CHRYSLER A604 DELAYED FORWARD ENGAGEMENT

COMPLAINT: After overhaul vehicle exhibits delayed and/or a shuddering condition, when shift lever is engaged into any forward range, followed by an immediate abort to “Limp Mode.”

CAUSE: The cause may be, that during the valve body cleaning process, retainer No.3 and/or one of the small “Buttons” in the solenoid switch valve train was not installed during reassembly. These parts can usually be found in the bottom of the solvent tank.

CORRECTION:  Install the solenoid switch valve train and retainer No.3 as shown in Figure 1.

NOTE: Retainer location No. 4 and Torque Converter Clutch Switch Valve Train shown in Figure 1 are for “92 ” and later only!

FORWARD ENGAGEMENT

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CHRYSLER A604 – “Buzzing” Noise When Selector Lever Is Placed In Drive Or Reverse

COMPLAINT:  When the manual selector lever is placed into either Drive and/or Reverse from the Park and/or Neutral position, a “Buzzing” noise is heard coming from the transaxle area for approximately one to two seconds and then stops. Find obd2 scanner?

CAUSE: This noise is created by the solenoid assembly which includes four different solenoids.

CORRECTION: The “Buzzing” noise described above is NORMAL. The ONLY thing that can be done to help alleviate the “Buzzing” noise, is to ensure that the Solenoid Assembly Sound Cover is present, and installed properly as shown in Figure 1.
Drive Or Reverse 1
EAGLE 4HP-18
DELAYED FORWARD ENGAGEMENT OR PREMATURE FAILURE OF THE FORWARD CLUTCH

COMPLAINT: ZF-4HP-18 transmissions may exhibit a no move condition in any forward range and works fine in reverse.
CAUSE: One cause may be that either the 3-4 or 4-3 traction valve in the valve body has stuck in a stroked position preventing forward clutch apply (See Figure 18).
CORRECTION: Remove the valve body from the transaxle. Inspect and free the valve that is stuck.

Drive Or Reverse 2

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CHRYSLER A604 TRANSFER GEAR CHANGES (32 DEGREE)

CHANGE: Introduced as a running change, late in the 1991 model year, Chrysler changed the helix angle of the teeth on the transfer gears to 32 degrees instead of the previous 27.5 degrees.

REASON: To reduce a whining concern while the vehicle was in motion. Find more obd2 scanner to do better on auto repair.

PARTS AFFECTED:
(1) TRANSFER GEARS – The helix angle of the teeth on both transfer gears changed from 27.5 degrees to 32 degrees.  The new design transfer gears can be easily identified by the removal of the washer recess area in the center of the gears. This was done to create more spline engagement, to accommodate higher torque engines.

(2) REAR PLANETARY CARRIER – The spline area of the output shaft was increased by 1/8″ to accommodate the increased spline area in the transfer gear.

(3) OUTPUT SHAFT BOLT – New output shaft bolt was introduced at the same time with a Locktite patch added to the thread area, and the bolt was cadium plated. The new design bolt has a 5/16″ head thickness instead of the previous 1/4″ head thickness. All of this was done for a more stable torque retention.

(4) TRANSFER SHAFT NUT – Added Lock-tite patch to the thread area and cadium plated for a more stable torque retention.

(5) TRANSFER GEAR COVER – Has an added dimple in the cover to accommodate the increased head thickness of the output shaft bolt.

INTERCHANGEABILITY:
Individually the new design parts listed above ARE NOT interchangeable with previous design level parts.  However, by using the new parts in kit form, a 1991 model transaxle can be upgraded to the new design 32 degree transfer gears.

The only kit available for 1989-1990 model transaxles is a special “Low Lead Crown” 27.5 degree Transfer Gear Service Package. This kit is the only way to reduce gear whine concerns on these models.  Some hot car tools like tacho pro universal and ELM327 Bluetooth may help you more.

SERVICE INFORMATION:
89-90 Models, Special “Low Lead Crown” Service Package
54/59 Tooth Gear Set (2.36 Overall Gear Ratio ONLY) ………………………………….. 4638737
1991 Models, 32 Degree Service Package
46/50 Tooth Gear Set (2.36/2.19 Overall Gear Ratio ONLY) …………………………… 4713139
1991 Models, 32 Degree Service Package
49/47 Tooth Gear Set (2.52 Overall Gear Ratio ONLY) ………………………………….. 4713140
50 Tooth Output Gear and Bearing ……………………………………………………………….. 4713141
46 Tooth Transfer Gear and Bearing …………………………………………………………….. 4713142
49 Tooth Transfer Gear and Bearing …………………………………………………………….. 4713143
47 Tooth Output Gear and Bearing ……………………………………………………………….. 4713144
Rear Planetary Carrier (New Design) ……………………………………………………………. 4713145
Output Gear Washer …………………………………………………………………………………… 6501832
Output Gear Bolt (New Design) …………………………………………………………………… 6503548
Transfer Gear Nut (New Design) ………………………………………………………………….. 6502611
Transfer Gear Washer …………………………………………………………………………………. 6501833
Transfer Gear Cover (New Design) ………………………………………………………………. 4567255

CHRYSLER A904 SHUDDER IN REVERSE

SYMPTOM/CONDITION
Vehicle shakes during breakaway in reverse with medium to heavy throttle application (i.e. backing very slowly up a steep grade or backing up a trailer). Maybe you need some obd2 scanner for help?

DIAGNOSIS
Warm vehicle to normal operating temperature. Locate a relatively steep grade (where it is safe to stop and back up). Try backing the vehicle up very slowly from a full stop. If a sufficiently steep grade is not available, move the vehicle to an open, flat, paved area where it is safe to stop and back up. Apply the parking brake about half way. Shift to reverse and slowly open the throttle until the vehicle just begins to move. Vehicle speed should be no more than a slow walking pace. Extreme care must be taken not to overheat the transmission during this test. Do not open the throttle more than 10 seconds at a time. A low the transmission to cool by running at a fast idle in neutral for at least three minutes between attempts to breakaway during either of these tests, do the following repair:

PARTS REQUIRED
1986 Passenger Car Application
Fifth Avenue, Grand Fury, and Diplomat

Engine          Transmission      Torque Converter       Number
318 (5.2L)         A-999           Low stall/lock up         4431113
SHUDDER IN REVERSE
This repair involves the replacement of the torque converter.
1. Check engine for any driveability problems. Low carburetor air flow, early EGR valve operation, etc. have been found to be a contributor to reverse shake in some vehicles.
2. Perform a propane adjustment and/or correct any other driveability problems that may exist with the vehicle, using the appropriate Driveability Test Procedure.
3. If correcting any driveability problems with the vehicles does not eliminate the reverse shake, then it will be necessary to replace the torque converter with a new one.
4. Select the appropriate torque,converter for the vehicle from the parts list.
5. Replace the torque converter per the appropriate service manual Instructions.
6. Road test the vehicle and check for leaks.

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CHRYSLER 42RE “BUZZING” NOISE IN REVERSE

COMPLAINT: Some vehicles equipped with the 42RE transmission may exhibit a “buzzing” noise while the manual selector lever is in the Reverse position. Find obd2 code reader ?

CAUSE: The cause may be, the Pressure Regulator Valve buzzing because of a partially clogged main filter, or may be the PR valve itself.

CORRECTION: First install a brass “Screen” in place of the felt media filter in the bottom pan, as shown in Figure 1.  If this does not cure the condition, replace the aluminum PR valve in the valve body with the previous design steel PR valve (See Figure 2), available under OEM part number 4130169

SERVICE INFORMATION:
Pressure Regulator Valve (Steel) ………………………………………………………………… 4130169
Brass Screen (Aftermarket ATC) ………………………………………………………………..  12010D

NOISE IN REVERSE 1

NOISE IN REVERSE 2

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MAZDA G4A-EL STACKED SHIFTS

COMPLAINT: Vehicles equipped with G4A-EL transmissions may exhibit early or “Stacked Shift’s” with Converter Clutch apply by 20 mph., after overhaul, without storing any trouble codes. Find more obd code readers for help?

CAUSE: The cause may be, a mismatched 1993 Reverse and Forward drum was installed into as 1987-92 vehicle. REASON: 1987-92 Reverse and Forward drums have 12 “Projections.”
1993 Reverse and Forward drums have 16 “Projections.” These “Projections” are picked up by the “Pulse Generator” converting drum or turbine speed into an A.C. current or frequency that is sent to the ECAT computer. When a 16 “Projection” drum is installed into an 1987-1992 vehicle, drum or turbine speed will automatically be faster and may change shift strategy. (See Figure 1).

CORRECTION: Refer to Figure 2 to identify model year and install the proper drum for your application.

STACKED SHIFTS 1

STACKED SHIFTS 2

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