A/T - A604 OD/Reverse Clutch Failures
90chrysler15SUBJECT: A-604 0D/Reverse Clutch
Failures And/Or Excessive Metallic Debris In Oil Pan
NO.: 21-24-90
GROUP: TRANSMISSION
DATE: Dec. 3, 1990
MODELS:
1990-91 (AA) SPIRIT/ACCLAIM/LEBARON
(AC) DYNASTY/NEW YORKER/LANDAU/SALON
(AG) DAYTONA
(AJ) LEBARON COUPE/LEBARON CONVERTIBLE
(AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
(AY) IMPERIAL/NEW YORKER FIFTH AVENUE
DISCUSSION:
This bulletin covers diagnosis and repair of A-604 transaxles that exhibit one or more of the following symptoms/conditions:
Overdrive/Reverse clutch failure. Slipping in reverse, no reverse. Slipping in 1st, 2nd, and 3rd, no drive. Excessive bronze and other metallic debris in the oil pan. Fault codes, 22, 24, 36, 42, 46, 50, 51, and 53.
These symptoms/conditions may be the result of one or both of the following:
Figure 1:
1. An undersized input clutch hub in the area of the hub outer lip seal. This undersize condition will result in the OD/Reverse piston contacting the input clutch hub. This contact results in a scratching/scoring of the OD/Reverse piston. Figure 1.
Figure 2:
Figure 3:
The symptoms most likely to be experienced with this condition is a failure of the reverse and/or OD clutch.
If scratching or scoring of the OD/Reverse piston is found during your inspection, the input clutch hub and OD/reverse piston MUST be replaced.
2. A machining defect may exist on the reaction shaft support journal. The machining defect may not be visible to the naked eye. This machining defect will result in excessive wear of the input clutch hub bushing, reaction shaft support seal rings and input shaft seal rings and ring seats. Figure 2 and 3.
The symptoms most likely to be experienced with this condition are: Slipping in reverse, no reverse, and fault codes 36, and 50. Slipping in 1st and 2nd, no drive, and fault codes 36, 51, and 52. Slipping in 3rd, and fault codes 36, 53, and 46. Pressure switch and solenoid fault codes 22, 24, and 42 (caused by contamination from failure). Excessive bronze and other metallic debris in oil pan.
If the input clutch hub bushing is found excessively worn during your inspection, the reaction shaft support, input clutch hub, input shaft and the solenoid assembly MUST be replaced. Because of the large amounts of debris generated by this bushing wear, the transaxle should be completely disassembled and thoroughly cleaned.
TRANSAXLE RECONDITIONING REMINDERS
1. Always check and record the input shaft end play before disassembling the transaxle.
2. Replace all worn or failed components.
3. Always use Door Ease or its equivalent on all lip seals and "O" rings and mating parts for assembly ease. Use Vaseline or petroleum jelly to temporarily hold parts, such as thrust bearings in place during assembly. Do not use petroleum based greases such as chassis grease to hold parts in place. These greases could plug critical orifices or be incompatible with transmission fluid.
4. Replace torque convertor if a clutch failure has occurred.
5. The solenoid assembly can be reused unless the transmission has experienced a gear train failure or a clutch failure that has generated metallic debris.
6. Always flush the transmission oil cooler when reconditioning the transaxle.
7. Use Mopar ATF Plus (Type 7176) transmission fluid PN 4467721 to refill the transaxle. This is the preferred fluid, however Mopar Dexron II/Mercon transmission fluid, PN 4467723 may be used if ATF Plus is not available.
POLICY: Information only