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Dodge Sprinter. Manual - part 268

CONDITION

POSSIBLE CAUSES

CORRECTION

NO UPSHIFT OF 1ST

GEAR AT TIMES

1. Connector Ballast Unit. Output
Speed Sensor Loose, Incorrectly
Contacted.

1. Check Connectors, Replace
Output Speed sensor If Neces-
sary.

2. Output Speed Sensor Defective

2. Replace Output Speed Sen-
sor.

LEAKAGE AT THE AREA

OF THE ELECTRICAL

PLUG TO THE CONDUC-

TOR PLATE

1. Deformation O-Rings.

1. Replace O-Rings.

2. Deformation Adapter.

2.Replace Adaptor.

3. The Conductor Plate Is Not Fitted
Surface To Surface On The Valve
Body In One Corner, The Plug Is
Not Centered In The Socket And
The O-ring Will Not Seal.

3. Remove Nose Of Conductor
Plate.

4. Contacting At The Conductor
Plate Leaky. Oil In Harness, Some-
times In The Control Module.

4. Replace Conductor Plate.

LEAKAGE AT THE AREA

OF BELL HOUSING/

TORQUE CONVERTER

1. Bolts (Torx M6) Outer Disc Carri-
er B1.

1. Clean Thread and Install the
Bolts Using Sealer.

OIL LEAKS

1. 6 Lower Bolts (TorxM8) Converter
Housing.

1. Clean Thread and Install the
Bolts Using Sealer.

2. Oil Drain Plug Converter Loose
Resp. No Seal Ring Installed.

2. Install Drain Plug Correctly.

3. Weld Seam Of Torque Converter
Leaky.

3. Replace Torque Converter.

4. Radial Sealing Ring Oil Pump
Defective.

4. Replace Sealing Ring.

5. O-Ring Oil Pump Defective Or
Not Installed.

5. Install O-Ring.

6. Bushing Of Oil Pump Loose,
caused By Missing Fit Bolt At
Transmission/Engine Flange.

6. Install Fit Bolt If Necessary.

STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR

Damaged or worn threads in the aluminum trans-

mission case and valve body can be repaired by the
use of Heli-Coils™, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-Coil™ tap, or
equivalent, and installing a Heli-Coil™ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.

Heli-Coil™, or equivalent, tools and inserts are

readily available from most automotive parts suppli-
ers.

REMOVAL

(1) Disconnect the negative (ground) battery cable.

CAUTION: Isolate ground lead to prevent accidental
contact.

(2) Apply parking brake.
(3) Move gear selector lever to position “N”.
(4) Remove oil drain plug (2) (Fig. 26) and drain

automatic transmission oil into a clean container.

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AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION

(5) Remove oil filler pipe.

(a) Remove bolts (2) (Fig. 27) to cylinder head.
(b) Remove bolt (3) (Fig. 27) to transmission

flange and bolt (2) to transmission housing.

27) out of the fill hole in the side of the transmis-
sion housing.

(d) Guide oil filler pipe (1) (Fig. 27) up and

out.

(6) Remove exhaust heat shield (5) (Fig. 28).
(7) Remove retaining bracket (4) (Fig. 28).

(8) Detach propeller shaft (1) (Fig. 28) at transmis-

sion (Refer to 3 - DIFFERENTIAL & DRIVELINE/
PROPELLER

SHAFT/PROPELLER

SHAFT

REMOVAL). Move propeller shaft to the right and tie
up.

(9) Remove the cooler lines at transmission.

(a) Remove bracket for the oil cooler feed and

return lines (1) (Fig. 29) from engine oil pan
flange. Detail shows right side of motor. Position is
mirrored for the left side of engine.

(b) Detach bracket of cable retainer (4) (Fig. 30)

from the threaded shank of a engine oil pan bolt
(5).

out.

(d) Remove the bolts holding the oil cooler lines

(6) (Fig. 31) to the left and right sides of transmis-
sion and hang the lines to the side.

Fig. 26 Drain Transmission

1 - SEAL
2 - DRAIN PLUG

Fig. 27 Fill Tube

1 - FILL TUBE
2 - BOLTS TO CYLINDER HEAD AND TRANSMISSION HOUS-
ING
3 - BOLT TO TRANSMISSION FLANGE

Fig. 28 Propeller Shaft and Heat Shield

1 - PROPELLER SHAFT
2 - BOLT
3 - BOLT
4 - RETAINING BRACKET
5 - HEAT SHIELD
6 - WASHER
7 - BOLT

AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION

21 - 43

(10) Disconnect the transmission electrical connec-

tor (2) (Fig. 32) from transmission and hang to the
side. Turn sealing ring (3) counterclockwise and dis-
connect plug connection (2).

(11) Detach shift cable at transmission.

(a) Unlatch ball socket latch (Fig. 33) of cable.
(b) Unclip shift cable retainer from retainer

bracket. When pulling out cable, press together
hooks of shift cable retainer at the points shown
(arrows).

can remain on transmission lever.

Fig. 29 Cooler Line Supports

1 - COOLER LINES

Fig. 30 Cable Support

1 - CABLE
2 - BOLT

Fig. 31 Driver’s Side Cooler Line

1 - COOLER LINE

Fig. 32 Transmission Electrical Connector and

Cooler Line

1 - COOLER LINE
2 - TRANSMISSION ELECTRICAL CONNECTOR
3 - SEALING RING

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AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION

(12) Remove the torque converter bolts.

(a) Remove the steering gear (1) (Fig. 34) from

the chassis crossmember.

(b) Lower the steering gear (1) (Fig. 34) down-

wards.

cover (1) (Fig. 35) at back of engine flange.

(d) Rotate engine by hand until bolts (2) (Fig.

35) are in front of opening. Rotate engine forwards
at crankshaft.

(e) To remove bolts, position a ratchet with long

extension and joint nut as shown (Fig. 36).

(f) Remove the two bolts (2) (Fig. 35) at each of

the three locations at circumference of driving
plate.

(13) Remove torque converter drain plug and drain

automatic transmission oil into a clean container. Re-
install the drain plug and torque the plug to 14 N·m
(130 in.lbs.).

(14) Support engine. Insert wooden block between

oil pan and front chassis crossmember beam.

(15) Remove vent hose bracket and tie back to one

side.

Fig. 33 Shift Cable at Transmission

1 - SHIFT CABLE
2 - TRANSMISSION SHIFT LEVER

Fig. 34 Steering Gear

1 - STEERING GEAR
2 - BRACKET

Fig. 35 Torque Converter Access Cover

1 - TORQUE CONVERTER ACCESS COVER
2 - BOLT

Fig. 36 Torque Converter Bolts Access

1 - BOLT
2 - STABILIZER BAR
3 - REINFORCEMENT PLATE
4 - OPENING
5 - CHASSIS CROSSMEMBER
6 - STEERING GEAR

AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION

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Content .. 266 267 268 269 ..