-

tor (Fig. 12).

(11) Disconnect solenoid/pressure switch assembly

connector (Fig. 12).

(12) Raise vehicle on hoist.
(13) Remove front wheel covers (if equipped) and

front wheel/tire assemblies.

(14) Remove left splash shield.
(15) Remove left and right halfshaft assemblies.

Refer to DIFFERENTIAL AND DRIVELINE for
proper procedures.

Fig. 10 Battery Removal/Installation

1 - BATTERY

Fig. 11 Battery Tray Removal/Installation

1 - BATTERY TRAY

Fig. 12 Component Connector Location

1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR

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40TE AUTOMATIC TRANSAXLE (Continued)

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