Standard Procedure - Aluminum Thread Repair; Removal - Dodge Intrepid Service Manual

21 - 10 TRANSAXLE
42LE AUTOMATIC TRANSAXLE (Continued)
Fig. 9 Converter Leak Points—Typical
1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG
(1) If it is suspected that the leakage is gear lube,
check the differential for proper fluid level. High oil
level can result in leakage from the differential vent.
CAUTION: A crushed vent baffle will cause oil to
leak from vent hose.
(2) If fluid level is correct, add 1/4 to 1/2 ounce of
leak detecting florescent dye to the differential.
(3) Clean the suspect area of the transaxle with
solvent.
(4) Road test the vehicle until the leak reoccurs.
(5) Using a black light determine the source of the
leak and repair as required.
(6) Do not add oil dye to both the ATF sump and
the differential sump at the same time. This can
cause confusion when trying to pinpoint a leak
source.
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
axle case and valve body can be repaired by the use
of Heli-Coils, or equivalent. This repair consists of
drilling out the worn-out damaged threads. Then tap
the hole with a special Heli-Coil tap, or equivalent,
and installing a Heli-Coil insert, or equivalent, into
the hole. This brings the hole back to its original
thread size.
Heli-Coil, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.

REMOVAL

NOTE:
When a transaxle failure has contaminated the fluid,
the oil cooler(s) must be flushed (Refer to 7 -
COOLING/TRANSMISSION - STANDARD PROCE-
DURE). The cooler bypass valve in the transaxle
must be inspected and/or replaced also. The torque
converter must also be replaced with an exchange
unit. This will ensure that metal particles or sludged
oil are not later transferred back into the recondi-
tioned (or replaced) transaxle.
NOTE: If the Torque Converter is being replaced, it
is necessary to restart the TCC Break-In Strategy.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/POWERTRAIN
STANDARD PROCEDURE)
The transaxle can be removed without having to
remove the engine.
(1) Disconnect battery.
(2) Remove wiper blades.
(3) Remove right and left wiper module covers.
(4) Remove steel cowl/strut support.
CAUTION: Be careful of sharp edges around cowl/
wiper area.
(5) Remove engine air inlet tube.
(6) Remove transaxle harness connectors at cowl
area.
(7) Remove upper bell housing stud nuts from bell
housing studs. Detach heater hose tube and throttle
body support bracket.
(8) Remove upper bell housing studs.
(9) Lift vehicle on hoist.
(10) Loosen clamps at intersection of rear exhaust
system to front catalytic converter pipes.
(11) Separate rear exhaust from left catalytic con-
verter pipe and right extension pipe.
(12) Remove rear exhaust system.
(13) Remove nuts retaining exhaust pipes to trans-
mission mount.
(14) Loosen clamp at right extension at right cata-
lytic converter. Remove right extension.
(15) Disconnect crankshaft position sensor connec-
tor and remove sensor (Fig. 10). The sensor is located
on the upper right side of the transaxle bell housing.
(16) Remove dipstick tube.
(17) Disconnect the gear selector cable from the
transaxle.
(18) Disconnect transmission range sensor connec-
tor. Disconnect input and output speed sensor con-
nector.
(19) Disconnect and plug transaxle cooler lines at
the transaxle.
(20) Remove lower control arm pinch bolts.
(21) Pry lower control arms down and out of steer-
ing knuckles.
LH
CONTROL MODULE -