Troubleshooting
the 604 (41TE)
by Dave Skora
Figure 1
Keep in mind that, while the proce- Type 1: Conditions suggest a prob-
CAUTION: Before dures for other vehicles will be similar, lem with the TCM:
you should always check your shop • There are codes that indicate a
beginning any type of manual for the specific terminal assign- TCM problem.
ments for the vehicle you’re working • There are no codes.
electrical system diag- on. • You can’t communicate with
nosis, you should have Before you begin any electrical or the TCM.
computer system diagnosis:
an excellent under- • Always start with the basic Type 2: Codes indicate an electri-
standing of Ohm’s Law. checks for connections, cal problem with a TCM input.
grounds, etc. Type 3: Codes indicate an electri-
• Make sure the battery is in cal problem with a TCM output.
A
mong the more common calls good condition and fully Type 4: A code indicates an incor-
to the ATRA HelpLine are charged (12.45 minimum rest- rect gear ratio:
problems with the Chrysler ing voltage). • Clutch Volume Index (CVI)
604 (41TE) transaxle. In this article, numbers are incorrect.
we’re going to look at the procedures CAUTION: Before beginning any • Clutch is slipping.
necessary to troubleshoot most of the type of electrical system diagnosis, you
electrical problems that show up on should have an excellent understand- Type 1 Problems
this unit. ing of Ohm’s Law. You’ll need a lab (TCM and TCM
While these units and systems are scope, DVOM and an ammeter, and Communications)
all virtually the same, there are some you should know how to use them. These problems include no codes,
differences in the specific computer Current tests require your ammeter or no communication, or TCM codes 11–
terminal configurations from vehicle current clamp to have a minimum cur- 17, 19, 20 and 45.
to vehicle. We’ve included a chart rent rating of 10 amps. If you can’t communicate with the
of terminal assignments for 1989–99 There are four common types of TCM, try erasing any trouble codes
Caravans, and the signals you should electrical or computer problems that from all other modules.
expect at each terminal. We’ll use that you’re likely to run into on these units. Check terminal 56, all grounds
chart for the explanations and proce- So the first step in any diagnosis is to and terminals 8 and 11 using the
dures we’re covering. identify which type of problem you’re 1989-99 Caravan (41TE) Terminal ID
dealing with: and Voltage Chart (figures 1 and 2).
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Troubleshooting the 604 (41TE)
1989–99 Caravan (41TE) Terminal ID and Voltage Chart
Terminal Years Wire Colors Application Values
1 1989–95 Red/Black PRNDL 12 V in P, OD, L 0 V in R, N, D
1996–99 Lt Green/Black PRNDL 12 V in P, R, 3/2 0 V in N, OD, L
2 All Tan/Black PRNDL 12 V in OD 0 V in P, R, N, D, L
3 1989–95 Violet Neutral Switch 12 V in R, OD 0 V in P, N, D, L
1996–99 Violet PRNDL 12 V in R, N, OD 0 V in P, 3/2, L
4 All White/Black CCD– Data Stream Signals
5 1989–95 Black/Violet CCD+ Data Stream Signals
6 1989–95 Brown/Blue Engine RPM 1.0 VAC at Idle 2.0 VAC at 2000 RPM
1996–99 Gray/Black Engine RPM 1.0 VAC at Idle 2.0 VAC at 2000 RPM
7 1996–99 Pink SCI Data Stream Signals
8 1989–95 Yellow Starter Relay 12 V Start 0 V Ignition On
1996–99 Yellow/Red Starter Relay 12 V Start 0 V Ignition On
9 All Black/Lt Green O/D Pressure Switch 12 V Off 0 V in 3rd & 4th
10 1996–99 Yellow/Dk Green Torque Management 7–10 V Ignition On
11 1989–95 Dk Blue Ignition On Ignition Feed
1996–99 Red/White Ignition On Ignition Feed
12 All Orange/Dk Blue TPS 0.5–1.2 V at Idle 4.0–4.5 V at WOT
13 1989–95 Dk Blue/Red TSS & OSS Ground Less than 0.10 V
1996–99 Dk Blue/Black TSS & OSS Ground Less than 0.10 V
14 All Lt Green/White OSS Signal 550–600 Hz or 3 VAC at 30 MPH
15 All Lt Green ETAX Relay Control 12 V Ignition On 0V Limp
16 All Red Switched ETAX 12.45 V Min Engine Running
17 All Red Switched ETAX 12.45 V Min Engine Running
19 1989–95 White/Dk Blue 2–4 Solenoid Control 6.5–7.5 Amps 100% On
1996–99 White 2–4 Solenoid Control 6.5–7.5 Amps 100% On
20 All Lt Blue L/R Solenoid Control 6.5–7.5 Amps 100% On
41 1989–95 Black/Yellow Neutral Switch N/A
1996–99 Brown/White PRNDL 12V in R, OD, 3/2, L 0V in P, N
42 1989–95 Violet/White PRNDL 12V in R, N, OD, D 0V in P, L
1996–99 Violet/White PRNDL 12V in OD, 3/2 0V in P, R, N, L
43 1989–95 Black/Violet CCD+ Data Stream Signals
1996–99 Violet/Brown CCD+ Data Stream Signals
44 1989–95 White/Black CCD– Data Stream Signals
45 1989-95 Gray/Black Engine RPM
46 1996–99 Pink/Lt Blue SCI Receive
47 All Yellow/Black 2–4 Pressure Switch 12 V Off 0 V in 2nd & 4th
49 All N/A OD Cancel Switch 12 V Allowed 0 V Canceled
50 All Dark Green L/R Pressure Switch 12 V Off 0 V in 1st & Rev.
51 All Black/Lt Blue TPS & Sensor Grounds Less than 0.10V
52 All Red/Black TSS Signal 0.7–1.0 VAC or 1000 Hz at Idle
2.6–3.5 VAC or 3100 Hz at 3000 RPM
53 All Black/Yellow Sensor Ground Less than 0.10 V
54 1989–95 Black/Yellow Sensor Ground Less than 0.10 V
1996–99 Violet/Lt Green Thermistor 1.8 V at 140ºF
56 1989–95 Red/White Battery 12.45 V Min at Rest
1996–99 Red/Dk Blue Battery 12.45 V Min at Rest
57 1989–95 Red Brown TCM Ground Less than 0.10 V
1996–99 Black/Red TCM Ground Less than 0.10 V
58 1989–95 Red/Brown TCM Ground Less than 0.10 V
1996–on White/Orange VSS Output 0–5 V Digital Signal
59 1989–95 Pink/Yellow UD Solenoid 6.5–7.5 Amps 100% On
1996–99 Pink UD Solenoid 6.5–7.5 Amps 100% On
60 All Brown OD Solenoid 6.5–7.5 Amps 100% On
Figure 2
22 GEARS October 2005
If any terminal is out of specs, discon- Type 2 Problems L/R, 2–4 and OD Pressure Switches
nect the TCM and retest terminals 56, (TCM Inputs) — To troubleshoot the pressure switch
8 and 11. If voltages are good at these These problems are TCM input circuits:
circuits with the TCM disconnected, codes, such as TSS, OSS, pressure • Disconnect the TCM.
the TCM may be the problem. switches, gear select, crank sensor, TPS • Connect a jumper between ter-
• Test and repair any circuits and temperature sensor (after 1995). minal 56 and 15. The ETAX
that indicate a problem. TSS and OSS Sensors — To test the relay should power the cir-
• Reconnect the TCM. sensor’s operation, use a scope or mul- cuits.
timeter to monitor the circuits direct- • With the engine off, move the
If you still can’t communicate ly. Use the 1989-99 Caravan (41TE) gear selector to drive.
with the TCM, you may need to try a Terminal ID and Voltage Chart to iden- • Connect a voltmeter to the
different scan tool or software. tify sensor terminals at the TCM. L/R 1989-99 Caravan (41TE)
To check for CCD communication Use a scan tool to watch the TCM Terminal ID and Voltage Chart
between modules, check for varying process the signals: for the terminal number. Your
voltage between CCD communication In park, the TSS should read close voltmeter should display 12
terminals: to engine RPM. The OSS should read volts.
• 1989–95: terminals 43 (+) zero. • Apply air pressure to the L/R
and 4 (–) At a stop in drive, both sensors pressure tap. The voltmeter
• 1996-on: terminals 5 (+) and should read zero, even during a stall should display 0V.
44 (–) test. If the TSS develops a signal, a • Release the air pressure and
clutch is slipping or the TSS circuit is 12V should reappear.
With the engine running, voltage generating a false signal caused by EMI
should be between 2.3 and 2.5DCV. If (Electromagnetic Interference) or a bad If the switch circuit tests okay and
there seems to be data stream activity, ground. the pressure switch code returns, look
your scan tool or software may not be Now operate the vehicle in third for a crossleak or the TCM may be bad.
compatible with the TCM. gear, in lockup. Both sensors should If the switch is bad, check the circuits
Another method to check for com- read the same RPM as the engine. or replace the solenoid pack.
munication problems is to access other Accelerate and decelerate: Make sure Repeat the test for the 2–4 and OD
modules in the vehicle and deter- both sensor signals change with engine pressure switch circuits. Reconnect the
mine what data is being received and RPM. If not, either a clutch is slipping TCM.
what isn’t. An example would be the or the speed sensor needs further test- Diagnostic Tip: A pressure switch
instrument panel data stream display- ing. trouble code may be caused by valve
ing engine RPM but not VSS. This Diagnostic Tip: Bad grounds, con- body crossleaks. Common examples
would indicate a TCM communication nections, alternator diodes and EMI can are 2–4 or L/R pressure switch codes,
problem. affect speed sensors. If the clutches are which can indicate a bad solenoid pack,
good and there are no external prob- a sticky solenoid switch valve, or a
lems, the TCM may be bad. warped valve body.
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GEARS October 2005 23
Troubleshooting the 604 (41TE)
Engine RPM, Temperature and
TPS Inputs — Locate the engine RPM
signal input at TCM terminal 45. The
TCM should be connected for this test.
Use a lab scope or multimeter to check
for a 0–5 volt pulsing signal.
On 1996-on models, check the
temperature sensor voltage at terminal
54. Locate terminal 12 for the TPS sig-
nal. See the 1989-99 Caravan (41TE)
Terminal ID and Voltage Chart for
specifications.
Type 3 Problems
Solenoid Circuit Errors — Solenoid
circuit codes 41–44 can be difficult to
fix. This is partly because the TCM
goes into limp mode by turning the
ETAX relay off. Since the solenoid
circuits are off, testing is limited and
inconclusive. Here’s how to test for Figure 3
code 41, indicating a faulty L/R sole-
noid circuit: solenoid windings. If the solenoid cir- indicate clutch clearance prob-
• Make sure the battery is fully cuit still reads 6.5–7.5 amps, the circuit lems. These codes can also set
charged with a minimum rest and solenoid are good, so the TCM is by faulty speed sensors, cross-
voltage of 12.45 volts. likely the problem. Reconnect the TCM leaks, wrong stall converter,
• Disconnect the TCM. when finished. an accumulator problem, tem-
• Connect a jumper wire VSS Output Signal (96-on) — Use perature too high or too low,
between terminals 56 and a scan tool to check for VSS data in the or a bad TCM.
15. This should energize the PCM and IPC, or check for a frequency • These transaxles use an
ETAX relay and supply bat- signal at terminal 58. With the drive Electrically Modulated
tery voltage to the solenoid wheels turning at 12 MPH, the VSS Converter Clutch (EMCC).
circuits. On some models you signal should be about 2.5 Hz. With the An EMCC slip code may be
may have to turn the ignition drive wheels turning at 40 MPH, the caused by a bad converter, a
switch on. You now have con- signal should be about 800 Hz. pump problem, or a warped
trol over the entire solenoid valve body. Test EMCC
circuit (minus the TCM). Type 4 Problems operation by monitoring the
• Make sure terminal 20 at the Gear Ratio Problems — The TCM EMCC release pressure tap.
TCM connector has battery detects gear ratio errors by calculating With EMCC partially applied,
voltage. signals from the input and output speed release pressure should be
• Ground the L/R solenoid cir- sensors. Make sure both sensors are between 15–60 PSI; with the
cuit at terminal 20 through an working. See Type 2 Problems in this EMCC fully applied, release
ammeter, lab scope or jumper article. If they are working, the clutches pressure should be below 5
wire with an inductive current are slipping, a hub or shell maybe PSI.
clamp to monitor current (fig- stripped or the solenoid pack is bad.
ure 3). A few points to remember about Once you’ve verified that all cir-
gear ratio problems: cuits related to the problem or symptom
As soon as you measure the cur- • Code 35 (Lost Pump Prime) are working properly, the most likely
rent flow, remove the jumper wire; you is usually caused by a clogged problem is a bad TCM. By performing
should have 6.5–7.5 amps. If it’s too filter, warped valve body or these tests, you should be able to identi-
high or low, look for a problem in the worn pump. fy and isolate most electrical problems
circuit. If the current is correct, suspect • Codes 37 (Solenoid Switch in any 41TE transaxle.
a bad TCM. Valve Stuck in the Lockup
To verify the circuit, repeat the Position) or 47 (Solenoid
current flow test for the other three Switch Valve Stuck in the
solenoids circuits at terminals 19, 59 Low/Reverse Position) may
and 60. As a final test, cycle the suspect also be caused by a warped
circuits on for one second and then off, valve body.
about 10–12 times. This will heat up the • Codes 60–63 (CVI codes)
24 GEARS October 2005
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