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C H RY S L E R A604 INDEX DESCRIPTION............................................................ ......................................................................................... 4 DIAGNOSIS TESTS.................................................................. ........................................................................... 10 CLUTCH APPLICATION CHART....................................................................................................................... 11 PRESSURE CHECKS................................................................. ........................................................................... 13 OIL CIRCUIT DIAGRAMS.................................................................................................................................... 15 GENERAL DIAGNOSIS CHARTS........................................................................................................................ 30 MAINTENANCE AND ADJUSTMENTS............................................................................................................... 33 TEAR DOWN AND RE-ASSEMBLY....................................................................................................................... 35 VALVE BODY ...................................................................... ................................................................................... 41 SPECIFICATIONS.................................................................. ................................................................................ 78 BELLHOUSING I.D.................................................................... ............................................................................ 82 REPAIR PACKAGE FOR "89" MODELS.............................................................................................................. 85 AUTOMATIC TRANSMISSION SERVICE GROUP 18639 S.W. 107TH AVENUE MIAMI, FLORIDA 33157 (305) 670-4161 Copyright © ATSG 2006 Updated August, 2003 INTRODUCTION CHRYSLER A604 (41TE) The A604 electronic controlled automatic overdrive transaxle has some very unique features. This unit contains no bands or freewheel devices and shifts from clutch to clutch, which requires very precise programming of the onboard transaxle controller. The electronic system is designed to abort the transaxle to second gear if a transaxle problem is detected, however you will still have reverse, park and neutral, which will allow the operator to "Limp" home. Through a variety of different fault codes the technician will be able to diagnos the cause of the malfunction, and repair the concern. This booklet is designed to provide you with the procedures necessary to service, overhaul or repair the A604 transaxle. Note: There have been many engineering changes in this transaxle since its introduction in 1989. ATSG also has available an "Update Handbook" which includes the many changes and is required along with this manual for a proper overhaul or repair. No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without written permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts. The information and part numbers contained in this booklet have been carefully compiled from industry sources known for their reliability, but ATSG does not guarantee its accuracy. Copyright © ATSG 2003 DALE ENGLAND JIM DIAL FIELD SERVICE CONSULTANT TECHNICAL CONSULTANT WAYNE COLONNA ED KRUSE TECHNICAL SUPERVISOR TECHNICAL CONSULTANT PETER LUBAN GREGORY LIPNICK TECHNICAL CONSULTANT TECHNICAL CONSULTANT JON GLATSTEIN DAVID CHALKER TECHNICAL CONSULTANT TECHNICAL CONSULTANT ROLAND ALVAREZ JERRY GOTT TECHNICAL CONSULTANT TECHNICAL CONSULTANT GERALD CAMPBELL MIKE SOUZA TECHNICAL CONSULTANT TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP 18639 S.W. 107TH AVENUE MIAMI, FLORIDA 33157 (305) 670-4161 1
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