Trasmision Completa Caliber 2007

2008 Dodge Caliber R/T
2008 AUTOMATIC TRANSMISSION CVT - Service Information - Caliber
2008 AUTOMATIC TRANSMISSION
CVT - Service Information - Caliber
ERVICE INFORMATION
SCRIPTION
TOMATIC-CVT
e continuously variable transmission (CVT) has a torque converter and allows optimal driving force in
ponse to the accelerator pedal operation, therefore giving us smooth driving without shift shock. The
T also has a manual mode function for both smooth driving without shift shock, and enjoyable driving
h manual ratio selection.
e CVT allows for maximum driving force and performance when compared to a conventional A/T. When
throttle is fully opened, driving force for the conventional automatic transmission changes unevenly
ause the ratio is shifted in steps. On the other hand, driving force for the CVT changes smoothly because
s possible for it to accelerate while keeping it in the peak power range of the engine. Therefore, CVT
ids the loss of driving force, and enables smooth and shock free driving.
ordinated control of the engine and the multifaceted shift diagram have made it possible to realize both,
ooth and powerful driving with a good ratio change response and an improvement in fuel consumption.
ERATION
TOMATIC-CVT
RK POWERFLOW
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ércoles, 25 de Enero de 2012 04:48:45
04:48:29 p.m. Page 1 © 2006 Mitchell Repair Information Company, LLC.
. 1: Park Powerflow
urtesy of CHRYSLER LLC
REVERSE BRAKE (RELEASED)

FORWARD CLUTCH (RELEASED)
PARKING GEAR (FIXED)
en the forward clutch and the reverse brake are released, the driving force from the engine runs idly and
wer is not transmitted to the primary pulley.
en the parking gear is fixed, the torque load from the tires is not transmitted up to the primary pulley.
VERSE POWERFLOW
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ércoles, 25 de Enero de 2012 04:48:29 p.m. Page 2 © 2006 Mitchell Repair Information Company, LLC.
. 2: Reverse Powerflow
REVERSE BRAKE (ENGAGED)

en the reverse brake is engaged, the planetary carrier is fixed and the driving force from the engine
ates the sun gear reversely.
erefore, the primary pulley is rotated reversely and the driving force is outputted in the reverse rotating
ection.
UTRAL POWERFLOW
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. 3: Neutral Powerflow

en the forward clutch and the reverse brake are released, the driving force from the engine runs idly and
ot transmitted to the primary pulley.
en the forward clutch and the reverse brake are released, the planetary carrier runs idly and the torque
m the tires are not transmitted.
IVE POWERFLOW
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. 4: Drive Powerflow

FORWARD CLUTCH (ENGAGED)
en the forward clutch is engaged, the driving force from the engine rotates the sun gear normally through
forward clutch.
erefore, the primary pulley is rotated normally and the driving force is outputted in the normally rotated
ection.
FT LOW TO HIGH - PHASE 1
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. 5: Shift Low To High - Phase 1

PULLEY RATIO LINKAGE 5-

SECONDARY
VALVE
STEPPER MOTOR 6-
SECONDARY
PULLEY
7 - PRIMARY
RATIO CONTROL VALVE
PULLEY
LINE PRESSURE -
en the line pressure circuit is closed by the ratio control valve, the line pressure is not applied to the
mary pulley.
en the secondary valve moves downwards, line pressure is applied to the secondary pulley.

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SECONDARY
VALVE
STEPPER MOTOR 6-
SECONDARY
PULLEY
7 - PRIMARY
RATIO CONTROL VALVE
PULLEY
LINE PRESSURE -
e pulley ratio linkage moves to the left direction of the stepper motor. The line pressure circuit opens due
he movement of the ratio control valve which links to the pulley linkage, and line pressure is applied to
primary pulley.
e secondary valve moves to open and fluid in the secondary pulley is drained while maintaining the
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ley pressure.


SECONDARY
VALVE
STEPPER MOTOR 6-
SECONDARY
PULLEY
7 - PRIMARY
RATIO CONTROL VALVE
PULLEY
LINE PRESSURE -
applying line pressure to the primary pulley, the sliding element moves to the right direction and the
el belt is pushed outward on the primary pulley.
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actuating the "moving-pulley" of the primary pulley to the right direction, the ratio control valve starts to
ve to the right direction through the pulley ratio linkage which is driven by the sliding element.
pulling the steel belt to the primary pulley side, the moving-pulley of the secondary pulley moves to the
ht side also.


SECONDARY
VALVE
STEPPER MOTOR 6-
SECONDARY
PULLEY
7 - PRIMARY
RATIO CONTROL VALVE
PULLEY
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LINE PRESSURE -
ditionally, the sliding element of the primary pulley moves to the right direction and the ratio control
ve also moves to the right side and closes the line pressure circuit; this is a completion of the shift.
e secondary valve moves downwards to apply the line pressure to the secondary pulley in order to apply
mping force to the steel belt.
FT HIGH TO LOW - PHASE 1
. 9: Shifting High To Low - Phase 1


SECONDARY
VALVE
STEPPER MOTOR
6-
SECONDARY
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PULLEY
7 - PRIMARY
RATIO CONTROL VALVE
PULLEY
LINE PRESSURE -
e pulley ratio linkage moves to the right direction in the stepper motor. As the ratio control valve which
ks to the pulley ratio linkage, moves fluid and the primary pulley is drained.
cause the secondary valve is moving downwards, line pressure is maintained in the secondary pulley.


SECONDARY
VALVE
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STEPPER MOTOR 6-
SECONDARY
PULLEY
7 - PRIMARY
RATIO CONTROL VALVE
PULLEY
LINE PRESSURE -
e stepper motor (2) first moves to the right which causes the ratio valve (3) to vent oil from the primary
vable pulley at a speed that allows some belt clamping to be maintained. As the oil is exhausted, the
veable side of the primary pulley moves to the left allowing the belt to be pulled down into the low ratio
ition by the constantly maintained line pressure in the secondary pulley. As the primary pulley moveable
e moves to the left, the ratio valve is pulled to the left which closes off the oil venting from the primary
ley thereby stopping the ratio change. For each position of the stepper motor, there is a corresponding
ition of the primary moveable sheave therefore.

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SECONDARY
VALVE
STEPPER MOTOR 6-
SECONDARY
PULLEY
7 - PRIMARY
RATIO CONTROL VALVE
PULLEY
LINE PRESSURE -
ditionally, the moving-pulley of the secondary pulley moves to the left direction and the steel belt is
hed outside. In accordance with this, the sliding element of the primary pulley moves to the left side.
e moving-pulley of the primary pulley moves to the right direction, then the ratio control valve also
ves to the left direction and closes the drain circuit; this is a completion of the shift.
AGNOSIS AND TESTING
TOMATIC-CVT
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. 12: TEST PORTS

Line Pressure 5 - Torque

Converter
Release
Pressure
Forward Clutch Pressure 6-
Secondary
Pressure
7-
Reverse
Primary Pressure
Brake
Pressure
Torque Converter Apply Pressure -
Fluid pressure Fluid pressure (measurement

Remarks
(minimum - reference value)
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maximum)
Reference value Mpa Measurement Reference value
-
(kg/cm2 condition Mpa (kg/cm2)
0.5 - 1.5 (5.1 -
ne pressure 0.5 - 6.0 (5.1- 61.2) Idling -
15.3)
rward clutch Idling (D 0.5 - 1.0 (5.1 - P, R and N positions:
0.1 - 1.5 (1.0 - 15.3)
essure position) 10.2) 0 Mpa (0 kg/cm2)
0.1 - 1.5 (1.0 -
mary pressure 0.1 - 6.0 (1.0 - 61.2) Idling -
15.3)
rque converter 0.0 - 0.2 (0.0 -
0.0 - 1.0 (0.0 - 10.2) Lock-up ON: -
ply pressure 2.0)
rque converter 0.0 - 0.2 (0.0 -
0.0 - 1.0 (0.0 - 10.2) Lock-up OFF: -
ease pressure 2.0)
0.1 - 1.5 (1.0 -
condary Pressure 0.1 - 6.0 (1.0 - 61.2) Idling -
15.3)
verse brake Idling (R 0.5 - 1.0 (5.1 - Out of R position: 0
0.1 - 1.5 (1.0 - 15.3)
essure position) 10.2) Mpa (0 kg/cm2)
MOVAL
TOMATIC-CVT
. 13: Air Cleaner Assembly

1. Disconnect battery cables (2). See Fig. 13.

2. Remove air cleaner assembly (1).
3. Remove battery.
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Fig. 14: Battery Tray

Courtesy of CHRYSLER LLC
4. Remove battery tray (1). See Fig. 14.

5. Drain coolant. Refer to STANDARD PROCEDURE .
Fig. 15: Inlet Air Tube

6. Remove inlet air tube (1). See Fig. 15.

7. Remove vacuum supply lines.
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Fig. 16: Shifter Cable And Bracket

8. Remove the shifter cable (2) and bracket (3). See Fig. 16.
Fig. 17: Cooler/Trans Lines At Cooler

9. Remove coolant lines (2) at CVT fluid cooler.
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Fig. 18: Heater Hose To Trans Cooler

0. Remove heater hose (3) at CVT fluid cooler.
Fig. 19: Speed Sensor

1. Remove the speed sensor connector (1). See Fig. 19.
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Fig. 20: Vent Tube

2. Remove the wiring harness from the top of the transmission (2). See Fig. 20.
3. Remove the transmission vent tube (1).
Fig. 21: Throttle Body Support Bracket

4. Remove the throttle body support bracket (1). See Fig. 21.
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Fig. 22: Bell Housing Bolt Holes

5. Remove the upper bell housing bolts (1). See Fig. 22.
Fig. 23: Top CVT Trans Mount

6. Remove the upper transmission mount bolts (1).

7. Remove the upper transmission mount through bolt.
8. Remove the upper transmission mount (2).
9. Raise vehicle on a hoist.
0. Drain transmission fluid.
1. Remove the left front lower splash shield.
2. Remove the right front lower splash shield.
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3. Remove lower splash shield (if equipped).
Fig. 24: Jack For Support

4. Support the transmission with a jack (1). See Fig. 24.

5. Remove the starter. Refer to REMOVAL .
Fig. 25: Fill Tube

6. Remove the two transmission fill tube bolts (2) and remove the fill tube.
7. Drain the transmission fluid.
8. Remove both front wheels.
9. Remove the right and left halfshafts. Refer to REMOVAL .
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Fig. 26: Inspection Cover

0. Remove inspection cover (1). See Fig. 26.

1. Mark the torque converter to the flex plate for alignment upon installation.
Fig. 27: Torque Converter Bolts

2. Remove torque converter bolts (1). See Fig. 27.
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Fig. 28: Jack At Trans Mount

3. Support the engine with a screw jack (2).
Fig. 29: Front Engine Mount

4. Remove the through bolt (1) at the front transmission mount. See Fig. 29.
5. Remove bolts (2) at the transmission cross member.
6. Remove the transmission cross member.
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Fig. 30: Rear Engine Mount

7. Remove the transmission rear mount thorough bolt (2).
Fig. 31: 2WD REAR MOUNT

8. Remove the rear mount to transaxle bolts (1).

9. Remove the PTU if equipped. Refer to REMOVAL .
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0. Remove the lower transmission bell housing bolts (2). See Fig. 32.
1. Lower transmission.
SASSEMBLY
TOMATIC-CVT
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. 33: CVT Externals - Exploded View

WASHER 16 - OIL
STRAINER
SHIFT LEVER 17 - PLAIN
WASHER
18 -
INHIBITOR SWITCH MANUAL
LEVER
19 -
CVT FLUID FILTER
BUSHING
20 -
O-RING MANUAL
VALVE
21 - STEPPER
CVT FLUID COOLER
MOTOR
SHIM 22 - LIP
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SEAL
23 - SNAP
OUTPUT SPEED SENSOR
RING
24 - VALVE
O-RING BODY
HARNESS
25 - OIL PAN
- TRANSAXLE
GASKET
- PULLEY RATIO LINKAGE 26 - OIL PAN
27 - TORQUE
- SPRING
CONVERTER
- CONTROL VALVE 28 - O-RING
29 - INPUT
- BRACKET SPEED
SENSOR
- O-RING 30 - O-RING
. 34: CVT Internals - Exploded View

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O-RING 24 - BAFFLE
PLATE
SIDE OIL SEAL 25 - DRIVEN
SPROCKET
(OIL PUMP)
26 - BAFFLE
ADJUSTABLE SHIM
PLATE
27 - OIL
OUTER RACE
PUMP
28 - LIP
REDUCTION GEAR ASSEMBLY
SEAL
29 - SNAP
OUTER RACE
RING
30 - DRIVEN
ADJUSTABLE SHIM
PLATES
31 - NEEDLE
OUTER RACE
BEARING
32 - SUN
DIFFERENTIAL ASSEMBLY
GEAR
33 - NEEDLE
- OUTER RACE
BEARING
34 -
- FORWARD CLUTCH ASSEMBLY PLANETARY
CARRIER
35 - NEEDLE
- NEEDLE BEARING
BEARING
36 - SNAP
- SEAL RING
RING
37 -
- OIL PUMP COVER RETAINING
PLATE
38 - DRIVEN
- BAFFLE PLATE
PLATES
39 - DISH
- BRACKET
PLATE
40 - SNAP
- ADJUSTABLE SHIM
RING
41 -
- ADJUSTABLE SHIM RETAINING
PLATE
42 - SPRING
- CONVERTER HOUSING RETAINER
ASSEMBLY
43 -
REVERSE
- CONVERTER HOUSING OIL SEAL
PLATE
PISTON
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44 - DETENT
- OIL PUMP CHAIN
SPRING
45 -
- DRIVE SPROCKET TRANSAXLE
CASE
- THRUST WASHER -
1. Refer to the exploded views above as necessary when performing the following steps.
Fig. 35: Torque Converter

2. Drain the CVT fluid from the transaxle assembly.

3. Remove the power transfer unit assembly and o-ring (4WD only).
4. Remove the torque converter (1) from the transaxle. See Fig. 35.
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Fig. 36: 9878 Transmission Service Stand

5. Install Transmission Service Stand 9878 (1) to the belt side of the transmission case (3) using the
upper transmission mount bolts (2).
Fig. 37: Output Speed Sensor

6. Remove the output speed sensor (1) from the converter housing. Remove and discard the o-ring from
the output speed sensor. See Fig. 37.
CAUTION: Set aside and reuse any adjusting shim found between the output
speed sensor and the converter housing.
Fig. 38: Input Speed Sensor

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7. Remove the input speed sensor (1) from the transaxle case. Remove and discard the o-ring from the
input speed sensor. See Fig. 38.
Fig. 39: Shift Lever

8. Remove the nut (1) holding the shift lever (2) to the manual shaft.
9. Remove the shift lever from the manual shaft. See Fig. 39.
Fig. 40: Transmission Range Sensor

0. Remove the bolts (2) holding the transmission range sensor (TRS) (1) to the transaxle case.
1. Remove the (TRS) transmission range sensor (1) from the transaxle case and the manual shaft. See
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Fig. 40.
Fig. 41: Terminal Body

2. Remove the snap ring (1) from the terminal body (2) and press the terminal body into the transaxle
case. See Fig. 41.
CAUTION: Be careful not to cause damage to the terminal body.
Fig. 42: Fluid Cooler

3. Remove CVT fluid cooler (1) from transaxle case. Remove and discard the CVT fluid cooler o-ring.
See Fig. 42.
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Fig. 43: Fluid Filter

4. Remove the bolts holding the CVT fluid filter to the transaxle case.
5. Remove the CVT fluid filter (1) from the transaxle case. See Fig. 43.
Fig. 44: Converter Housing Mounting Bolts

6. Remove the converter housing mounting bolts. See Fig. 44.
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Fig. 45: Converter Housing

7. Remove the converter housing (1) by tapping with plastic hammer. See Fig. 45.
CAUTION: There is a possibility that the drive sprocket adjusting shim may
be dislodged and fall out.
Fig. 46: Pull Outer Race Reduction Gear

8. Remove outer race of reduction gear bearing (1) from the converter housing using Puller 7794-A and
Puller C-637. See Fig. 46.
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Fig. 47: Remove Differential Side Oil Seal

9. Remove differential side oil seal (1) from converter housing using a screwdriver. (2WD) See Fig. 47.
Fig. 48: Remove Converter Housing Oil Seal

0. Remove converter housing oil seal (1) from converter housing using a screwdriver. See Fig. 48.
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Fig. 49: Outer Race Of Differential Side Bearing

1. Remove outer race (1) of differential side bearing from converter housing using a suitable punch. See
Fig. 49.
CAUTION: When removing the outer race, tap the outer race on both sides
evenly. When removing the outer race, do not damage the
converter housing.
Fig. 50: Input Shaft O-Ring

2. Remove and discard the O-ring (1) from the input shaft. See Fig. 50.
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Fig. 51: Adjusting Shim At Drive Sprocket

3. Remove the adjusting shim (1) from the drive sprocket, if necessary. See Fig. 51.
Fig. 52: Baffle Plate

4. Remove the nuts holding the baffle plate (1) to the transaxle. See Fig. 52.
5. Remove the baffle plate.
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Fig. 53: Snap Ring At Driven Sprocket

6. Expand the snap ring (1) and remove the driven sprocket (3), the oil pump chain (2), and the drive
sprocket. See Fig. 53.
Fig. 54: Thrust Washer At Oil Pump Cover

7. Remove the thrust washer (1) from the oil pump cover. See Fig. 54.
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Fig. 55: Snap Ring At Oil Pump

8. Remove the snap ring (1) from the oil pump. See Fig. 55.
Fig. 56: Reduction Gear Assembly

9. Remove the reduction gear assembly (1) from the transaxle case. See Fig. 56.
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Fig. 57: Differential Assembly

0. Remove the differential assembly (1) from the transaxle case. See Fig. 57.
Fig. 58: Bracket

1. Remove the bolts holding the bracket (1) to the oil pump cover and the transaxle. See Fig. 58.
2. Remove the bracket (1).
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Fig. 59: Baffle Plate 2

3. Remove the bolts holding the baffle plate (1) to the transaxle. See Fig. 59.
4. Remove the baffle plate.
Fig. 60: Reaction Shaft Support

5. Remove the bolts holding the reaction shaft support (1) to the transaxle. See Fig. 60.
6. Remove the reaction shaft support from the transaxle case.
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Fig. 61: Seal Rings

7. Remove and discard the seal rings (1) from the reaction shaft support. See Fig. 61.
Fig. 62: Oil Pan

8. Remove the bolts holding the oil pan (1) to the transaxle case. See Fig. 62.
9. Remove the oil pan from the transaxle case.
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Fig. 63: Oil Pan Gasket

0. Remove the oil pan gasket (1) from the transaxle case. See Fig. 63.
Fig. 64: Oil Strainer

1. Remove the bolts holding the oil strainer (1) to the valve body. See Fig. 64.
2. Remove the oil strainer.
3. Remove and discard the oil strainer o-ring.
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Fig. 65: Oil Pump Retaining Bolts

4. Remove the bolt (2) holding the oil pump to the transaxle case from the rear of the transaxle. See Fig.
65.
5. Remove the bolts (1) holding the oil pump to the transaxle case from inside the transaxle.
6. Remove the oil pump from the transaxle case.
Fig. 66: O-Ring At The Oil Pump Mounting

NOTE: One of the oil pump retaining bolts is installed from the outside of the
transaxle case into the rear part of the oil pump.
7. Remove and discard the o-ring (1) from the oil pump mounting bolt. (Only on bolt installed from the
outside of the transaxle case).
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Fig. 67: Lip Seal At The Transaxle Case

8. Remove and discard the lip seal (1) from the transaxle case. See Fig. 67.
Fig. 68: Detente Spring

9. Remove the bolt holding the detent spring (1) to the transaxle case. See Fig. 68.
0. Remove the detente spring from the transaxle case.
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Fig. 69: Forward Clutch Assembly

1. Remove the forward clutch assembly (1) from the transaxle case. See Fig. 69.
Fig. 70: Needle Bearing At Forward Clutch

2. Remove needle bearing (1) from forward clutch drum side of the sun gear. See Fig. 70.
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Fig. 71: Sun Gear At Planetary Carrier

3. Remove the sun gear (1) from the planetary carrier. See Fig. 71.
Fig. 72: Needle Bearing At Sun Gear

4. Remove the needle bearing (1) from the sun gear. See Fig. 72.
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Fig. 73: Planetary Carrier Assembly

5. Remove the planetary carrier assembly (1) from the transaxle case. See Fig. 73.
Fig. 74: Needle Bearing At Planetary Carrier

6. Remove the needle bearing (1) from the planetary carrier. See Fig. 74.
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Fig. 75: Bracket At Valve Body Assembly

7. Remove the bolts holding the bracket (1) to the valve body assembly. See Fig. 75.
8. Remove the bracket from the valve body assembly.
Fig. 76: Manual Lever

9. Remove the nut holding the manual lever (1) to the manual shaft. See Fig. 76.
0. Remove the manual lever.
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Fig. 77: Bolts For Valve Body Assembly

1. Use this picture when removing valve body attaching bolts.
Fig. 78: Control Valve Assembly

CAUTION: Tilt the valve body assembly away from the transaxle case on the
manual shaft side to ease removal. Pay attention to completely
remove the terminal body from the transaxle case.
2. Remove the valve body assembly from the transaxle case as follows:
Insert a 75 mm (3 in.) long 3 mm (0.118 in.) wide rod or wire into the linkage stopper hole of
the valve body assembly to fix the pulley ratio linkage (1). See Fig. 78.
Remove the bolts holding the valve body assembly to the transaxle case.
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Remove the valve body assembly from the transaxle case.
Fig. 79: Bushing At The Control Valve

3. Remove and set aside the bushing (1) from the valve body. See Fig. 79.
Fig. 80: Pin At Manual Shaft

4. Remove the pin at the manual shaft using a punch (2). See Fig. 80.
5. Remove the manual shaft from case.
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Fig. 81: Lip Seal At Transaxle Case

Fig. 82: Remove Outer Race

7. Remove outer race (1) of differential side bearing from converter main housing using Puller 9664 and
Puller C-637. See Fig. 82.
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Fig. 83: Select Shim At Transaxle Case

8. Remove the selective shim (1) from the transaxle case. See Fig. 83.
Fig. 84: Pull Outer Race Reduction Gear

9. Remove outer race of reduction gear bearing (1) from transaxle case using Puller C-637 and Puller
7794-A. See Fig. 84.
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0. Remove the selective shim (1) from the transaxle case. See Fig. 85.
Fig. 86: Side Oil Seal At Transaxle Case

CAUTION: When removing the side oil seal, do not damage the transaxle
case.
1. Remove side oil seal (1) from transaxle case using a screwdriver. See Fig. 86.
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Fig. 87: Retaining Plate Of The Reverse Brake

CAUTION: Check if there is damage, deformation, or burning on the surface

of any of the drive or driven plates. Check for permanent fatigue
of the dish plate, driven plates, retaining plate, snap ring, and the
drive plates. Replace all reverse brake components if any of these
conditions exist.
2. Remove the reverse brake snap ring using a screwdriver. Then remove the reverse brake retaining
plate, the drive plates, the driven plates, and the dish plate from the transaxle case. See Fig. 87
Fig. 88: Compress Clutches

CAUTION: Set the spring compressor right on top of the return spring of the
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spring retainer assembly. Do not remove the return springs from

the spring retainer assembly.
3. Compress the reverse brake return spring using Compressor 5058A (1) and Compressor 9875.
Remove the snap ring (2) from the transaxle case. See Fig. 88.
4. Remove the retaining plate and the spring retainer assembly.
Fig. 89: Apply Compressed Air

CAUTION: There is a possibility that the reverse brake piston might be stuck
if excessive pressure is required to remove.
5. Try removing the reverse brake piston from the transaxle case by hand if unable to remove by hand,
apply compressed air to the fluid passage (1) and remove the reverse brake piston from the transaxle
case. See Fig. 89.
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Fig. 90: Bolts At Drive Belt Assembly

6. Remove the case bolts (1) at the drive belt assembly (2). See Fig. 90.
NOTE: Pin at pulley sensor stays with drive belt assembly case.
7. Separate drive belt assembly case from main housing.
Fig. 91: Sheave Retaining Bolts

8. Remove the bolts (2) that hold both sheaves to the case (1). See Fig. 91.
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Fig. 92: Install Puller 9874

CAUTION: Do not allow the Puller 9874 to come in contact with the belt at
any time
9. Install the Puller 9874 (1) and Insert 8513A (2) onto the secondary sheave (3).
Fig. 93: Compress Sheave

CAUTION: Do not over tighten the compressor tool. Tighten to no more than
7 N.m (50 in. lbs.)
NOTE: The belt is directional, look for an arrow indicating the direction of the
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belt for installation
0. Compress sheave (2) to the stop.
Fig. 94: Remove Sheave From Case

CAUTION: Do not allow the primary sheave to contact the drive surface of
the secondary sheave.
NOTE: You may need to lightly tap case while holding secondary sheave.
1. Lift and move the secondary sheave (1) closer to the primary sheave.
Fig. 95: Pin At Sheave Height Sensor

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2. Remove the pin (1) from the sheave height sensor (3).
Fig. 96: Sheave Height Sensor

3. Lift the primary sheave (3) enough to remove the sheave height sensor (1).
Fig. 97: Drive Belt

4. Remove the drive belt (1) from both secondary (3) and primary sheaves (2).
5. Remove the secondary sheave.
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Fig. 98: Shim Under Sheave

6. Remove the shim (3) under the secondary sheave (1).
Fig. 99: Secondary Sheave

7. Remove the primary sheave.

8. Remove bolts at the park pawl.
9. Remove the park pawl.
SEMBLY
TOMATIC-CVT
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. 100: CVT Externals - Exploded View

WASHER 16 - OIL
STRAINER
SHIFT LEVER 17 - PLAIN
WASHER
18 -
INHIBITOR SWITCH MANUAL
LEVER
19 -
CVT FLUID FILTER
BUSHING
20 -
O-RING MANUAL
VALVE
21 - STEPPER
CVT FLUID COOLER
MOTOR
SHIM 22 - LIP
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SEAL
23 - SNAP
OUTPUT SPEED SENSOR
RING
24 - VALVE
O-RING BODY
HARNESS
25 - OIL PAN
- TRANSAXLE
GASKET
- PULLEY RATIO LINKAGE 26 - OIL PAN
27 - TORQUE
- SPRING
CONVERTER
- CONTROL VALVE 28 - O-RING
29 - INPUT
- BRACKET SPEED
SENSOR
- O-RING 30 - O-RING
. 101: CVT Internals - Exploded View

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O-RING 24 - BAFFLE
PLATE
SIDE OIL SEAL 25 - DRIVEN
SPROCKET
(OIL PUMP)
26 - BAFFLE
ADJUSTABLE SHIM
PLATE
27 - OIL
OUTER RACE
PUMP
28 - LIP
REDUCTION GEAR ASSEMBLY
SEAL
29 - SNAP
OUTER RACE
RING
30 - DRIVEN
ADJUSTABLE SHIM
PLATES
31 - NEEDLE
OUTER RACE
BEARING
32 - SUN
DIFFERENTIAL ASSEMBLY
GEAR
33 - NEEDLE
- OUTER RACE
BEARING
34 -
- FORWARD CLUTCH ASSEMBLY PLANETARY
CARRIER
35 - NEEDLE
- NEEDLE BEARING
BEARING
36 - SNAP
- SEAL RING
RING
37 -
- OIL PUMP COVER RETAINING
PLATE
38 - DRIVEN
- BAFFLE PLATE
PLATES
39 - DISH
- BRACKET
PLATE
40 - SNAP
- ADJUSTABLE SHIM
RING
41 -
- ADJUSTABLE SHIM RETAINING
PLATE
42 - SPRING
- CONVERTER HOUSING RETAINER
ASSEMBLY
43 -
REVERSE
- CONVERTER HOUSING OIL SEAL
PLATE
PISTON
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44 - DETENT
- OIL PUMP CHAIN
SPRING
45 -
- DRIVE SPROCKET TRANSAXLE
CASE
- THRUST WASHER -
Fig. 102: Pin At Sheave Height Sensor

2. Install the primary sheave (2) with the sheave height sensor, (3) spring and pin (1) into the belt side
case.
Fig. 103: Shim Under Sheave

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3. Install the secondary sheave positioning shim (3) into the belt side cover.
Fig. 104: Install Puller 9874

4. Install Puller 9874 (1) and Insert 8513 A, (2) onto secondary sheave.
Fig. 105: Drive Belt

5. Move the secondary sheave (3) close enough to the primary (2) sheave to allow the drive belt (1) to be
put around both secondary and primary sheaves.
NOTE: The drive belt is directional and will need to be installed in the same
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direction as noted in disassembly. if installed incorrectly failure will

occur.
6. Install the drive belt (1).
CAUTION: Do not over tighten the compressor tool. Tighten to no more than
7 N.m (50 in. lbs.).
7. Compress the secondary (3) sheave to the stop.

8. Install the drive belt (1) around both secondary (3) and primary (2) sheaves.
9. Install the primary sheave into place.
0. Remove Puller 9874 and Insert 8513A from the primary sheave.
Fig. 106: Sheave Retaining Bolts

1. Install the bolts (2) that hold both sheaves to the case (1).
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Fig. 107: Bolts At Drive Belt Assembly

CAUTION: Remove moisture, oil, and used sealant from the sealant
application surface. Make sure that the starting point and the
ending point are between two bolt holes.
2. Apply Loctite 509 sealer onto the belt side of the transaxle case.
3. Install the belt side assembly to the transaxle case.
4. Install the case bolts (1) to hold the drive belt assembly (2) to the transaxle. tighten to 45 N.m (33
ft.lbs.).
Fig. 108: Reverse Brake Piston

CAUTION: Inspect the reverse brake piston and, if damaged, replace it before
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installation. Apply CVT fluid to the seal when installing the reverse
brake piston.
NOTE: Rotate reverse brake piston into place.
5. Rotate and install the reverse brake piston (1) into the transaxle case. See Fig. 108.
Fig. 109: Retainer Assembly Return Spring

6. Align the return springs (3) of the spring retainer assembly (1) to the locating posts (2) of the reverse
clutch piston. See Fig. 109.
Fig. 110: Retaining Plate At Transaxle

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NOTE: There is a notch in the retaining plate that points to the top of the case.
7. Install the retaining plate (1) into the transaxle case with the notch on the plate to the top (2). See Fig.
110.
Fig. 111: Compress Clutches

CAUTION: Set the spring compressor on top of the spring retainer assembly.
8. Compress the reverse brake return spring using Compressor 5058 A (1) and Compressor 9875 and
install the snap ring into the transaxle case using a screwdriver. See Fig. 111.
Fig. 112: Clutch Disc Stack Up

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9. Install the dish plate (1) with the convex side down onto the reverse brake piston.
0. Install driven plate (2) and then a drive plate (6) until all the driven and drive plates are installed.
1. Install the retaining plate (3) into the reverse brake assembly.
2. Install the reverse brake snap ring (4) into the transaxle case.
Fig. 113: Measure Clearance

CAUTION: When conducting measurements, measure two or more places

and calculate the average value.
3. Measure the clearance between the snap ring and the retaining plate (1). See Fig. 113. The correct
clutch clearance is 1.2-1.5 mm (0.047-0.059 in.). If the clutch clearance is not within specifications,
measure the existing retaining plate and select the correct retaining plate.
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Fig. 114: Needle Bearing At Reverse Brake Piston

CAUTION: Apply Vaseline or assembly lube when installing the needle

bearing. Be careful to verify correct orientation of the needle
bearing when installing it.
NOTE: The inner race will need to face down.
4. Install the needle bearing (1) onto the reverse brake piston. Check for the direction of the needle
bearing while installing. See Fig. 114.
Fig. 115: Planetary Carrier Assembly

NOTE: The inner race will need to face down
5. Install the planetary carrier assembly (1) onto the reverse brake. See Fig. 115.
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Fig. 116: Needle Bearing At Sun Gear


6. Install the needle bearing (1) onto the primary pulley side of the sun gear. See Fig. 116.
Fig. 117: Sun Gear At Planetary Carrier

7. Install the sun gear (1) onto the planetary carrier. See Fig. 117.
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Fig. 118: Needle Bearing At Forward Clutch


NOTE: The inner race will need to face up.
8. Install the needle bearing (1) on the forward clutch drum side of the sun gear. See Fig. 118.
Fig. 119: Forward Clutch Assembly

9. Install the forward clutch assembly (1) into the transaxle case. See Fig. 119.
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Fig. 120: End Play

0. Measure the total end play (2) in the following steps. Total end play should be 0.25 - 0.55 mm (0.010
- 0.022 in).
Fig. 121: Measurement One

NOTE: Gauge Bar 6311 can be used for doing the following measurement.
1. Measure the distance (1) from the oil pump cover installation surface of the transaxle case to the
needle bearing installation surface of the forward clutch drum. Call this measurement one.
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Fig. 122: Measurement Two

2. Measure the distance (1 to 2) as shown in graphic. Call this measurement two.

3. Calculate the bearing thickness required to achieve the necessary end play with the following formula.
The bearing thickness is equal to measurement one, minus measurement two minus, the nominal end
play (0.40 mm or 0.016 "in).
Fig. 123: Needle Bearing On The Forward Clutch Assembly


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4. Install the selected needle bearing (1) on the forward clutch assembly. See Fig. 123.
Fig. 124: Detente Spring

5. Install the detent spring (1) onto the transaxle case. Install the bolt to hold the detent spring to the
transaxle case and tighten the mounting bolt to 7 N.m (61 in.lbs.). See Fig. 124.
Fig. 125: Installing Outer Race Of Differential Bearing Into Converter Housing
6. Install the outer race of the differential bearing (1) into the converter housing using Installer 9668 and
Installer 4628 on 4WD, use Installer 4628 on 2WD and Handle C-4171. See Fig. 125.
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Fig. 126: Measuring For Differential Preload Shim

1 - PRELOAD SHIM
2 - DIFFERENTIAL ASSEMBLY
3 - TRANSAXLE CASE
4 - CONVERTER HOUSING
CAUTION: When adjusting the preload, apply CVT fluid on the bearing to
make it roll smoothly. When conducting measurements, measure
two or more places and calculate the average value.
7. Measure for the differential preload shim (1) in the following steps. Refer to the graphic as necessary
when performing the steps. See Fig. 126.
Fig. 127: Differential Measurement One

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8. The required differential preload is 0.17 to 0.29 mm (0.007 0.011 to in).

9. Measure the distance (1-3) from the edge of the transaxle case to the select shim installation surface.
This is differential measurement one.
Fig. 128: Differential Measurement Two

0. Install the differential assembly on the converter case and measure the distance (differential
measurement two) (1-2) from the differential hub to the surface of the converter housing. See Fig.
128.
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Fig. 129: Differential Measurement Three

1. Install the outer race for the differential side bearing and measure the distance (differential
measurement three) (1-2) from the differential case to the outer race of the differential side bearing.
See Fig. 129.
2. The thickness of the required select shim is calculated as follows: differential measurement one,
minus differential measurement two, plus differential measurement three, plus 0.23 mm (0.009 in).

CAUTION: Do not re-use the select shim.
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3. Install the chosen select shim (1) into the transaxle case. See Fig. 130.
Fig. 131: Install Outer Race On Transaxle Case

4. Install the outer race (1) of the differential bearing on the transaxle case using the Installer D-129 and
Handle C-4171.
Fig. 132: Install Outer Race Reduction Gear Into Converter Housing
5. Install the outer race (1) of the reduction gear bearing into the converter housing using Installer C-
4628 and Handle C-4171. See Fig. 132.
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Fig. 133: Measuring For Reduction Gear Preload Shim

1 - REDUCTION GEAR
2 - TRANSAXLE CASE
3 - PRELOAD SHIM
4 - BEARING OUTER RACE
6. The required preload on the reduction gear assembly is 0.13-0.19 mm (0.005-0.0075 in). Measure for
the required preload shim (3) as follows: See Fig. 133.
Fig. 134: Reduction Assembly Measurement One

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7. Measure the distance (reduction assembly measurement one) (1-2) from the edge of the transaxle case
to the select shim installation surface.
Fig. 135: Reduction Assembly Measurement Two

8. Install the reduction gear assembly on the converter housing and measure the distance (reduction
assembly measurement two) (1-2) from the top of the reduction gear assembly to the edge of the
converter housing. See Fig. 135.
Fig. 136: Reduction Assembly Measurement Three

CAUTION: When adjusting the preload, apply CVT fluid on the bearing to
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make it roll smoothly. When conducting measurements, measure

two or more places and calculate the average value.
9. Install the outer race of the reduction gear bearing and measure the distance (reduction assembly
measurement three) (1-2) from the top of the reduction gear assembly to the outer race of the
reduction gear bearing. See Fig. 136.
0. The thickness of the required select shim is calculated as follows: reduction assembly measurement
one, minus reduction assembly measurement two, plus reduction assembly measurement three, plus
0.16 mm (0.006 in).

CAUTION: Do not re-use the select shim.
1. Install the chosen select shim (1) into the transaxle case. See Fig. 137.
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Fig. 138: Install Outer Race On Transaxle Case

2. Install the outer race (1) of the reduction gear bearing on the transaxle case using Installer C-4628 and
Handle C-4171. See Fig. 138.
Fig. 139: Lip Seal At The Transaxle Case

CAUTION: Do not re-use the lip seal. Apply CVT fluid when installing the lip
seal.
3. Install the new lip seal (1) on the transaxle case. See Fig. 139.
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Fig. 140: O-Ring At The Oil Pump Mounting

CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the O-
ring.
4. Install the new o-ring (1) onto the oil pump mounting bolts. (Only for bolts installed from the outside
of the transaxle case). See Fig. 140.
Fig. 141: Oil Pump Retaining Bolts

NOTE: One of the oil pump retaining bolts is installed from the outside of the
transaxle case in the rear part of the oil pump.
5. Install the oil pump on the transaxle case. Install and tighten the mounting bolts (1) to 19 N.m (14 ft.
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lbs.) Install and tighten the mounting bolt (2) to 28 N.m (20 ft. lbs.). See Fig. 141.

CAUTION: Do not re-use the lip seal. Apply CVT fluid when installing the lip
seal.
6. Install the new lip seal (1) into the transaxle case. See Fig. 142.
Fig. 143: Pin At Manual Shaft

7. Install the manual shaft (1) into the case.

8. Install the pin at the manual shaft using a punch (2).
9. To install the valve body assembly on to the transaxle case, insert a 75 mm (3 in.) long 3 mm (0.118
in.) wide rod or wire into the linkage stopper hole of the valve body assembly to set the pulley ratio
linkage (1) in position.
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Fig. 144: Position Terminal Body

0. Position the locating tab (1) of the terminal body and install the terminal body into the transaxle case.
See Fig. 144.

1. Install the valve body assembly (1) up from the bottom side and install it into the transaxle case. See
Fig. 145.
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Fig. 146: Aligning Notch Of Pulley Ratio Linkage

2. Align the notch (1) of the pulley ratio linkage with the sheave position sensor (2). See Fig. 146.

CAUTION: Apply CVT fluid when installing the bushing.
3. Install the bushing (1) into the valve body assembly. See Fig. 147.
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4. Tighten the mounting bolts of the valve body assembly to 8 N.m (70 in. lbs).

5. Install the manual lever (1) onto the manual shaft. Install and tighten the mounting nut to 22 N.m 194
in. lb. See Fig. 149.
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6. Install the bracket (1) onto the valve body assembly. Install and tighten the mounting bolts to 8 N.m
(70 in. lbs.). See Fig. 150.
Fig. 151: Oil Strainer O - Ring

CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-
ring.
7. Install the new o-ring (1) onto the new oil strainer. See Fig. 151.
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8. Install the new oil strainer (1) onto the valve body assembly. Install and tighten the mounting bolts to
8 N.m (70 in. bs.). See Fig. 152.

CAUTION: Do not re-use the oil pan gasket. Remove any moisture, oil, and
used gasket material from the surface where the new gasket is to
be installed. When installing the oil pan gasket, align the dowel
pin with the dowel pin hole in the oil pan gasket.
9. Install the oil pan gasket (1) onto the transaxle case. See Fig. 153.
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Fig. 154: Oil Pan

CAUTION: When installing the oil pan, align the dowel pin of the transaxle
case with the dowel pin hole of the oil pan.
0. Install the oil pan on the transaxle case (1). See Fig. 154. Install and tighten the mounting bolts to 8
N.m (70 in. lbs.).

1. Install the snap ring (1) onto the terminal body. See Fig. 155.
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Fig. 156: Seal Rings

CAUTION: Do not re-use the seal rings. Apply Vaseline or assembly lube
when installing the seal rings.
2. Install the new seal rings (1) onto the reaction shaft support. See Fig. 156.
Fig. 157: Reaction Shaft Support

3. Install the reaction shaft support (1) onto the transaxle case temporarily with the mounting bolts. See
Fig. 157.
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4. Install the baffle plate (1) temporarily with the mounting bolts. See Fig. 158.

5. Install the baffle plate (1). See Fig. 159. Install and tighten the mounting bolts to 6 N.m (52 in. lbs.).
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Fig. 160: Bracket

6. Install the bracket (1) as shown in graphic. Tighten the mounting bolts of the oil pump cover, baffle
plate, and brackets to 26 N.m (19 in. lbs.). See Fig. 160.
Fig. 161: Snap Ring At Oil Pump

7. Install the snap ring (1) into the oil pump. See Fig. 161.
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Fig. 162: Thrust Washer At Oil Pump Cover

CAUTION: Be sure to align the pawl of the thrust washer with the alignment
hole of the oil pump cover. Apply Vaseline or assembly lube when
installing the thrust washer.
8. Install the thrust washer (1) onto the oil pump cover. See Fig. 162.
Fig. 163: Oil Pump Chain

CAUTION: When necessary to replace any of the driven sprocket, oil pump
chain, or drive sprocket, replace all components as a matched set.
Pull the driven sprocket up softly and check that the driven
sprocket is securely installed.
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9. Expand the snap ring (1).

0. Install the driven sprocket, oil pump chain (2) and drive sprocket (3).
Fig. 164: Measuring Clearance Between Oil Pump Drive Sprocket And Converter Housing
1. The required clearance for the oil pump drive sprocket is 0.10-0.23 mm (0.004-0.009 in.). Measure
the clearance (1) between the oil pump drive sprocket (4) and the converter housing (5) in the
following procedure: See Fig. 164.
Fig. 165: Oil Pump Drive Sprocket Measurement One

2. Measure the distance (1-2) from the edge of the transaxle case to the select shim installation surface of
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the drive sprocket. This is the oil pump drive sprocket measurement one. See Fig. 165.
Fig. 166: Oil Pump Drive Sprocket Measurement Two

3. Measure the distance (1-2) from the edge of the converter housing to the surface touching the select
shim contact surface. This is the oil pump drive sprocket measurement two. See Fig. 166.
4. Calculate the thickness of the required select shim with the following formula: The select shim is
equal to the oil pump drive sprocket measurement one, plus the oil pump drive sprocket measurement
two, minus 0.16 mm (0.0065 in.).
Fig. 167: Adjusting Shim At Drive Sprocket

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5. Install the chosen select shim (1) onto the drive sprocket. See Fig. 167.
Fig. 168: Baffle Plate

6. Install the baffle plate (1) over the oil pump driven sprocket. Install and tighten the mounting nut to 6
N.m (52 in. lbs.). See Fig. 168.
Fig. 169: Input Shaft O-Ring

ring.
7. Install the new o-ring (1) onto the input shaft. See Fig. 169.
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Fig. 170: Differential Assembly

8. Install the differential assembly (1) into the transaxle case. See Fig. 170.
Fig. 171: Reduction Gear Assembly

9. Install the reduction gear assembly (1) into the transaxle case. See Fig. 171.
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Fig. 172: Install Converter Housing Oil Seal

CAUTION: Do not re-use the converter housing oil seal (1). Apply CVT fluid
when installing the converter housing oil seal (1).
0. Install the converter housing oil seal (1) into the converter housing with Installer 9858. See Fig. 172.
Fig. 173: Apply MOPAR gasket sealer

1. Apply MOPAR gasket sealer (1) on the converter housing installation surface of the transaxle case.
See Fig. 173.
CAUTION: Remove moisture, oil, and used sealant from the sealant
application surface. Make sure that the starting point and the
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ending point are between two bolt holes.
Fig. 174: Converter Housing Mounting Bolts

2. Install the converter housing on the transaxle case and tighten the bolts to 45 N.m (33 ft. lbs.).

3. Install the transmission range sensor (TRS) (1) over the manual shaft and onto the transaxle case. See
Fig. 175.
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Fig. 176: TRS Adjustment Tool

CAUTION: Do not re-use the TRS transmission range sensor.
4. Put the manual shaft in the N position (3). See Fig. 176. Install Park Neutral Switch Adjustment Tool
9876 (2) and adjust the position of the TRS (1).
Fig. 177: Bolts At TRS

5. Install and tighten the mounting bolts of the TRS to 6 N.m (49 in. lbs.).
6. Remove the TRS alignment tool from the TRS.
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7. Install the shift lever (1) onto the manual shaft. Install and tighten the mounting nut to 17 N.m (150 in.
lbs.). See Fig. 178.
Fig. 179: Input Speed Sensor O-Ring

ring.
8. Install the o-ring (1) onto the input speed sensor. See Fig. 179.
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Fig. 180: Input Speed Sensor

9. Install the input speed sensor (1) into the transaxle case. Install and tighten the mounting bolt to 6 N.m
(52 in. lbs.). See Fig. 180.
Fig. 181: Output Speed Sensor O-Ring

ring.
0. Install the new o-ring (1) onto the output speed sensor. See Fig. 181.
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Fig. 182: Output Speed Sensor

CAUTION: Be sure to install the select shim between the secondary speed
sensor and the converter housing before installing the secondary
speed sensor.
1. Install the output speed sensor (1) into the converter housing. Install and tighten the mounting bolt to
6 N.m (52 in lbs.). See Fig. 182.

CAUTION: Apply CVT fluid on the seal part when installing the CVT fluid
filter.
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2. Install the CVT fluid filter (1) into the transaxle case. See Fig. 183.
Fig. 184: CVT Fluid Filter O-Ring

ring.
3. Install the new o-ring (1) onto the CVT fluid filter.
Fig. 185: Fluid Cooler

4. Install the CVT fluid cooler (1) onto the transaxle case. Install and tighten the mounting bolts to 4
N.m (37 in.lbs.). See Fig. 185.
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Fig. 186: 9878 Transmission Service Stand

5. Remove the Transmission Service Stand 9878 (1) from the Belt side of the transmission case.
Fig. 187: Measure Torque Converter To Transmission

NOTE: When conducting measurements, measure two or more places and

calculate the average value.
6. Install the torque converter on the transaxle and measure the dimension (1) to see if it is at least 13
mm. If the measurement is less than 13 mm, the torque converter is not fully installed. See Fig. 187.
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NOTE: Use the designated brand of CVT fluid. Use of other brands of CVT fluid
other than the designated brand will deteriorate the driveability and the
durability of the CVT, and will cause damage to the CVT.
7. Fill the transaxle with CVT fluid. See STANDARD PROCEDURE.
STALLATION
TOMATIC-CVT
. 188: Bell Housing Bolt Holes

OTE: Refer to the following chart when the Transmission Control Module (TCM)
and/or transaxle has been replaced to determine if the TCM memory must be
erased.
TCM Transaxle Erase Memory?

Not
New Module Not Required
Replaced
Not Replaced Replaced
Relearn Required. Refer to STANDARD
Replaced With Used PROCEDURE .
N/A
Module
OTE: Verify that both dowel pins are present in the engine before installing the
transmission.
1. Install the transmission cooler lines (1, 2).

2. Install the lower transmission bell housing bolts (2) and tighten to 48 N.m (35 ft. lbs.). See Fig. 188.
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Fig. 189: Jack At Trans Mount

3. Raise the transmission using a screw jack (2). See Fig. 189.
Fig. 190: Front Engine Mount

4. Install the transmission crossmember and bolts, (2) tighten to 75 N.m (55 ft lbs.). See Fig. 190.
5. Install the through bolt at the front transmission mount (1) and tighten to 75 N.m (55 ft lbs.).
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Fig. 191: Rear Engine Mount

6. Install rear mount through bolt (1) and tighten bolt to 75 N.m (55 ft lbs.).
Fig. 192: 2WD REAR MOUNT

7. Install rear mount to transaxle and tighten bolts (1) to 75 N.m (55 ft lbs.). See Fig. 192.
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Fig. 193: Torque Converter Bolts

8. Install new converter bolts (1) and tighten to 48 N.m (35 ft. lbs.). See Fig. 193.
Fig. 194: Inspection Cover

9. Install cover at torque converter (1). See Fig. 194.

0. Install the PTU if equipped. Refer to INSTALLATION .
1. Install the right front lower splash shield.
2. Install the left front lower splash shield.
3. Install left half and right half shafts to the transaxle. Refer to INSTALLATION .
4. Install both front wheels. Refer to REMOVAL .
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5. Lower hoist.
6. Install upper bell housing bolts (1) and tighten to 48 N.m (35 ft. lbs.).
Fig. 196: Top CVT Trans Mount

7. Install the upper mount bolts and tighten to 75 N.m (55 ft lbs.).
8. Install the upper mount through bolt and tighten 75 N.m (55 ft lbs.).
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Fig. 197: Throttle Body Support Bracket

9. Install the throttle body support bracket (1) and tighten to 11 N.m (105 in. lbs.). See Fig. 197.
Fig. 198: Vent Tube

0. Connect the transmission vent tube (1). See Fig. 198.
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Fig. 199: Heater Hose To Trans Cooler

1. Install the heater hose at transmission cooler tube (3). See Fig. 199.

2. Connect coolant lines at transmission cooler. See Fig. 200.
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3. Install the shifter cable (1) and bracket (2), tighten nut to 11 N.m (105 in. lbs.). See Fig. 201.
4. Install the vacuum supply lines.

5. Install intake air tube (1). See Fig. 202.

6. Fill engine coolant. Refer to STANDARD PROCEDURE .
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7. Install the battery tray (1). See Fig. 203.

8. Install the battery.
Fig. 204: Air Cleaner Assembly

9. Install the air cleaner assembly (1). See Fig. 204.

0. Connect battery cables (2).
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Fig. 205: Fill Tube

1. Install the transmission fill tube (1) tighten bolt to 9 N.m (79 in. lbs.). See Fig. 205.
2. Fill the transmission with fluid to the correct level.
CAUTION: Use only MOPAR ® CVTF +4, use of any other type of automatic
transmission fluid may cause damage to the CVT.
3. Road test vehicle and inspect for leaks.
ECIFICATIONS
TOMATIC-CVT
EARANCES
DESCRIPTION SPECIFICATION
rward clutch 1.2-1.5 mm (0.047-0.059 in.)
tal end play 0.25 - 0.55 mm (0.010 - 0.022 in)
quired differential preload 0.17 to 0.29 mm (0.007 to 0.011 in)
quired preload, Reduction gear 0.13-0.19 mm (0.005-0.0075 in)
Reduction assembly measurement , minus
duction Assembly required select shim reduction assembly measurement, plus reduction
assembly measurement, plus 0.16 mm (0.006 in).
0.10-0.23 mm (0.004-0.009 in.) The select shim is
equal to the oil pump drive sprocket measurement
quired clearance, Oil pump drive sprocket
one plus the oil pump drive sprocket
measurement, two minus 0.16 mm (0.0065 in.).
rque converter installed depth at least 13 mm
RQUE
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DESCRIPTION N-m Ft. Lbs. In. Lbs.

bolts, drive belt 45 33 -
sembly - to - transaxle
case
Bolt, Detent spring to
7 - 61
case
Bolts, oil pump - to - 19 14 168
transaxle case
Bolt, oil pump - to -
28 20 247
ansaxle case (outside )
Bolts, Valve body
8 - 70
assembly - to - case
ut, Valve body manual
22 16 194
ver - to - manual shaft
Bolts, Oil strainer to
8 - 70
valve body
Bolts, oil pan - to -
8 - 70
transaxle case
Bolts, baffle plate 6 - 52
Bolts, oil pump cover 26 19 230
olts, Bracket oil pump
26 19 230
cover - to oil pump
Bolts, Baffle plate 26 19 230
olts, Baffle plate at oil
6 - 52
ump driven sprocket
lts, Converter housing
45 33 398
- to - transaxle case
Bolts, TRS 6 - 49
Nut, Shift lever to
17 13 150
manual shaft
olt, Speed input sensor
6 - 52
- to - transaxle case
Bolt, Speed output
ensor - to - transaxle 6 - 52
case
olts, Fluid cooler - to -
4 - 37
transaxle case
olts, transmission bell
48 35 -
housing - to - engine
Bolts, Transmission
75 55 -
crossmember
t, Rear mount through
75 55 -
bolt
Bolts, Rear mount to
75 55 -
transaxle
olts, Torque converter 48 35 -
Bolts, Upper
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transmission mount 75 55 -
Bolts, PTU support
68 50 -
bracket
lt, Catalytic Converter
28 - 250
Support Bracket
Nut, Upper mount
75 55 -
through bolt
Bolts, Throttle body
11 - 105
support bracket
Nut, Shifter cable 11 - 105
olts, Transmission fill
9 - 79
tube
Nut, Reduction gear 250 185 -
olts, Shifter - to - floor 70 52 -
olts, Bracket to Valve
8 70 -
Body
ECIAL TOOLS
TOMATIC-CVT
. 206: Installer 9714


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. 208: Spline Socket 9743



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. 212: Seal Installer 9871

. 213: Pressure Gauge 9873

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. 214: Sheave Compressor 9874

. 215: Compressor 9875

. 216: Park Neutral Switch Adjustment

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. 217: Seal Installer 9877

. 218: Bearing Installer 9919

. 219: Puller 7794-A

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. 220: Puller C-637

. 221: Remover, 9664

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. 222: Compressor 5058A

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. 223: Crankshaft Damper Removal Insert 8513

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. 224: Gauge Bar - 6311

. 225: Service Stand 9878

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. 226: Race Remover/Installer 9668

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. 227: Installer D-130

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. 228: Bearing Installer C-4628

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. 229: Compressor, Multi-Use Spring - 8900

. 230: Puller C-293-PA

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. 231: Inserts C-293-40

. 232: Insert C-4996

. 233: Inserts 9613

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. 234: Plug 8888

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. 235: Button 8923

. 236: Splitter 1126

. 237: Installer L-4507

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. 238: Installer C-3716-A

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. 239: Ball Joint Installer/Remover - 9333

. 240: Puller/Slide Hammer C-3752

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. 241: Seal Remover 9667

UTCH-FORWARD
SASSEMBLY
RWARD CLUTCH
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. 242: Exploded View Of Forward Clutch

Snap Ring 7-
Snap
Ring
Forward Clutch Drum 8-
Snap
Ring
9-
Input Shaft Internal
Gear
10 -
Dish Plate Snap
Ring
11 -
Driven Plate Drive
Plate
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Retaining Plate -
OTE: Refer to the exploded views above as necessary when performing the
following steps.
. 243: Forward Clutch Snap Ring

1. Remove the snap ring (1) from the forward clutch drum using a flat head screwdriver.
Fig. 244: Internal Gear At Forward Clutch

2. Remove the internal gear (1) from the forward clutch drum.
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Fig. 245: Snap Rings At Forward Clutch Drum

3. Remove the snap rings (1) from the forward clutch drum using a flat head screwdriver.
Fig. 246: Plates

4. Remove the retaining plate (1), the drive and driven plates (3), and the dish plate (2) from the forward
clutch drum (4).
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Fig. 247: Input Shaft Snap Ring

CAUTION: Do not expand the snap ring beyond necessity and do not deform
it.
5. Remove the snap ring (1), and remove the input shaft (2) from the forward clutch drum.
Fig. 248: Bottom Of Compressor

6. Place bottom of Compressor 8900 (1) in Vice (2).
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Fig. 249: Drum Over Compressor Bottom

7. Place the drum (1) over Compressor bottom 8900 in Vice (2).
Fig. 250: Compressor Top

8. Place correct ring (1) that comes with Compressor 8900 in drum (3).
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Fig. 251: Compress Drum

9. Install threaded rod (1) that comes with Compressor 8900 (2) in drum (3).
0. Compress tool until the snap ring (4) can be removed.
Fig. 252: Compressor 8900

1. Use snap ring pliers or a small screw driver to remove the snap ring (3) from the piston (1).
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Fig. 253: Snap Ring

2. Remove snap ring.
Fig. 254: Piston

3. Remove the piston (1) from the drum (3).

4. Remove the spring assembly (2) form the drum (3).
SPECTION
RWARD CLUTCH
1. Check driven plate, drive plate, retaining plate and forward clutch drum for damage, distortion or
burnt surfaces.
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2. Check snap ring and dish plate for damage, distortion or permanent fatigue.
3. Check input shaft and internal gear for damage and distortion.
SEMBLY
RWARD CLUTCH
. 255: Exploded View Of Forward Clutch

Snap Ring 7-
Snap
Ring
Forward Clutch Drum 8-
Snap
Ring
Input Shaft 9-
Internal
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Gear
10 -
Dish Plate Snap
Ring
11 -
Driven Plate Drive
Plate
Retaining Plate -

1 - SNAP RING
2 - RETAINING PLATE
3 - DRIVEN PLATE
4 - DRIVE PLATE
5 - DISH PLATE
6 - FORWARD CLUTCH PISTON
2. Refer to this view above as necessary when performing the following steps.
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Fig. 257: Spring

3. Install the spring assembly (1) into the drum (2).
Fig. 258: Piston

4. Install the piston (1) into the drum (3).
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Fig. 259: Snap Ring

5. Lay the snap ring onto the piston.

6. Install Compressor 8900.
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Fig. 261: Compress Drum

7. Compress the piston.

8. Use snap ring pliers or a small screw driver to install the snap ring (3) onto the piston (1).
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1 - SNAP RING
2 - RETAINING PLATE
3 - DRIVEN PLATE
4 - DRIVE PLATE
5 - DISH PLATE
6 - FORWARD CLUTCH PISTON
CAUTION: Install so that the installation order of each plate is correct.
9. Install the dish plate (5), the driven plate (3), the drive plate (4), the retaining plate (2) and one piece
of the snap ring (1), in the forward clutch piston (6).
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Fig. 264: Retaining Plate Clearance

CAUTION: When conducting measurements, measure two or more places

and calculate the average value. If clearance is beyond standard
value, replace the forward clutch assembly.
0. Measure the clearance between the snap ring (1) and the retaining plate (2). the correct clutch
clearance is 1.2-1.5 mm (0.047-0.059 in.).
Fig. 265: Input Shaft Snap Ring

CAUTION: Do not expand the snap ring beyond level required to install and
do not deform it.
1. Install the input shaft (2) in the forward clutch drum, and install the snap ring (1).
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Fig. 266: Snap Rings At Forward Clutch Drum

2. Install one piece of the snap ring (1) into the forward clutch drum.
Fig. 267: Internal Gear At Forward Clutch

3. Install the internal gear (1) into the forward clutch drum.
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Fig. 268: Forward Clutch Snap Ring

4. Install the snap ring (1) in the forward clutch drum.
UID
AGNOSIS AND TESTING
USES OF BURNT FLUID
rnt, discolored fluid is a result of overheating which has three primary causes.
Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or
clutch seal failure.
A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the
result of a faulty or damaged oil cooler, or severe restrictions in the coolers and lines caused by debris
or kinked lines.
Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing
or similar high load operation will overheat the transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling
system, and the engine/axle ratio combination needed to handle heavy loads.
FECTS OF INCORRECT FLUID LEVEL
ow fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid
ssures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the
d into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either
e, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and
tch operation. Foaming also causes fluid expansion which can result in fluid overflow from the
nsmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful.
UID CONTAMINATION
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nsmission fluid contamination is generally a result of:
adding incorrect fluid

failure to clean dipstick and fill tube when checking level
engine coolant entering the fluid
internal failure that generates debris
overheat that generates sludge (fluid breakdown)
failure to replace contaminated converter after repair
e use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts,
page, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this
dition by using recommended fluids only.
e dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other
eign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to
pe the cap and tube clean before withdrawing the dipstick.
gine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to
lace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the
nsmission, an overhaul is necessary.
e torque converter should be replaced whenever a failure generates sludge and debris. This is necessary
ause normal converter flushing procedures will not remove all contaminants.
ANDARD PROCEDURE
ECK OIL LEVEL
1. Verify that the vehicle is parked on a level surface.

2. Remove the dipstick tube cap.
WARNING: There is a risk of accident from vehicle starting off by itself when
engine is running. There is a risk of injury from contusions and
burns if you insert your hands into the engine when it is started
or when it is running. Secure vehicle to prevent it from moving off
by itself. Wear properly fastened and close-fitting work clothes.
Do not touch hot or rotating parts.
3. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P".
4. Shift through the transmission modes several times with the vehicle stationary and the engine idling.
5. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine running.
Push the Oil Dipstick 9336 into transmission fill tube until the dipstick tip contacts the oil pan and
pull out again, read off oil level, repeat if necessary.
NOTE: The dipstick will protrude from the fill tube when installed.
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Fig. 269: CVT TRANSMISSION FILL GRAPH

6. Check transmission oil temperature using the appropriate scan tool.

7. The transmission Oil Dipstick 9336 has indicator marks every 10 mm. Determine the height of the oil
level on the dipstick and using the height, the transmission temperature, and the Transmission Fluid
Graph, determine if the transmission oil level is correct. See Fig. 269.
8. Add or remove oil as necessary and recheck the oil level.
9. Once the oil level is correct, install the dipstick tube cap.
UID AND STRAINER SERVICE
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. 270: Oil Pan


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ring.
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8. Install the new oil strainer (1) onto the control valve assembly. Install and tighten the mounting bolts
to 8 N.m (70 in. lbs.). See Fig. 274.

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Fig. 276: Oil Pan

N.m (70 in.lbs.).
NOTE: Only transmission fluid of the type labeled Mopar® CVTF+4 (Automatic
Transmission Fluid) should be used in this transaxle.
1. Check the oil level. See STANDARD PROCEDURE.
ANSMISSION FILL
avoid overfilling transmission after a fluid change or overhaul, perform the following procedure:
1. Verify that the vehicle is parked on a level surface.

2. Remove the dipstick tube cap.
3. Add following initial quantity of MOPAR® CVTF+4, Automatic Transmission Fluid, to the
transmission:
If only fluid and filter were changed, add 7.0 L (14.8 pts.) of transmission fluid to transmission.
If the transmission was completely overhauled or the torque converter was replaced or drained,
add 8.1 L (17.1 pts.) of transmission fluid to transmission.
4. Check the transmission fluid. See STANDARD PROCEDURE, and adjust as required.
DY-VALVE
ERATION
LVE BODY
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tline of the Functions of the Main Components
mponent Function
rque converter Optimizes the supply pressure for the torque converter depending on driving
gulator valve conditions.
utch regulator
Adjusts the clutch operating pressure depending on operating conditions.
ve
essure regulator Optimizes the discharge pressure (line pressure) from the oil pump depending
ve on driving conditions.
Controls flow-in/out of line pressure to/from the primary pulley depending on
ift control valve
the stroke difference between the stepping motor and the primary pulley.
ck-up/Select Switches use of the lock-up solenoid control pressure between
itch solenoid applying/releasing lock-up and engaging/releasing the forward/reverse clutch
ve (the forward clutch and the reverse brake).
Switches use of the lock-up solenoid control pressure between
lect switch valve applying/releasing lock-up and engaging/releasing the forward/reverse clutch
(the forward clutch and the reverse brake).
ne pressure
Controls the line pressure control valve.
enoid valve
ck-up solenoid
Controls the lock-up control valve.
ve
ck-up/Select
itch solenoid Controls the select switching valve.
ve
epping motor Controls the pulley ratio.
condary valve Reduces the line pressure and adjusts the secondary pressure.
Engages when making a selection. Adjusts the forward clutch pressure and the
lect control valve
reverse brake pressure.
ck-up control
Adjusts engaging/releasing pressure for the torque converter.
ve
condary pressure Controls flow-in/out of line pressure to/from the secondary pulley depending on
enoid valve driving conditions.
MOVAL
LVE BODY
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. 277: Oil Pan


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7. Remove the bolts holding the bracket (1) to the valve body assembly. See Fig. 280.
8. Remove the bracket from the valve body assembly.
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9. Remove the nut holding the manual lever (1) to the manual shaft. See Fig. 281.
0. Remove the manual lever from the manual shaft.

CAUTION: Tilt the valve body assembly away from the transaxle case on the
manual shaft side to ease removal. Pay attention to completely
remove the terminal body from the transaxle case.
1. Remove the valve body assembly from the transaxle case as follows:
Insert a 75 mm (3 in.) long 3 mm (0.118 in.) wide rod or wire into the linkage stopper hole of
the valve body assembly to fix the pulley ratio linkage (1). See Fig. 282.
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Remove the bolts holding the valve body assembly to the transaxle case.
Remove the valve body assembly from the transaxle case.
SASSEMBLY
LVE BODY
. 283: Bushing At The Control Valve

1. Remove and discard the bushing (1) from the valve body. See Fig. 283.

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Fig. 285: Pulley Ratio Linkage

CAUTION: Do not drop the pulley ratio linkage.
3. Remove the pulley ratio linkage (1) from the valve body. See Fig. 285.
Fig. 286: Return Spring At The Control Valve

4. Remove the return spring (1) from the valve body. See Fig. 286.
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Fig. 287: Manual Valve

CAUTION: Do not drop the manual valve.
5. Remove the manual valve (1) from the valve body. See Fig. 287.
Fig. 288: Valve Body Harness

6. Remove the valve body harness (1) from the valve body. See Fig. 288.
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Fig. 289: Stepping Motor

7. Remove the stepping motor (1) from the valve body. See Fig. 289.
SEMBLY
LVE BODY
. 290: Lip Seal At Transaxle Case

CAUTION: Do not re-use the lip seal. Apply CVT fluid when installing the lip seal.
1. Install the new lip seal (1) into the transaxle case. See Fig. 290.
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Fig. 291: Stepping Motor

2. Install the stepping motor (1) onto the control valve body. Install and tighten the mounting bolts to 8
N.m (70 in. lbs.). See Fig. 291.
Fig. 292: Valve Body Harness

3. Install the valve body harness (1) onto the control valve body. See Fig. 292.
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Fig. 293: Manual Valve

CAUTION: Ensure the manual valve is free of dirt, lint or other debris. Apply
CVT fluid when installing the manual valve.
4. Install the manual valve (1) into the control valve body. See Fig. 293.
Fig. 294: Return Spring At The Control Valve

5. Install the return spring (1) into the control valve body. See Fig. 294.
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Fig. 295: Pulley Ratio Linkage

CAUTION: Apply CVT fluid when installing the pulley ratio linkage.
6. Hook the pawl of the pulley ratio linkage (1) onto the stepping motor and install it on the control
valve. See Fig. 295.
STALLATION
LVE BODY
. 296: Control Valve Assembly

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1. To install the control valve body assembly on to the transaxle case, insert a 75 mm (3 in.) long 3 mm
(0.118 in.) wide rod or wire into the linkage stopper hole of the control valve assembly to set the
pulley ratio linkage (1) in position. See Fig. 296.
Fig. 297: Position Terminal Body

2. Position the locating tab (1) of the terminal body as shown in graphic and install the terminal body
into the transaxle case. See Fig. 297.

3. Install the control valve assembly (1) up from the bottom side and install it into the transaxle case. See
Fig. 298.
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Fig. 299: Aligning Notch Of Pulley Ratio Linkage

4. Align the notch (1) of the pulley ratio linkage with the sheave position sensor (2). See Fig. 299.

CAUTION: Apply CVT fluid when installing the bushing.
5. Install the bushing (1) into the control valve assembly. See Fig. 300.
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6. Tighten the mounting bolts of the control valve body assembly to 8 N.m (70 in. lbs).

7. Install the manual lever (1) onto the manual shaft. Install and tighten the mounting nut to 22 N.m (16
in. lbs.). See Fig. 302.
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8. Install the bracket (1) onto the control valve assembly. Install and tighten the mounting bolts to 8 N.m
(70 in. lbs.). See Fig. 303.

ring.
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0. Install the new oil strainer (1) onto the control valve assembly. Install and tighten the mounting bolts
to 8 N.m (70 in. lbs.). See Fig. 274.

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Fig. 307: Oil Pan

N.m (70 in. lbs.).

3. Install the snap ring (1) onto the terminal body. See Fig. 308.
4. Fill transmission with the required fluid. See STANDARD PROCEDURE.
ECHANISM-SHIFT
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MOVAL
FT MECHANISM
. 309: Center Console Housing Screws

1. Remove shift knob and shift bezel. Refer to REMOVAL .

2. Remove two screws (1).
Fig. 310: Center Console

3. Pull on side of housing (1) and unsnap housing tabs.

4. Disconnect console housing wire connector (2) and instrument panel connector (3).
5. Remove from vehicle.
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Fig. 311: Shifter Hold Down Bolts

6. Remove the bolts (1) at the shifter.

7. Separate the shift cable from the shifter.
Fig. 312: Shifter

8. Lift the shifter enough to gain access to electrical connector.
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Fig. 313: Electrical Connector At Shifter

9. Unplug the electrical connector at the shifter.

0. Remove the shifter.
STALLATION
FT MECHANISM
. 314: Electrical Connector At Shifter

1. Plug the electrical connector in at the shifter.
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Fig. 315: Shifter

2. Install the shifter in place.

3. Clip the shift cable to the shifter.

4. Install the shifter bolts and tighten to 70 N.m (52 ft. lbs.).
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5. Place console housing (1) over shifter lever ensuring console tabs seat properly.
Fig. 318: Center Console Housing Screws

6. Install screws (1).

7. Replace shift bezel and knob. Refer to INSTALLATION .
ABLE-GEAR SHIFT
MOVAL
AR SHIFT CABLE
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1. Remove the air box (1). See Fig. 319.

2. Disconnect the negative battery cable (2).

3. Remove shifter cable (2) at transmission bracket (3). See Fig. 320.
4. Remove the nut (4) on the shifter cable to shift lever.
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Fig. 321: Shifter Cable Grommet

5. Remove the grommet (1) at the bulkhead.

6. Remove the shifter. See REMOVAL.
Fig. 322: Shifter Cable Clip At Floor

7. Squeeze clip (2) at cable (1).
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Fig. 323: Clip And Cable

8. Pull cable from bracket (2) at bulkhead (1).

9. Loosen the hold down bolts at the air bag module. Refer to REMOVAL .
Fig. 324: Shifter Cable

0. Pull the cable (1, 2) through the bulkhead into the engine compartment.
STALLATION
AR SHIFT CABLE
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. 325: Shifter Cable

1. Install the shifter cable (1, 2) through the bulkhead and into the passenger compartment.
Fig. 326: Clip And Cable

2. Install the cable into the bracket (2) at bulkhead (1).
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Fig. 327: Shifter Cable Clip At Floor

3. Insure that the cable clips into place.

4. Tighten the hold down bolts at the air bag module. Refer to INSTALLATION .
5. Install the shifter. See INSTALLATION.
Fig. 328: Shifter Cable Grommet

6. Install the shifter cable grommet (1) at the bulkhead.
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7. Clip the cable (2) into the bracket (1) install the nut (4) over the shifter cable at the transmission shift
lever. See ADJUSTMENTS.
Fig. 330: Air Cleaner Assembly

8. Connect the negative battery cable (2).

9. Install the air box (1)
JUSTMENTS
JUSTMENTS
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. 331: Shifter Cable And Bracket

1. Place TRS switch and selector lever in the PARK position.

2. Loosen the nut (4) that holds the shifter cable to the manual lever.
3. While pressing the manual lever towards the front of the vehicle in the PARK position direction,
tighten the nut to 13 N.m (10 ft. lbs.).
4. Make sure that the park system is engaged when lever is placed in the PARK position.
5. Place the selector lever in PARK position and turn the ignition switch to on position (engine not
running).
6. Make sure that the selector lever can be shifted to a different position other than PARK when the
brake pedal is depressed. Also make sure the lever can be shifted from PARK only when the brake
pedal is depressed.
7. Move and check for excessive effort, sticking, noise or rattle.
8. Confirm that the selector lever stops at each position with the feel of engagement when it is moved
through all the positions. Check whether or not the actual position the selector lever is in matches the
position shown by the shift position indicator and the transaxle valve body.
9. Confirm that the backup lamps illuminate only when the lever is placed in the REVERSE position.
Confirm the backup lamps do not illuminate when the lever is placed in the PARK or NEUTRAL
positions with the lever pushed against the REVERSE position.
0. Confirm the engine will only start when the lever is placed in the PARK or NEUTRAL positions.
IFT INTERLOCK CABLE
SCRIPTION
SCRIPTION
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. 332: Shifter's Serpentine Pattern

e Shifter's serpentine pattern does not require the shifter to have a button on the knob to release it from
rk". There is a blocking lever within the Shifter that prevents undesired shifting out of "Park".
. 333: Park Lock Lever And Bushing

PARK LOCK LEVER

PARK LOCK LEVER TRAVEL STOP
SOLENOID SHAFT
SOLENOID BUSHING
e shifter has a solenoid which is actuated by depressing the brake pedal. This prevents shifting out of
rk" without the brake pedal being depressed. To operate the solenoid, the ignition must be in the "On" or
un" position and the brake pedal must be depressed. The Brake Switch sends a signal to the Cabin
mpartment Node (CCN) and the CCN, in turn, energizes the solenoid that moves the Park Lock Lever to
ow the driver to shift out of 'Park". On the right side of the Console Pod is a plug that allows access to the
k Lock Lever for manual operation.
AGNOSIS AND TESTING
AGNOSIS & TESTING
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. 334: KEY LOCK CABLE ADJUSTMENT AT SHIFTER

SHIFTER HOUSING TAB BROKEN

ADJUSTER SET INCORRECTLY - SPRING COLLAPSED TOO FAR
ADJUSTER NOT SET/SECURED
e Interlock Cable is attached to a lever within the Shifter that prevents the Shift Lever from moving out of
rk" without the key (theft prevention). The Interlock Cable adjustment is preset at the factory. When
perly adjusted, the Interlock System prevents the key being removed from the Key Cylinder when the
ft Lever is in a position other then "Park".
Symptom Possible Cause Corrective Action

1. The Interlock Cable adjustment
is not set correctly (spring 1. Check the Interlock Cable Adjustment.
collapsed too far).
2. The Interlock Cable is not
y is trapped and secured properly at the shifter 2. Be sure the Interlock Cable is properly
nnot be removed housing. secured at the shifter housing.
om the ignition
hen the Shift 3. Shifter housing tab is broken. 3. Replace shifter mechanism.
ver is in the 4. Check the Interlock Cable Housing
4. Interlock Cable routing through
ark" position. the instrument panel area is routing. The Interlock Cable has a clip that
locates it to the Instrument Panel structure.
causing increased friction within
The Interlock Cable must be free to move
the Interlock Cable Housing
through this clip. The clip is located behind
(bind/kink in Interlock Cable).
the panel.
1. The Interlock Cable adjustment
1. Check the Interlock Cable adjustment.
is not set correctly.
2. The Interlock Cable is not
2. Be sure the Interlock Cable is properly
secured properly at the shifter
y can be secured to the shifter housing.
housing.
moved no matter
3. Shifter housing tab broken. 3. Replace shifter mechanism.
hat position the
ift Lever is in. 4. Check the Interlock Cable Housing
4. Interlock Cable routing through routing. The Interlock Cable has a clip that
the instrument panel area is locates the Interlock Cable to the Instrument
causing increased friction within Panel structure. The Interlock Cable must be
the Interlock Cable Housing free to move through this clip. The clip is
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(bind/kink in Interlock Cable). located behind the panel.

5. Interlock cable not secured in 5. Secure Interlock cable in Ignition
Ignition Cylinder. Cylinder.
1. Turn the ignition to the "On" or "Run"
position. Brake lamps must be on for the
1. Brake lamp switch may be mis- shifter solenoid to receive a signal. If the
adjusted. brake lamps switch is mis-adjusted, the
solenoid will not be energized. Replace
Brake Lamp Switch.
2. No Voltage to Brake lamp
switch from 10 amp fuse #3 in 2. Repair circuit or fuse #3.
TIPM
3. If the shifter build date is before 2/1/2006
(located on the label on the rear of the shifter
housing) and the solenoid bushing can be
located, reinstall the bushing on the solenoid
3. Solenoid bushing to Park Lock shaft and use a soldering iron, melt the end
Lever is out of position or has of the solenoid shaft so that the bushing will
ift Lever will not fallen out. not come off of the shaft. Verify the
ove to the right operation of the Park Lock Lever.
that it can be If the solenoid bushing cannot be located or
oved out of the the shifter build date is after 2/1/2006,
ark" position replace the shifter assembly.
4. Solenoid is sluggish or hesitant.
Low voltage to solenoid. The 4a. Correct the low voltage condition. If the
voltage with key on, engine off, voltage is above 10.1 volts, replace the
should be at least 10.1 volts. There shifter assembly.
may be up to a 3 second delay
before full voltage is received at
the solenoid after the engine is
4b. Sticky residue around solenoid plunger
started.
5. Park Lock Lever on the right
side of the sifter is not moving 5. Check Park Lock Solenoid operation.
when the brake pedal is depressed.
6. Park Lock Lever is sluggish and
scrapping against the inside of the 6. Replace the shifter assembly.
Shifter Housing.
1. Key Interlock Lever within the
ift Lever will shifter is not releasing when the 1. Check Interlock Cable operation and cable
ove to the right key is turned to the "On" or "Run" adjustment.
t will not move positions.
wn toward the
Reverse" position. 2. Interlock Cable is not routed 2. Check Interlock Cable routing.
properly.
ift Lever can be 1. Interlock Cable Cartridge not 1. Remove the steering column shroud and
oved without properly installed into the Lock check for correct installation of the Interlock
rning the key on. Housing. Cable Cartridge into the Lock Housing.
1. Shift Cable not fully seated into 1. Check the Shift Cable installation at the
ift Lever the Transmission Bracket. transmission. Be sure both of the Shift Cable
ficult to pull out Housing locking tabs are fully engaged into
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any gear. the bracket.

2. Shift Cable to Transmission
2. Tighten the nut to 20 N.m (175 in. lbs.).
Lever nut is loose.
MOVAL
FT INTERLOCK CABLE
1. Disconnect the battery.
Fig. 335: Shifter Bezel

2. Remove the shifter bezel (1).
Fig. 336: Counsel Screws

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3. Remove the screws (1) at the console.
Fig. 337: Counsel

4. Pull the console (1) back and remove electrical connector (2) (if equipped).
5. Remove the console (1).

6. Remove the bolts (1) at the shifter.

7. Separate the shift interlock cable from the shifter.
8. Remove lower shroud at steering column. Refer to REMOVAL .
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Fig. 339: Shift Interlock Cable At Column

9. Place the ignition switch in the ON position.

0. Depress the clip on the shift interlock cable (2) and pull cable out of column (1).
1. Remove the cable.
STALLATION
FT INTERLOCK CABLE
1. Install the cable between the shifter and the steering column.
2. Clip the shift interlock cable to the shifter.
3. Install the shifter in place.

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4. Install the shifter bolts and tighten to 70 N.m (52 ft. lbs.).
Fig. 341: Counsel

5. Install the console (1).

6. Connect the electrical connector (2) (if equipped).
Fig. 342: Counsel Screws

7. Install the screws (1) at the console.
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Fig. 343: Shifter Bezel

8. Install the shifter bezel (1).
Fig. 344: Shift Interlock Cable At Column

9. With the ignition switch in the ON position, push the interlock cable (2) into the column (1) until it
clicks into place.
0. Check operation of the ignition-shift interlock feature.
1. Install the lower shroud.
JUSTMENTS
JUSTMENTS
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. 345: Center Console Housing Screws

1. Remove shift knob and shift bezel. Refer to REMOVAL .

2. Remove two screws (1).

3. Pull on side of housing (1) and unsnap housing tabs.

4. Disconnect console housing wire connector (2) and instrument panel connector (3).
5. Remove from vehicle.
6. Adjust interlock cable/system as follows: Pry up on cable adjuster lock to release and allow cable to
"self-adjust". Lock cable adjustment by pressing down on the adjuster lock until bottomed at the cable
housing.
AL-TORQUE CONVERTER
MOVAL
RQUE CONVERTER SEAL

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1. Remove transmission. See REMOVAL.
Fig. 347: Torque Converter

2. Remove torque converter.

3. Remove torque converter seal using Slide Hammer C-3752 and oil Seal Remover 9667.
STALLATION
RQUE CONVERTER SEAL
. 348: Install Converter Housing Oil Seal

1. Install torque converter seal using oil seal Installer 9858.
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Fig. 349: Measure Torque Converter To Transmission

NOTE: When conducting measurements, measure two or more places and

calculate the average value.
2. Install the torque converter on the transaxle and measure the dimension (1) to see if it is at least 13
mm. If the measurement is less than 13 mm, the torque converter is not fully installed. See Fig. 187.
NOTE: Use the designated brand of CVT fluid. Use of other brands of CVT fluid
other than the designated brand will deteriorate the driveability and the
durability of the CVT, and will cause damage to the CVT.
3. Install the transmission. See INSTALLATION.
AL-HALFSHAFT LEFT SIDE
MOVAL
LFSHAFT LEFT SIDE SEAL
1. Remove halfshaft. Refer to REMOVAL .
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Fig. 350: LEFT SIDE DIFFERENTIAL OIL SEAL

2. Remove left side differential oil seal.
STALLATION
LFSHAFT LEFT SIDE SEAL
. 351: LEFT SIDE DIFFERENTIAL OIL SEAL

1. Install the left side differential oil seal using Installer 9871 (2) and Handle C-4171 (3).
2. Install halfshaft. Refer to INSTALLATION .
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AL-HALFSHAFT RIGHT SIDE
MOVAL
LFSHAFT RIGHT SIDE SEAL
1. Remove halfshaft. Refer to REMOVAL .

2. If all wheel drive remove the PTU. Refer to REMOVAL .
Fig. 352: DIFF SEAL 4WD CONVERTER SIDE

3. Remove the seal (2) form the transaxle using a screwdriver (3).
STALLATION
LFSHAFT RIGHT SIDE SEAL
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. 353: DIFF SEAL CONVERTER SIDE

1. Install the seal using Installer 9877(2) and Handle C-4171 (3).
2. If all wheel drive install the PTU. Refer to INSTALLATION .
3. Install Halfshaft. Refer to INSTALLATION .
ANSMISSION RANGE SENSOR
MOVAL

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1. Disconnect battery cables (2).

2. Remove air cleaner assembly (1).

3. Remove battery.
4. Remove battery tray (1).

5. Remove inlet air tube (1).
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6. Remove the shifter cable (2).

7. Remove nut (1) at shift lever.

8. Remove shift lever (2).
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9. Remove bolts (2) at TRS.

0. Remove TRS (1).
STALLATION
. 360: Transmission Range Sensor

1. Install TRS into position (1).
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Fig. 361: TRS Adjustment Tool

2. Put the manual shaft in the N position (3).

3. Install Alignment Tool 9876 (2) and adjust the position of the TRS (1).
Fig. 362: Bolts At TRS

4. Install and tighten the mounting bolts of the TRS to 6 N.m (49 in. lbs.).
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5. Remove Alignment Tool 9876 and Install the shift lever (2) onto the manual shaft (1).
6. Install and tighten the mounting nut to 17 N.m (150 in. lbs.).
OOLER-TRANSMISSION OIL
MOVAL
MOVAL
. 364: Cooler/Trans Lines At Cooler

1. Raise the vehicle on a hoist.
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2. Remove the left front tire.

3. Remove the left front splash shield.
4. Drain the coolant.
5. Remove the transmission lines (2) at the cooler (3).
6. Remove the coolant lines (1) at the cooler.
7. Remove the mounting bolts at the cooler.
8. Remove the cooler from the transmission.

9. Remove the fluid filter (1).
STALLATION
TALLATION
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. 366: Fluid Filter

CAUTION: Apply CVT fluid on the seal part when installing the CVT fluid filter.
1. Install the CVT fluid filter (1) into the transaxle case.
Fig. 367: CVT Fluid Filter O-Ring

ring.
2. Install the new o-ring (1) onto the CVT fluid filter.
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3. Install the CVT fluid cooler onto the transaxle case.

4. Install and tighten the mounting bolts to 4 N.m (37 in.lbs.).
5. Install the coolant lines (1) at the cooler.
6. Install the transmission lines (2) at the cooler (3).
7. Install the left front splash shield.
8. Install the left front tire.
9. Lower the hoist.
0. Top off coolant. Refer to STANDARD PROCEDURE .
1. Top off transmission fluid. See STANDARD PROCEDURE.
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Trasmision Completa Caliber 2007

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2008 Dodge Caliber R/T

2008 AUTOMATIC TRANSMISSION CVT - Service Information - Caliber

2008 AUTOMATIC TRANSMISSION

CVT - Service Information - Caliber

REVERSE BRAKE (RELEASED)

REVERSE BRAKE (ENGAGED)

REVERSE BRAKE (RELEASED)

REVERSE BRAKE (RELEASED)

FT LOW TO HIGH - PHASE 1

. 5: Shift Low To High - Phase 1

PULLEY RATIO LINKAGE 5-

FT LOW TO HIGH - PHASE 2

. 6: Shift Low To High - Phase 2

PULLEY RATIO LINKAGE 5-

FT LOW TO HIGH - PHASE 3

. 7: Shift Low To High - Phase 3

PULLEY RATIO LINKAGE 5-

FT LOW TO HIGH - PHASE 4

. 8: Shift Low To High - Phase 4

PULLEY RATIO LINKAGE 5-

FT HIGH TO LOW - PHASE 1

. 9: Shifting High To Low - Phase 1

PULLEY RATIO LINKAGE 5-

FT HIGH TO LOW - PHASE 2

. 10: Shifting High To Low - Phase 2

PULLEY RATIO LINKAGE 5-

FT HIGH TO LOW - PHASE 3

. 11: Shifting High To Low - Phase 3

PULLEY RATIO LINKAGE 5-

AGNOSIS AND TESTING

. 12: TEST PORTS

Line Pressure 5 - Torque

Fluid pressure Fluid pressure (measurement

. 13: Air Cleaner Assembly

1. Disconnect battery cables (2). See Fig. 13.

Fig. 14: Battery Tray

4. Remove battery tray (1). See Fig. 14.

Fig. 15: Inlet Air Tube

6. Remove inlet air tube (1). See Fig. 15.

Fig. 16: Shifter Cable And Bracket

Fig. 17: Cooler/Trans Lines At Cooler

9. Remove coolant lines (2) at CVT fluid cooler.

Fig. 18: Heater Hose To Trans Cooler

0. Remove heater hose (3) at CVT fluid cooler.

Fig. 19: Speed Sensor

1. Remove the speed sensor connector (1). See Fig. 19.

Fig. 20: Vent Tube

Fig. 21: Throttle Body Support Bracket

Fig. 22: Bell Housing Bolt Holes

Fig. 23: Top CVT Trans Mount

6. Remove the upper transmission mount bolts (1).

3. Remove lower splash shield (if equipped).

Fig. 24: Jack For Support

4. Support the transmission with a jack (1). See Fig. 24.

Fig. 25: Fill Tube

Fig. 26: Inspection Cover

0. Remove inspection cover (1). See Fig. 26.

Fig. 27: Torque Converter Bolts

2. Remove torque converter bolts (1). See Fig. 27.

Fig. 28: Jack At Trans Mount

3. Support the engine with a screw jack (2).

Fig. 29: Front Engine Mount

Fig. 30: Rear Engine Mount

7. Remove the transmission rear mount thorough bolt (2).