CHRYSLER A500/A518 - NO SHIFT TO 4TH GEAR

COMPLAINT: Before and/or after rebuild, vehicles equipped with the A500/A518 transmission may exhibit a "No 4th" gear condition. Get obd2 scanner for more? Vehicle Speed, Engine RPM, Throttle Position, Coolant Temperature, MAP sensor and overdrive cancel information have all been verified, and are correct on the scanner.

CAUSE: The cause may be, an internally grounded Park/Neutral switch, a grounded Park/Neutral switch wire, or an internally grounded Starter Relay. These can be easily detected, because the engine will start in ranges other than Park or Neutral. The center terminal of the Park/Neutral switch provides the ground for the starter solenoid circuit through the selector lever in Park and Neutral positions only. The computer moniters this ground circuit from the starter relay.  If the Park/Neutral circuit is grounded while in the Drive position, the vehicle may exhibit a no 4th gear condition.

CORRECTION: Refer to Figure 1 for the location of the Park/Neutral switch. Disconnect the three pin harness connector from the switch, and see if the engine will start.
Note: For safety reasons, perform this test with the rear wheels off the ground.

If the engine will not start, perform the switch test as shown in Figure 1, and replace the Park/Neutral switch as necessary. If the engine does start, locate the "Starter Relay", normally found on the "Firewall" or "Fender Well", depending on the model. Check for continuity to ground on the brown with yellow tracer wire on early models, or the black with white tracer wire on late models, and repair or replace as necessary.
Note: The wire color at the center terminal of the Park/Neutral switch is normally the wire color at the Starter Relay.

If the Park/Neutral switch wire does not have continuity to ground, cut the wire at the starter relay and try again to start the engine. If the engine still starts, replace the relay.

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CHRYSLER A500/518 - Premature Overdrive Carrier Failure

COMPLAINT: Premature failure of overdrive carrier and bearing. The bearing is actually destroyed first and the bearing takes out the overdrive carrier.

CAUSE: The cause is lack of lube oil to the carrier bearing.

CORRECTION: Replace the bearing and overdrive carrier. BEFORE installing the new overdrive carrier, machine a chamfer on the inside diameter that is .050" wide as shown in Figure 1. This will provide more lube oil for the carrier bearing. Get obd2 scanner to know more?

CHRYSLER A604 - Premature Failure Of o.d./Reverse Clutches

COMPLAINT: Premature failure of the overdrive and the reverse clutch plates, and all lip seals and "0" rings are good.

CAUSE: The cause may be an orifice and screen assembly blown out of the overdrive/reverse piston (See Figure 2).

CORRECTION: Replace the Orifice/Screen Assembly with a new one, available under OEM part number 4531903, and stake the new assembly in place (See Figure 2). They were not all staked in place at the factory.

SERVICE INFORMATION:
Overdrive/Reverse Piston Orifice/Screen Assy ........................................................ 4531903

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CHRYSLER A500 (42RE) SERIES - New Design Direct Clutch Housing

CHANGE: Chrysler Corporation re-designed the Direct Clutch Housing on the A500 (42RE) transmission, during the 98-99 model years, on some models only..Find more obd2 scanner for help? This clutch is applied in 3rd gear and reverse. Refer to Figure 1 for cut-away illustrations af both previous and current design housings.

REASON:
Greatly improved application of the Direct Clutch and improved durability.

PARTS AFFECTED:
(1) DIRECT CLUTCH HOUSING - Now is manufactured with the outer lip seal groove in the clutch housing instead of the clutch piston. Also the addition of another bushing in the clutch housing to support the clutch housing when installed on the pump cover, and addition of "V" shaped grooves where the steel plates and pressure plate ride in drum, as shown in Figure 2.
(2)DIRECT CLUTCH OUTER SEAL - Now an inside lip design, to accommodate the changes in the clutch housing, as shown in Figure 2.
(3)DIRECT CLUTCH PISTON - Now manufactured without the seal groove in the piston to accommodate the new seal in the housing, as shown in Figure 2.
(4)DIRECT CLUTCH PRESSURE PLATE - Now manufactured with two of the locating tabs missing, and must be oriented properly to fit into the clutch housing because of the added "V" shaped grooves, as shown in Figure 3.

INTERCHANGEABILITY:
None of the parts listed above will interchange with any of the previous design parts, but when using the parts listed above as a package, will retro-fit back to all models of the Chrysler A500 (42RE) transmissions. Some hot car tools like Fiat KM Tool and BMW Icom can help you more on auto repair.

SERVICE INFORMATION:
Direct Clutch Housing (New Design) .....................................................................4531285AB
Direct Clutch Outer Lip Seal (New Design)........................................................... 4058487AB
Direct Clutch Inner Lip Seal (New Design) ........................................................... 2852925AA
Direct Clutch Piston (New Design) ........................................................................ 4617154AB
Direct Clutch Pressure Plate (New Design) ............................................................ 4617176AB