TSB 21-15-99

Transaxle Seepage Misdiagnosis - Case Porosity

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Date: : Oct. 1, 1999

models:

1999 (FJ) Avenger/Sebring
1999 (GS) Chrysler Voyager (international Market)
1999 (JA) Cirrus/Stratus/Breeze
1999 (JX) Sebring Convertible
1999 (NS) Town & Country/Caravan/Voyager

Discussion:

This bulletin involves properly identifying the seepage location (porosity) and if applicable, using a peening process to seal the porous area of the transaxle case.  

Symptoms:

Some vehicles may exhibit seepage from the transaxle case. This seepage may be due to case porosity in the cooler boss area and can be misdiagnosed as leakage from the pan, or input speed sensor. Transaxles that may exhibit this condition have a web of metal attaching the cooler bosses and the input speed sensor boss (Figure 1). This web forms a circular pocket in that area.  

Diagnosis:

Start the vehicle and warm the transaxle fluid to 930 C (200') F). Clean the transaxle pan and the area around the input speed sensor. Pay particular attention to cleaning the boss area between the cooler lines, above the input speed sensor (Figure 1). With a helper in the vehicle, set the parking brake, place the transaxle in reverse, apply the service brake and raise the RPM to approximately 1100 RPM for at least 3 minutes. Inspect the cooler line boss area just above the input speed sensor (Figure 1). If seepage is noted from the pocket formed by the web of metal, the following repair procedure can be used. If case seepage is not noted in this area, further diagnosis will be required.  

Parts:        none

EQUIPMENT REQUIRED:
1    NPN Air Hammer
1    PH59 Snap-On Tapered Punch Or Equivalent  

repair:

1.    Remove components for clear access to the transaxle as follows: FJ Models - Air intake hose (throttle body to airbox), air box cover & filter, and left cooling fan module. JA/JX Models - Transaxle Control Module (TCM), TCM bracket and solenoid pack electrical connector. NS/GS Models - Air intake hose at throttle body & resonator, airbox cover & filter, and solenoid pack electrical connector.

2.    Using a suitable air hammer and blunt punch attachment (Snap-On PH59 or equivalent), insert the punch into the pocket formed by the web of metal (Figure 1).

3.    Operate the air hammer for 15 to 20 seconds while moving the punch in a circular motion within the pocket. Start in the center of the pocket and work outwards in a clockwise or counter clockwise pattern.

4.    Repeat step 3 and then reassemble the vehicle.

NOTE: ONLY OPERATE THE AIR HAMMER IN 15  TO 20 SECOND INTERVALS.

5.    Re-test the transaxle for leaks by performing the procedure listed in the diagnosis section.

6.    If the leak is repaired, return the vehicle to the customer.

NOTE: BE SURE TO CLEAN ANY REMAINING TRANSAXLE FLUID FROM THE VEHICLE TO PREVENT CONTINUED DRIPPING ON THE GROUND.

7. If the area continues to leak, the transaxle will require replacement.

Notes:

POLICY:    Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No: 21-00-20-92 ................................................................ 0.7 Hrs.

FAILURE CODE:    AM - Authorized Modification


Thanks to Bob Bergevin for supplying the TSB information

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Last Update: October 27, 1999