A/T Transfer Gear - Whine or Whistle Type Noise
NO.: 21-40-93GROUP: Transmission
EFFECTIVE DATE: Jan. 28, 1994
SUBJECT:
31TH Transaxle Transfer Gear Noise
MODELS:
1989 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AG) Daytona
1989 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1994 (AS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 31TH TRANSAXLES BUILT WITH 3.02 OR 3.22 FINAL DRIVE GEAR RATIOS. 1994 MODEL YEAR VEHICLES MUST HAVE A TRANSAXLE DATE CODE PRIOR TO 1826 (REFER TO ILLUSTRATION) FOR THIS BULLETIN TO APPLY.
SYMPTOM/CONDITION:
The transaxle emits a load sensitive high frequency whine or whistle-like noise at any vehicle speed in either a drive or coast condition.
DIAGNOSIS:
Test drive the vehicle on smooth asphalt pavement and listen for the noise.
NOTE:
THIS WHINE OR WHISTLE-LIKE NOISE IS TRANSMISSION LOAD RELATED. DO NOT CONFUSE THIS NOISE WITH TIRE NOISE OR AIR CONDITIONING COMPRESSOR NOISE.
PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves installing a service kit that contains revised transfer and output gears with a 32 degree tooth angle.
1. Remove the transaxle assembly using the procedure outlined in the appropriate Service Manual, i.e., Page 21-47 of the 1993 Van/Wagon Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370-3105).
NOTE A:
THE TRANSFER SHAFT, GOVERNOR SUPPORT AND GOVERNOR BODY MUST ALL BE REPLACED TOGETHER BECAUSE THE JOURNAL DIAMETERS WERE CHANGED.
NOTE B:
USE OLD NUTS AND WASHERS WHEN PERFORMING OUTPUT AND TRANSFER GEAR BEARING ADJUSTMENTS. AFTER SELECTING THE PROPER SHIMS AND VERIFYING CORRECT END PLAY AND TURNING TORQUE, REMOVE THE OLD NUTS AND WASHERS AND INSTALL THE NEW ONES AND TORQUE TO 200 FT.LBS. (271 N-m).
2. Refer to the transfer shaft repair and the output shaft repair procedures outlined in the appropriate Service Manual, i.e., Page 21-66 and 21-71 of the 1993 Van/Wagon Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370-3105) to install the gear, shaft, governor, and bearing components of the gear noise service kit.
3. Output and transfer gear retaining stirrup and strap installation:
a. Place stirrup (P/N 4567336), serration side out, over the output gear retaining nut hex, aligning the sides of the stirrup slot with the flats on the nut. Make sure the two tapped holes in the gear line-up with the curved slots in the stirrup. Refer to Figure 1.
b. Place the retaining strap (P/N 4659134) over the stirrup so the strap holes are aligned with the tapped gear holes.
c. Install the two stirrup retaining bolts (P/N 6503355) into the tapped gear holes and finger tighten.
d. Index the stirrup clockwise tight against the output gear nut and torque the stirrup retaining bolts to 200 In.Lbs. (23 N-m), refer to Figure 2.
e. Carefully bend the three retaining strap tabs up and tightly against both retaining bolt heads (a total of six tabs). This must be done carefully to prevent the retaining bolts from coming loose. Refer to Figure 3.
4. Use the procedure described in step 3 to install the transfer gear nut retaining components.
5. Apply RTV sealant (P/N 4318025) to the revised end cover (P/N 4659342) mating surface and install. Torque the screws to 165 In.Lbs. (19 N-m).
6. Reinstall the transaxle assembly by reversing the procedures in step 1.
7. Adjust the gear shift and throttle pressure linkages using the procedures outlined in the appropriate Service Manual i.e., Page 21-44 of the 1993 Van/Vagon Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370-3105).
8. Refill the transaxle with Mopar ATF Plus Type 7176 (P/N 4467721).
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 21-31-04-90 6.9 Hrs.
FAILURE CODE: 68 - Noisy