1. Introduction
This ATSG technical manual provides comprehensive instructions and detailed information necessary for the diagnosis, overhaul, and repair of the Chrysler A604 (41TE) automatic transaxle. This transmission model has been widely used in various Chrysler vehicles since 1989. The manual is designed to assist both professional technicians and do-it-yourself enthusiasts in performing accurate and effective repairs.
It covers all critical aspects from initial diagnosis to complete reassembly, ensuring a thorough understanding of the transmission's operation and maintenance. Adherence to the procedures outlined in this manual is crucial for successful repair and optimal performance of the A604 (41TE) transmission.
This image displays the front cover of the ATSG Chrysler A604 (41TE) Automatic Transmission Repair Manual. The cover features a blueprint-style drawing of the A604 transmission, with text indicating "CHRYSLER PASSENGER CARS TECHTRANTM MANUAL" and "A604 41TE". It also highlights "NEW UPDATES AND CHANGES INCLUDED" and a caution regarding altering calibration. The bottom of the cover reads "AUTOMATIC TRANSMISSION SERVICE GROUP".
2. Transmission Overview
The Chrysler A604, also known as the 41TE, is a four-speed automatic transaxle. It is electronically controlled and features a torque converter clutch. This section provides a general overview of its design, primary components, and operational characteristics. Understanding the basic structure is fundamental before proceeding with any diagnostic or repair procedures.
- Application: Found in numerous Chrysler, Dodge, and Plymouth front-wheel-drive vehicles.
- Control System: Electronically controlled for precise shift timing and torque converter lock-up.
- Key Components: Includes valve body, planetary gear sets, clutch packs, and various sensors.
3. Diagnosis and Troubleshooting
Effective diagnosis is the first step in any transmission repair. This section details common symptoms, diagnostic trouble codes (DTCs), and systematic troubleshooting procedures to accurately identify the root cause of transmission issues. It includes flowcharts and diagnostic charts to guide users through the process.
Common Symptoms:
- Delayed or harsh shifts
- No engagement in certain gears
- Slipping or loss of power
- Unusual noises (whining, clunking)
- Check Engine Light illumination with transmission-related codes
Troubleshooting Steps:
- Verify fluid level and condition.
- Scan for Diagnostic Trouble Codes (DTCs) using an appropriate scan tool.
- Perform road tests to observe transmission behavior under various conditions.
- Inspect electrical connections and wiring for damage or corrosion.
- Conduct pressure tests to evaluate hydraulic system integrity.
4. Disassembly and Assembly Procedures
This section provides step-by-step instructions for the complete disassembly and subsequent reassembly of the A604 (41TE) transaxle. Each step is accompanied by detailed descriptions and, where applicable, references to specific tools required. Proper sequence and attention to detail are paramount to avoid damage and ensure correct operation after reassembly.
Key Procedures Covered:
- Removal of external components (sensors, solenoids, pan).
- Separation of transmission case halves.
- Disassembly of planetary gear sets and clutch assemblies.
- Inspection and cleaning of all internal components.
- Reassembly sequence with emphasis on proper component alignment and sealing.
5. Component Rebuilding
Many internal components of the A604 (41TE) can be rebuilt or serviced individually. This section focuses on the procedures for rebuilding specific sub-assemblies, such as the valve body, clutch packs, and torque converter. It includes instructions for replacing worn seals, gaskets, and friction materials.
Examples of Rebuildable Components:
- Valve Body: Disassembly, cleaning, inspection of bores, and reassembly with new seals.
- Clutch Packs: Replacement of friction and steel plates, checking clearances.
- Pump Assembly: Inspection of gears, housing, and seal replacement.
6. Technical Specifications and Torque Values
Accurate specifications and correct torque values are critical for the longevity and proper function of the transmission. This section provides comprehensive tables for all necessary clearances, end plays, and bolt torque specifications. Always refer to these values during assembly to prevent premature wear or failure.
Example Specifications Table:
| Component | Specification | Torque Value |
|---|---|---|
| Valve Body Bolts | N/A | 8-10 Nm (71-88 in-lbs) |
| Transmission Pan Bolts | N/A | 12-14 Nm (106-124 in-lbs) |
| Output Shaft End Play | 0.10 - 0.30 mm | N/A |
7. Electrical System Information
The A604 (41TE) is an electronically controlled transmission, relying on various sensors and solenoids for proper operation. This section includes detailed wiring harness locations, routing diagrams, and electrical schematics. Understanding the electrical system is crucial for diagnosing electronic faults and ensuring correct sensor and solenoid function.
Key Electrical Components:
- Input and Output Speed Sensors
- Transmission Range Sensor (TRS)
- Pressure Switches
- Solenoid Pack (Shift Solenoids, TCC Solenoid)
8. Important Updates and Engineering Changes
Since its introduction, the A604 (41TE) transmission has undergone numerous engineering changes and updates. This manual covers the core information, but for the most current and comprehensive repair, it is highly recommended to consult the ATSG "Update Handbook." This supplementary handbook details all significant modifications and is essential for a proper overhaul or repair, ensuring you have the latest information for all model years.
9. Visual Aids: Parts Identification and Exploded Views
To facilitate accurate identification and assembly, this manual includes detailed exploded views of various transmission sub-assemblies. These diagrams visually represent the order and relationship of components, making it easier to identify individual parts and understand their placement during disassembly and assembly. Specific sections are dedicated to valve body identification and extension housing overviews.
10. Support and Resources
The Automatic Transmission Service Group (ATSG) is dedicated to providing high-quality technical information for automatic transmissions. Their professional technical staff, with over 100 combined years of experience, produces these in-depth manuals. For additional support, updates, or to inquire about other technical resources, please refer to official ATSG channels.
This manual is a critical resource for anyone undertaking the repair or overhaul of the Chrysler A604 (41TE) transmission, designed to save significant time and effort.