Hi everyone, first post here, could really use some suggestions.

Van is a 1999 Dodge Grand Caravan with a 3.8L engine, I bought it used about a year ago. Over all it is in fairly good shape. I was told the transmission was overhauled about 6 months before I bought it but I do not have proof of that and do not know the details of the work that was done. It Has 320,000 km on it. 20,000 from me.
It has been completely trouble free for me, drives great, starts everytime (even in -35*c weather) and shifts perfectly and smoothly all day long... until Thursday morning...

I stopped at an intersection, proceeded to drive on and half way through the turn the transmission dropped out of gear as if I put it in neutral... I coasted to stop and proceeded to try the other gears, there was nothing... I shut the van off and restarted and I was able to select drive and drive away, BUT as soon as it tried to change into second gear once again it just dropped out of gear as before. Again no gears would work.
Once again I restarted the van and this time tried reverse first, no reverse, but like the first time I could select "D" "3" or "L" I put it in drive and pulled away, again the same thing happened... Okay, again I restarted but this time I dropped it straight down to "L" in low gear I could drive as long as I wanted, but only up to about 30kp/h being in low gear...

Now, I have been researching this since than. Two days now. I am aware of "Limp Mode" Does limp mode usually allow for reverse? or is it forward only?
When in limp mode, would one be able to drive with "D" selected for more than 60 feet without droppig out of gear?

I have found many many cases very similar to mine, but none exactly like it.
I have a scan tool and get codes P0700 and P0732 (Gear Ratio 2 not Correct)
I have changed out the input and output sensors. Same thing.
I have changed the oil and filter. Same thing.
I have removed the solenoid pack, opened it up, cleaned it out (it was fairly dirty) re-assembled and installed...same thing.

Currently I am going through the electrical as I am reluctant to believe the transmission would just be blown from one stop sign to the next. There was absolutely no warning signs. Seriously, it went from being one of the smoothest transmissions I have ever driven to non-working between stop signs...???

Re-cap
-Start van, I can select any gear except reverse, reverse does not work at all, ever.
-After selecting one of the selectable gears I can drive up until 2nd gear is called for at which point it basically drops into neautral and I can no longer select any gear at all.
-Shut van off, restart and I can do the exact same thing all day long. No reverse.

Please help!

Dave

 

when you dropped the pan, did you see lots of debris? sounds like a solenoid or stuck valve problem in the valve body. Before ripping into that, I'd disconnect the battery for a half hour and try again. Is it the 41th transmission? I have a factory service manual for the 1998 model, but it doesn't seem to have a nice diagnosis section for this transmission, and nothing like what you describe. lots of electrical and pressure tests. I will try to make pdf copies and post them, again this is from a 1998 though. I cannot post all 80 or so pages, I'll do all the testing pages and valve body stuff. I'm assuming you don't want to rip the guts out of this thing and leave out the overhaul pages.

 

Well, it took some doin' but I have made pdf copies of the entire 41th transmission chapter of the factory service manual, but I cannot upload to this site, even though I broke it apart so that each file will be under the limit. If you private message me your email, I will email it to you. I will also message the moderator if he can have this chapter up on the site for all. I know you'll get a LOT of info out of it...just keep in mind that this is from a 1998 factory service manual, but I seriously doubt it is any different from the 1999.

 

Down Low

Welcome to DF

Mirageman i got your email. Let me know what PDF files you are looking for, this way i'll post it.

The P0732 code is a gear ratio error in 2nd gear. How is the fluid? Red or Pink? If they are, You may have a broken hard part inside the transmission.

Symptom:
P0700-INTERNAL TRANS CONTROLLER
When Monitored and Set Condition:
P0700-INTERNAL TRANS CONTROLLER
When Monitored: After a reset (ignition key turned to the RUN position or after cranking
engine), and every 60 seconds thereafter. Also after an internal (TCM) invalid delay check.
Set Condition: The watchdog fault line remains high after the period has elapsed for the
too early/too late watchdog test, or the transmission relay remains on after the watchdog
expires. Transmission in LIMP-IN and MIL on after 10 secs of vehicle operation.
POSSIBLE CAUSES
CHECKING SYMPTOMS AND POSSIBLE CAUSES
LOW BATTERY VOLTAGE CAUSING SYMPTOM
INTERMITTENT CODE P0700
P0700 GLOBAL GOOD TRIP COUNTER LESS THAN 3
SETTING DIAGNOSTIC TROUBLE CODE P0700
TEST ACTION APPLICABILITY
198 Check the Global Good Trip counter.
Is the Global Good Trip counter 3 or less ?
All
Yes ® Replace TCM.
Perform Transaxle 41AE/TE Verification TEST VER-1A
No ® Go To 199
199 Write down and record all DTC’s and one trip failures.
With the DRB, erase DTC’s.
Follow the instructions below, and try to set the code.
Code P0700 - Turn the Ignition from Off to On, then start the Engine. Place foot on
Brake and move the Shift Lever through all Gear Positions.
Did the erased DTC come back ?
All
Yes ® Replace TCM.
Perform Transaxle 41AE/TE Verification TEST VER-1A
No ® Go To 200
200 Inspect the following for pushed out terminals or flared connections: - Engine ground
connections - TCM grounds (pins 53 and 57) - TCM Battery Feed pin 56 - Power Feed
to Trans Control Relay from EATX fuse in the PDC - TCM Fused Ign Sw Output pin
11.
Was a defective condition found?
All
Yes ® Repair as necessary.
Perform Transaxle 41AE/TE Verification TEST VER-1A
No ® Go To 201
201 Connect the DRB to the Data Link Connector. Reconnect any disconnected components.
With the DRB, erase all Trouble Codes and set the Global Good Trip Counter
equal to zero.
With the DRB, display Transmission temperature. Start and run the Engine until the
Transmission is HOT (above 110 deg. F) CHECK THE TRANSAXLE FLUID.
ADJUST IF NECESSARY.
Road test the vehicle. With the DRB, monitor the Engine RPM. Make 15 to 20
1-2,2-3,3-4 upshifts. Perform these shifts from a standing start to 45 MPH with a
constant throttle opening of 20 to 25 degrees.
Below 25 MPH, make 5 to 8 wide open throttle kickdowns to 1st gear. Allow at least
5 seconds each in 2nd and 3rd gear between each kickdown.
If the vehicle is equipped with AutoStick, place the shift lever in the AutoStick
position and perform a complete upshift and downshift sequence.
Did the Transaxle function properly during the road test ?
All
Yes ® Test Complete.
No ® Go To 202
TEST ACTION APPLICABILITY
202 Note: Low Battery voltage can cause many of the non-DTC Symptoms (denoted by a
preceding asterisk) listed in the Symptoms List.
Check the Battery voltage with a voltmeter.
Is the Battery voltage low ?
All
Yes ® Repair low Battery voltage as necessary and verify that original
symptom exists before proceeding with any non-DTC (Symptoms
preceeded with an asterisk) symptom repairs.
Perform Transaxle 41 TE/AE Verification TEST VER-1A
No ® If Battery voltage is OK, refer to Symptoms List for problems
related to Transmission and select the Non-DTC Symptom (preceeded
with an asterisk) from the Symptoms List that best
describes the existing problem.
Perform Transaxle 41 TE/AE Verification TEST VER-1A

 

Symptom:
ADDITIONAL GEAR RATIO ERROR IN 2ND (P0732)
POSSIBLE CAUSES
INTERMITTENT 2ND GEAR SLIPPAGE
UD AND 2-4 CVI’S OUT OF SPEC
UD AND 2-4 PRESSURE < 105 PSI
UD PRESSURE < 5 PSI IN 4TH GEAR
TRANSAXLE (2-4 SEALS)
2-4 ACCUM SEALS WELDED TOGETHER
UD ACCUMULATOR SEALS WELDED TOGETHER
TRANSAXLE (UD SEALS)
TRANSAXLE SEALS
UD PRESSURE > 5 PSI IN 4TH GEAR
TEST ACTION APPLICABILITY
1 Before beginning this diagnostic procedure, test for P0732 GEAR RATIO ERROR IN
2ND must be completed first.
Has test for P0732 GEAR RATIO ERROR IN 2ND been completed?
ALL
Yes ® Go To 2
No ® Refer to Symptom List and perform test for P0732 GEAR RATIO
ERROR IN 2ND
2 If the Transmission is slipping, the TCM will initiate a Loss of Prime test, and a
Trouble Code will be set.
Is Code P1791 present ?
All
Yes ® Refer to symptom ADDITIONAL LOSS OF PRIME (P1791) in the
TRANSMISSION category.
No ® Go To 3
3 With the DRBIIIt, check the UD and 2-4 Clutch Volume Indexes.
Is the UD Clutch Volume Index between 24 and 70, and the 2-4 Clutch Volume Index
between 20 and 77 ?
All
Yes ® Go To 4
No ® Repair as necessary per service procedures. Replace or repair
parts as necessary.
Perform 41TE/AE Transaxle Verification Test VER-1A
TEST ACTION APPLICABILITY
4 Turn ignition off to the lock position. Install 0 to 300 PSI pressure gauges on UD and
2-4 pressure ports. Raise the Drive Wheels off the ground and properly support the
Vehicle. Start Engine, apply Brakes, and place Gear Select Lever in OD.
With the DRBIIIt, select the 2nd GEAR CLUTCH TEST.
Firmly apply Brakes and open Throttle to 30 degrees. Read the UD and 2-4 pressures
from the pressure gauges.
What is the result of the 2nd Gear Clutch Test ? ( Choose only one)
All
Both UD & 2-4 pressure less than 105 PSI
Repair or replace Valve Body as necessary. (Regulator Valve
sticking)
Perform 41TE/AE Transaxle Verification Test VER-1A
2-4 pressure less than 105 PSI
Go To 5
UD pressure less than 95 PSI
Go To 6
None of the Above
Go To 7
5 Remove the Valve Body. Inspect the 2-4 Accumulator Seals.
Are the 2-4 Accumulator seal ends welded together or otherwise damaged ?
All
Yes ® Replace 2-4 Accumulator seals. Also, replace Accumulator if it
plastic. (Replace with Aluminum)
Perform Transaxle 41AE/TE Verification TEST VER-1A
No ® Repair as necessary per Service instructions. Replace worn or
damaged parts as necessary. Pay special attention to 2-4 Clutch
Seals, 2-4 Accumulator Seal, and Valve Body Seal.
Perform Transaxle 41AE/TE Verification TEST VER-1A
6 Remove the Valve Body. Inspect the UD Accumulator Seals.
Are the UD Accumulator Seals welded together or otherwise damaged ?
All
Yes ® Replace UD Accumulator Seals.
Perform Transaxle 41AE/TE Verification TEST VER-1A
No ® Repair as necessary per Service instructions. Replace worn or
damaged parts as necessary. Pay special attention to UD Clutch
Seals, Input Clutch Hub Bushing and Reaction Shaft Support
Rings.
Perform Transaxle 41AE/TE Verification TEST VER-1A
7 Did the 2nd Gear Clutch Test pass ( Input speed remain at 0 RPM) ? All
Yes ® Go To 8
No ® Go To 9
8 The conditions required to set this DTC are not present at this time.
Does the customer complain of intermittent 2nd gear slippage particularly when hot
or cold ?
All
Yes ® Repair as necessary per service manual instructions. Replace
worn or damaged parts as necessary. Replace all seals.
Perform 41TE/AE Transaxle Verification Test VER-1A
No ® Test Complete.
TEST ACTION APPLICABILITY
9 Install a 0 to 300 PSI pressure gauge on the UD pressure port.
With the Drive Wheels raised off the ground and the Vehicle properly supported,
start the Vehicle. Monitor RPM display. Place the Gear Select Lever in OD, and
accelerate the Vehicle to 50 MPH or until 4th gear engages. Read the UD pressure
gauge.
Is the UD pressure above 5 psi in 4th gear ?
All
Yes ® Go To 10
No ® Repair as necessary per service instructions. Replace worn or
damaged parts as necessary. Carefully inspect Gear Train for
failure. Replace all Seals.
Perform 41TE/AE Transaxle Verification Test VER-1A
10 Replace the Solenoid Pack. Restart the Vehicle on the hoist. Monitor RPM display.
Accelerate the Vehicle to 50 MPH or until 4th gear is engaged. Read the UD pressure
gauge.
Is the UD pressure above 5 psi in 4th gear ?
All
Yes ® Replace the TCM.
Perform Transaxle 41AE/TE Verification TEST VER-1A.
No ® Repair as necessary per Service instructions. Replace worn or
damaged parts as necessary. Inspect Gear Train for failure.
Replace all seals.
Perform Transaxle 41AE/TE Verification TEST VER-1A