NO: 18-24-95 - JustAnswer



NO: 18-24-95

SUBJECT: Improved Transmission Shift Quality

DATE: Jun. 23, 1995

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.

NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE.

SYMPTOM/CONDITION:

1992 AC, & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX), **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTER CLUTCH (EMCC).

Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE #2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled.

**ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE

OCT. 24, 1994 (MDH 10-24-XX).

The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are:

1. Coastdown Tip-In Bump: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips beck into the throttle to accelerate, a noticeable bump may be felt.

2. Coastdown Shift Harshness: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts.

3. 1995 LH with 42LE Transaxle - Sluggishness/Lack of Response: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH.

4. 1989-1994 with 41TE & 42LE Transaxles: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH.

5. 1993 with 41TE Transaxle: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control.

6. 1989-1994 with 41TE Transaxle - Harsh/Delayed Garage Shifts: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or malfunctioning PRNDL or neutral start switch.

7. 1989-1994 with 41TE & 42LE Transaxles- Poor Shift Quality After a Battery Disconnect: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However, if a transmission is rebuilt or a new transmission or TCM is installed, the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned).

NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY.

8. Early 1993 with 41TE & 42LE Transaxle - Intermittent Speed Control Drop Out: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993).

9. 1989-1993 with 41TE & 42LE Transaxles - New fault code 35 (failure to achieve pump prime) has been added for Improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions.

Code 21 (OD Pressure Switch Circuit) - Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions.

Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) - In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode.

Code 24 (Low Reverse Pressure Switch Circuit) - Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition.

DIAGNOSIS:

Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC’s) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color.

If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1.

If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9.

EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM’S:

|Quantity |Part No. |Description |

|1 |CH5500 |Flash Programming Kit |

|1 |CH6000 |Scan Tool (DRB III) |

|1 |CH7035 |General Purpose Interface Bus Cable (GPIB) |

|1 |CH7025 |DIN Cable |

|1 |4669020 |Label - Authorized Software Update |

|1 |4275086 |Label - Authorized Modification |

|AR |4504048 |Package, Oil Filter 41TE |

|AR |4796730 |Package, Oil Filter 42LE |

|AR |4467721 |Fluid, Mopar Automatic Transmission - Type 7176 |

PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY:

TRANS. CONTROL MODULE AND MODEL APPLICATION

|Quantity |Part No. |Description |

|AR |4686606 |1993 - 1995 AA, AC, AG, AJ, AR, AS, ES, & AY |

|AR |4796121 |1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine |

|AR |4796122 |1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine |

|AR |4796123 |1992 AA, AC, AG, AJ, & AS with 3.0L Engine |

|AR |4796124 |1992 AC, AS, ES, & AY with 3.3L & 3.8L Engine |

|**AR |5269726 |1995 FJ** |

|AR |4606105 |1995 JA with 2.5L Engine |

|AR |4797708 |1993- 1995 LH |

|AR |4504048 |Package, Oil Filter 41TE |

|AR |4796730 |Package, Oil Filter 42LE |

|AR |4467721 |Fluid, Mopar Automatic Transmission - Type 7176 |

NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N’S:

• 4796121, 4796122, 4796123, and 4796124

When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed.

In addition to the normal TCM installation procedure, perform the following steps:

A. Remove the cover from the wiring harness connector at the TCM. (See Illustration)

B. Locate CAVITY 49 of the TCM harness connector.

C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570.

D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends.

E. Install the TCM wiring harness connector cover.

REPAIR PROCEDURE NO. 1

This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure.

1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM.

If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 on Page 7.

o 4686174, 4686175, 4686208, 4686209, 4686223, 4686224, 4686490 or 4686491.

If the vehicle is equipped with a TCM WITH cooling fins and is not one of the above part numbers the TCM CAN be flashed, go to step 2.

NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED.

2. Connecting the MDS and DRB III to the vehicle (Refer to Illustration)

o With the ignition off, disconnect the vehicle 60 way connector from the TCM on the vehicle.

o Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TCM on the vehicle.

o Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500)

o Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025).

o Connect the MDS to the DRB III.

o Power the DRB III and Adapter by connecting the battery leads to the vehicle battery.

1. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS.

2. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU.

3. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU.

4. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU.

5. Enter the VIN and press NEXT MENU.

6. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen.

If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit.

7. After programming is complete, disconnect the MDS and DRB III, then go to step 14.

Vehicles with TRANSAXLE Control Modules that CANNOT be Flashed

8. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18- 27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by:

o Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles:

1. Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column.

2. Select STAND-ALONE DRB III.

3. Select 94-95 DIAGNOSTICS.

4. Select TRANSMISSION.

5. Select MISCELLANEOUS.

6. Select TSB and follow the instructions on the DRB III screen.

o Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles:

1. Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column.

2. Select SYSTEM

3. Select TRANSMISSION.

4. Select ADJUSTMENTS.

5. Select TSB and follow the instructions on the DRB II screen.

NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER.

9. Replace the TCM with a revised TCM as specified in the Parts Required section of this TSB. Loosen the TCM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM.

10. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TCM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed).

o Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS.

o From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times.

o Select EATX DIAGNOSTICS.

o Select EATX STATE DISPLAY and press F2.

o Select ADJUSTMENTS and press F2.

o Select PINION FACTOR and press F2.

o Follow the instructions on the MDS screen.

NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY.

11. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles).

o Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle.

o From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2.

o Follow the instructions on the MDS screen.

NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW.

12. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label.(See Illustration)

13. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker.(See Illustration)

REPAIR PROCEDURE NO. 2:

This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure.

1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1 starting on page 5.

2. Disconnect the DRB III and MDS from the vehicle.

3. Change the transmission fluid using following the procedure:

A. Raise the vehicle with an appropriate hoist.

B. Clean the transaxle oil pan and mating area thoroughly.

C. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet.

D. Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed O-rings also may cause delayed garage shifts.

E. Separate the transaxle oil filter and O-ring from the valve body and discard. Install the new oil filter specified in the Parts Required section of this TSB.

F. Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.).

NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (P/N 4467721). USE OF DEXTRON IIE OR DEXRTRON III MAY CAUSE CLUTCH SHUDDER.

G. Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube.

H. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral.

I. Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick.

J. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick.

4. Drive the vehicle at least 10 miles.

5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2.

6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission.

7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body.

8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2.

NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW.

9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1 on page 9.

POLICY:

Reimbursable within the provisions of the warranty.

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