Service Procedure
A. Inspect Transaxle Clutch Slave Cylinder Date Code1. Raise the vehicle on an appropriate hoist.
2. Remove and save the fasteners along the bottom of left front plastic fender shield.
3. Pull the plastic fender shield back to locate the transaxle clutch slave cylinder on the far left end of the transaxle case (Figure 1). Inspect the six digit build date code on the transaxle clutch slave cylinder housing (Figure 1).
> If the date code is 030712 (ddmmyy) or below, the transaxle clutch slave cylinder does not require replacement. Install the left front plastic fender shield fasteners, lower the vehicle from the hoist and return the vehicle to the customer.
> If the date code is 040712 (ddmmyy) or above, or the date code numbers are not legible, the transaxle clutch slave cylinder must be replaced. Continue with Section B. Replace Transaxle Clutch Slave Cylinder.
B. Replace Transaxle Clutch Slave Cylinder
NOTE:
The following procedure is only required if the transaxle clutch slave cylinder date code indicates that replacement is required per the inspection in Section "A."
CAUTION:
The transaxle must be removed from the vehicle to do this repair
procedure. Do not attempt to remove the clutch slave cylinder from the
transaxle case with the transaxle installed in the vehicle.
1. Lower the vehicle from the hoist and using the following procedure,
depressurize the transaxle hydraulic circuits:
a. Connect the wiTECH scan tool to the vehicle.
b. Select the "TCM" icon.
c. Select the "Misc. Functions" tab.
d. Select "Hydraulic Circuit Depressurization" from the list.
e. Follow the screen prompts to complete the depressurization procedure.
2. Disconnect and remove the battery
3. Remove and save the engine cover.
4. Disconnect the brown electrical connect to the transaxle Smart Drive Unit (SDU) (Figure 2).
5. Remove and save the Power Distribution Center (PDC) fasteners and relocate the PDC out of the way (Figure 3).
6. Remove and save the battery tray upper retaining bolts.
7. Raise the vehicle on an appropriate hoist.
8. Remove and save both front wheels.
9. Remove and save the underbody splash shield (Figure 4).
10. Remove and save the front air dam plastic panel (Figure 4).
11. Remove and save the left plastic fender shield.
12. Remove the transaxle drain plug and drain the gear oil from the
transaxle (Figure 5).
13. Install the transaxle drain plug and tighten to 25 ft.lbs.
(35 Nm) (Figure 5).
14. Disconnect the transaxle braided ground strap at the transaxle case.
15. Remove and save the battery tray lower retaining bolts and battery tray.
16. Using a small punch, open the crimps on the right and left halfshaft retaining nuts (Figure 6). There are two crimps per nut.
CAUTION:
Attempting to remove the halfshaft nuts without opening up the nut crimps will result in halfshaft thread damage during nut removal.
17. Remove and discard the halfshaft retaining nuts.
18. Remove and discard the right and left side lower ball joint pinch bolts and nuts.
19. Remove and save the right and left halfshafts from the vehicle.
20. Remove the Charge Air Cooler (CAC) hose from the charge air cooler.
21. Remove the shift cable bracket at the transaxle case.
22. Remove and save the catalytic converter lower bracket (Figure 7).
23. Lower the vehicle from the hoist.
24. Disconnect all wiring harness connectors for the transaxle and oxygen sensors.
25. Remove the CAC hose from the vehicle.
26. Place a floor jack under the transaxle and lift transaxle to remove weight from the transaxle mount.
27. Remove and save the transaxle mount (Figure 8).
28. Disconnect the transaxle shift cable from the transaxle shift arm.
29. Remove and save the two upper bellhousing bolts.
30. With the transaxle raised with the floor jack, place a small block of wood between the left side load beam and the transaxle case. Then lower the transaxle onto the block of wood.
31. Lift the vehicle on the hoist.
32. Remove and save the rear transaxle mount (Figure 9).
33. Remove and save the one lower starter bolt.
34. Place a transmission jack under the transaxle and strap the
transaxle to the transmission jack to ensure the transaxle does not fall during removal (Figure 10).
CAUTION:
Use extreme care when strapping the transaxle to the transmission jack. Do not allow the strap to contact any external transaxle components. If any external components are damaged, the transaxle assembly must be replaced.
35. Using a transmission jack, raise the transaxle and remove the wood block that was placed between the transaxle case and left side load beam in Step 30.
36. Remove and save the left side aluminum load beam (Figure 10).
37. Place a screw jack under the engine oil pan to support the engine.
38. Remove and save the four engine adapter-to-transaxle bellhousing bolts.
39. Carefully separate the transaxle from the engine and lower the transaxle from the vehicle.
NOTE:
Do not remove the transaxle from the transmission jack. Replacement of the clutch slave cylinder can be performed with the transaxle on the transmission jack.
40. Measure and record the clutch slave cylinder rod depth from the straight edge to the tip of the clutch slave cylinder rod (Figure 11).
NOTE:
If a depth micrometer is not available, an alternate method to measure the clutch slave cylinder rod depth is to stack feeler gauges between the face of the straight edge and the tip of the clutch slave cylinder rod. Whatever method is used to measure the depth must be repeatable.
41. Using a small pick, remove and save the slave cylinder rod nut retaining clip and housing (Figure 12).
NOTE:
Save the slave cylinder rod nut retaining clip housing. It will be used later in this procedure as an alignment tool.
42. Remove and save the slave cylinder rod nut and support bearing assembly (Figure 13).
43. Using an adjustable wrench, turn the slave cylinder rod approximately turn counterclockwise to break the slave cylinder rod loose from the slave cylinder piston (Figure 14).
CAUTION:
Use care not to damage threads on the slave cylinder rod.
44. Disconnect the slave cylinder electrical connector (Figure 15).
45. Remove and discard the hydraulic tube retaining clip (Figure 16).
46. Carefully disconnect the hydraulic tube from the slave cylinder (Figure 17).
47. Remove and save the four slave cylinder retaining bolts (Figure 18).
48. While holding the slave cylinder rod with one hand, carefully unscrew the slave cylinder from the transaxle (Figure 19).
CAUTION:
Do not remove the slave cylinder rod from the transaxle, slave cylinder rod oil seal damage may occur.
49. Using a small wire brush, carefully clean the old thread locking compound from the slave cylinder rod threads (Figure 20).
50. Using a lint free towel, carefully clean the transaxle case flange and black diaphragm for the slave cylinder (Figure 21).
51. Apply Mopar Lock & Seal Adhesive to the slave cylinder rod threads (Figure 22).
52. While holding the slave cylinder rod with one hand, carefully screw the new slave cylinder onto the slave cylinder rod until the rod bottoms out in the slave cylinder.
53. Install the four slave cylinder retaining bolts. Tighten the mounting bolts to 90 in.lbs.
54. Connect the hydraulic hose to the slave cylinder and insert the hydraulic tube retaining clip.
55. Connect the electrical connector to the slave cylinder.
56. Install the two provided nuts onto the slave cylinder rod (Figure 23). Tighten the nuts against themselves. This will provide a method to tighten the slave cylinder rod.
57. Using a torque wrench, tighten the slave cylindder rod to 80 in.lbs.(9 N.m) (Figure 24).
58. Carefully remove the two nuts from the slave cylinder rod without loosening the slave cylinder rod.
59. Install the support bearing. Tighten the slave cylinder rod nut until approximately inch (4 mm) of slave cylinder rod protrudes past the slave cylinder rod nut (Figure 25). This will be an approximate starting point.
60. Measure the clutch slave cylinder rod depth. Adjust the slave cylinder rod depth (by tightening, to move the shaft towards the bellhousing face, or loosening, to move the shaft away from the bellhousing face, the bearing support nut) to the original depth measured in Step 40 of this procedure (Figure 26).
61. Use the original slave cylinder rod nut retaining clip housing (with the metal retainer clip removed) as an alignment tool (Figure 27). Slide the original clip housing onto the slave cylinder rod and verify that it slides all the way over the support bearing retaining nut. If required, turn the slave cylinder rod nut slightly to allow the clip housing to slide over the nut. After aligning the nut and clip housing, remove and discard the original slave cylinder rod nut retaining clip housing.
CAUTION:
Failure to align the slave cylinder rod nut to the clip housing will cause issues with installing the new slave cylinder rod nut retaining clip.
62. Using an 8 mm deep well socket, carefully push the new slave cylinder rod nut retaining clip onto the slave cylinder rod (Figure 28).
63. Use the following procedure to reset the Dual Mass Flywheel:
CAUTION:
Do not attempt to install the transaxle without resetting the dual mass flywheel. Damage to the dual mass flywheel and/or transaxle clutch will occur.
a. Install Special tool 10310 onto the dual mass flywheel as shown in Figure 29 and 30.
b. Tighten the jack screw until the reset fingers are over the slot in the inner plate (Figure 31).
c. Tighten both set screws on the tool until each of the reset fingers are depressed to the level of the inner plate (Figure 31).
CAUTION:
Do not over tighten the tool set screws. It requires very little torque to push the reset fingers into position. Over tightening the set screws will bend the reset fingers.
d. Carefully loosen the jack screw and then remove the special tool. A properly reset dual mass flywheel will look like the flywheel shown in Figure 32.
NOTE:
When the engine is started for the first time the reset fingers will automatically disengage, allowing the spring loaded inner plate to engage against the clutch drive hub.
64. Use the following procedure to install the transaxle into the vehicle:
a. Using a transmission jack raise the transaxle into position.
b. Install the four engine adapter-to-transaxle bellhousing bolts. Tighten the two bolts at the 3 and 9 o'clock position to 59 ft. lbs. (80 Nm). Tighten the two bolts at the 5 and 7 oclock position to 30 ft.lbs. (40 Nm).
c. Using the transmission jack, raise the transaxle up and install the left side aluminum load beam (Figure 10).
d. Remove the engine jack.
e. Install the one lower starter bolt. Tighten the bolt to 18 ft. lbs. (23 Nm).
f. Install the rear transaxle mount (Figure 9).
g. With the transaxle raised, place a small piece of wood between the left side load beam and the transaxle case. Then lower the transaxle onto the block of wood and remove the transmission jack from under the vehicle.
h. Lower the vehicle from the hoist.
i. Install the two upper bellhousing bolts. Tighten the bolts to 59 ft.lbs. (80 Nm).
j. Connect the transaxle shift cable to the transaxle shift arm.
k. Place a floor jack under the transaxle, raise the transaxle into position and remove the block of wood.
l. Install the transaxle mount (Figure 8).
65. Connect all wiring harness connectors for the transaxle and oxygen sensors.
66. Raise the vehicle on the hoist.
67. Install the lower catalytic converter bracket (Figure 7).
68. Install the shift cable bracket to the transaxle case.
69. Install the right and left halfshafts.
Tighten the right halfshaft intermediate bracket to 18 ft.lbs. (24 Nm). Tighten the new halfshaft retaining nuts to 148 ft.lbs. (200 Nm). Tighten the ball joint pinch bolt to 52 ft.lbs. (70 Nm).
70. Using special tool 10287, crimp both halfshaft retaining nuts. The tool must be positioned so that the crimp is on the left side of the slot in the halfshaft (Figure 34). The nut will split when a loud pop is heard while tightening the tool.
Continue tightening until the tool jaw bottoms on the halfshaft.
71. Lower the vehicle from the hoist
72. Install the charge air cooler hose.
73. Install the battery tray.
74. Raise the vehicle on the hoist.
75. Install the transaxle braided ground strap to the transaxle case.
76. Use the following procedure to fill the transaxle with fluid:
a. Remove and save the black rubber fill plug from the left side of the transaxle case (near the left halfshaft) (Figure 35).
b. Using a suction gun, fill the transaxle with Mopar C Series Manual & Dual Dry Clutch Transmission Fluid SAE 75W. Do Not Substitute with any other type of fluid.
CAUTION:
Be sure that the suction gun is clean and has no other residual fluid(s) in it.
c. Fill the transaxle until fluid runs out of the fill hole. The bottom of the fill hole is the full level of the transaxle.
d. Install the black rubber fill plug into the transaxle case opening.
77. Install the left plastic fender shield.
78. Install the front air dam plastic panel (Figure 4).
79. Install the underbody splash shield (Figure 4).
80. Partially lower the vehicle from the hoist and install the front wheels. Tighten the lugs to:
> Aluminum Wheels 92 ft. lbs. (125 Nm).
> Steel Wheels 89 ft. lbs. (120 Nm).
81. Lower the vehicle from the hoist and install the Power Distribution Center (PDC) (Figure 3).
82. Connect the brown electrical connector to the transaxle Smart Drive Unit (SDU) (Figure 2).
83. Install the battery. Tighten the battery post nuts to 45 in.lbs. (5 Nm).
84. Install the engine cover.
85. Connect the wiTECH scan tool to the vehicle.
86. Clear all Diagnostic Trouble Codes (DTCs).
87. Select the "TCM" icon from the main view screen.
88. Select the "Misc. Functions" tab.
89. Select "Bleed Hydraulic Circuit" from the list.
90. Select "Continue" and then follow the screen prompts to complete the bleed procedure.
91. Select "Hydraulic Circuit Depressurization" from the list and follow the screen prompts to complete the depressurization procedure.
92. With the transaxle depressurized, check the hydraulic fluid level at the reservoir and add fluid if required.
93. Select "Reset of Data Group" from the list.
94. Select "All Data" from the list.
95. Follow the screen prompts to complete the data reset.
96. Select "Learn Clutches Contact Point" from the list.
97. Follow the screen prompts to complete the learn procedure.
98. Select "Quick Learn" from the list.
99. Follow the screen prompts to complete the quick learn.
100. Using the wiTECH, calibrate the steering angle sensor.
101. Again, clear all Diagnostic Trouble Codes (DTCs).
102. Remove the wiTECH from the vehicle.
103. Road test the vehicle to verify the repair.