Repair Procedures
REPAIR PROCEDURE NUMBER ONEVehicles With Flashable Transaxle Control Modules
If the vehicle has a TCM part number that is not listed in the illustration, the vehicle will require that the control module be replaced. Some vehicles that have had service controllers installed may be flashed. Therefore, always check the TCM part number to be sure that a flash controller is not replaced.
EQUIPMENT/PARTS REQUIRED:
1 CH6OOO Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7OOO J1962 Cable (Except LH Models)
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
Note:
The MOPAR diagnostic system is required to perform the following repair and the system must be operating with release 16 or higher installed.
REPAIR PROCEDURE:
This procedure involves flashing the Transaxle Control Module with new software (calibrations) using the DRB III.
1. Examine the TCM part number on the vehicle. If the part number is listed above, the controller can be flashed using the DRB III.
2. Connecting the MDS and DRB III to the Vehicle:
A) With the ignition off, disconnect the vehicle 60 way connector from the TCM on the vehicle.
B) Connect the 60 way harness, from the Flash Programming Kit, CH5500 to the TCM on the vehicle.
C) Connect the Flash Programming Adapter to the 60 way harness.
D) Connect the DRB III to the Flash Programming Adapter with DRB III DIN cable CH7025.
E) Connect the MDS to the DRB III.
F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery.
3. Use the arrow keys on the DRB III MAIN MENU Screen and select # 2 MDS DIAGNOSTICS.
4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU, then press NEXT MENU.
5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU.
6. Use the arrow keys on the MDS and select PROGRAM CONTROLLER PART, then press NEXT MENU.
7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the controller.
8. The MDS will display the part number of the controller on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming.
If the controller on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the controller on the vehicle and compare it to the part number displayed. If the controller has already been updated, proceed to step 9.
9. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process.
10. Change the transmission fluid following the procedure outlined in the Service Manual (removing the pan and loosening the valve body will speed up draining the fluid. Remember to tighten the valve body attaching screws).
Note:
Use only Mopar ATF plus transmission fluid (automatic transmission fluid type 7176). Use of Dextron IIE may cause clutch shudder.
11. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral.
12. Using the procedure listed in the Service Manual, complete the following:
A) Electronic Pinion Factor Procedure (not required on LH, LHS models).
B) Quick Learn Procedure (required whenever a transaxle or TCM is replaced).
Note:
Before performing the quick learn, it is imperative that the vehicle be shifted into OD with the engine running and the oil level set to the correct level. this procedure will purge the air in the clutch circuits to prevent erroneous clutch volume values which could cause poor initial shift quality.
13. Drive the vehicle at least 10 miles.
14. Change the transmission fluid again following the procedure outlined in the Service Manual.
Note:
The following step is required by law.
15. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label.
16. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker.
PRODUCTION VEHICLES THAT MAY NOT HAVE FLASH CONTROLLERS
1989 - 1992 All with 3.0L Engine
1990 - 1992 All with 3.3L and 3.8L Engine
1993 AA, AC, AS, & AY with 41TE Transaxle
PARTS REQUIRED:
Part No. Trans. Control Module And Model Application
1 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY
1 4796121 1989 - 1991 AA, AC, AG, AJ, AS, & AY with 3.0L Engine
1 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine
1 4796123 1992 AA, AC, AG, AJ, AS, & AY with 3.0L Engine
1 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.8L Engine
This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, and on 1993 and later models, setting the pinion factor.
1. Using a DRB II or DRB III, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments.
Note:
This step will be electronically verified when the module is inspected at the Chrysler return center.
2. Replace the transmission control module with the new module following the procedures outlined in the appropriate Service Manual.
3. Change the transmission fluid following the procedure outlined in the Service Manual.
Note:
Use only Mopar ATF plus transmission fluid (automatic transmission fluid type 7176). Use of Dextron IIE may cause clutch shudder.
4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral.
5. Using the procedure listed in the Service Manual, complete the following:
A) Electronic Pinion Factor Procedure (1993 and later models only).
B) Quick Learn Procedure (required whenever a transaxle or TCM is replaced).
6. Drive the vehicle at least 10 miles.
7. Change the transmission fluid again following the procedure outlined in the Service Manual.
Note:
The following step is required by law.
8. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label.
REPAIR PROCEDURE NUMBER TWO:
Vehicles With Flashable Transaxle Control Modules
This procedure involves flashing the Transaxle Control Module with new software (calibrations) using the DRB III.
1. Follow the steps listed under Procedure 1, except changing the transaxle fluid is not required.
Vehicles With Transaxle Control Modules That Cannot Be Flashed
This repair involves the replacement of the transmission control module with a module that incorporates revised software, setting the pinion factor and transaxle quick learn.
1. Follow the steps listed under Procedure 1, except changing the transaxle fluid is not required.