2002 Caravan 3.8L

Had the trans replaced with a remanufactured unit 15,000 miles ago. And a 1-2 harsh shift that I had in the original trans was not fixed. The remanufactured has since been rebuild 3-4 times under warranty with no change to the 1-2 harsh shift. The shop has no idea what else to do. They have installed a trans go shift kit and the Sonnex update.

Under heavy throttle it shifts great. The harsh shift is under light to moderate throttle.

Any ideas?

 

I've never had that problem with my '03, so I can't give you any first-hand experience. But this sounded familiar, so I dug around a bit and came up with the thread linked below. This thread wanders around like many do, and the first 3 pages are generally about things not in your ballpark.
But I think your same issue is discussed starting at post#33. At that point, a couple of experienced and knowledgable guys are saying that this problem is known to be a "normal" abnormal problem. So you can take that FWIW, and depending on how harshly your van is shifting, perhaps give some consideration to just living with it asis.
http://forum.chryslerminivan.net/sho...fting-problems

 

I have read that thread previously. They are originally talking about a shudder/miss/ chuging that happens to these vans at 45-60mph after TC lock up. I was experiencing the same condition and fixed it with a new coil, wires and plugs.

Anyhow, my 1-2 shift is fairly harsh. Much worse than it was before my original tranny went out. Having had the remanufactured trans rebuilt 3-4 times, 2 new valve bodies, a Sonnax update kit all new sensors and a new solenoid pack. I don't think the issue is with the trans..... unless the remanufacturer and the trans rebuilder has made the same mistake repeatably.

 

It's the pits having the same problem come back at you over and over again. I suppose they must have tried another TCM somewhere along the way too? Have you considered taking it to another tranny shop, just to get a new set of professional eyes on it? You have yourself a RPITA there.

 

A TCM has not been tried. I am pretty close to taking it to the local dealer for a diagnosis.

 

I would check the transmission control module for updates first and then check the CVI ( Clutch volume Index ) And then a clutch test. I would get rid of the shift kit and put the transmission back to factory specs.

Here is the CVI specs.CLUTCH CLEARANCES

DESCRIPTION
METRIC
STANDARD

Low/Reverse Clutch (Select Reaction Plate) 0.89-1.47 mm 0.035-0.058 in.
2/4 Clutch (No Selection) 0.76-2.64 mm 0.030-0.104 in.
Reverse Clutch (Select Snap Ring) 0.89-1.37 mm 0.035-0.054 in.
Overdrive Clutch (No Selection) 1.07-3.25 mm 0.042-0.128 in.
Underdrive Clutch (Select Pressure Plate) 0.94-1.50 mm 0.037-0.059 in.

 

Here is a TSB for the 1-2 harsh shift.

This bulletin is supplied as technical information only and is not an authorization for repair.
THE DRBIIIŽ FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON
DealerCONNECT.
FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH
FILES AND REPROGRAMMING INSTRUCTIONS WILL ALSO BE AVAILABLE ON
ITIL/ISIS DVD DECEMBER, 2007.
SUBJECT:
Flash: Shift Quality Improvements Or Torque Converter Shudder With Coordinated
Change
OVERVIEW:
This bulletin involves selectively erasing and reprogramming the Powertrain Control
Module (PCM) with new software, performing Quicklearn and depending on the
Symptom/Condition, replacing the torque converter with a revised part.
MODELS:
2007 (RG) Chrysler Voyager (International Markets)
2007 (RS) Town & Country/Voyager/Caravan
NOTE: This bulletin applies to models equipped with a 3.3L or 3.8L engine (sales
code EGA, EGM or EGH).
SYMPTOM/CONDITION:
Some customers may experience the following:
1. Shift quality concerns associated with 1 - 2 or 2 - 3 upshift harshness and / or 2 - 1
coast down harshness.
2. Transmission Shudder.
a. If experienced, the shudder may occur when the transmission temperature is
between 38° C and 54° C (100° F and 130° F) during steady state driving with the
torque convertor in partial lock (EMCC) operation. The shudder feels like the vehicle
is being driven over rumble strips.
NUMBER: 21-015-07
GROUP: Transmission
DATE: October 19, 2007
DIAGNOSIS:
Using a Scan Tool (DRBIIIŽ) and appropriate Diagnostic Procedures available in
DealerCONNECT>TechCONNECT, verify all transmission systems are functioning as
designed.
If the vehicle operator describes the Symptom/Conditions and / or they can be verified,
perform the appropriate Repair Procedure as follows:
ˇ Symptom Condition 1 - Shift Quality, Perform Flash Only.
ˇ Symptom Condition 2 - Shudder, Perform Flash and Torque Converter
Replacement.
PARTS REQUIRED:
Qty. Part No. Description
1 04275086AB Label, Authorized Modification
AR (1) 05093926AB Kit, Torque Converter (Includes EMCC1 friction
material)
SPECIAL TOOLS/EQUIPMENT REQUIRED:
NPN Battery Charger
CH2002 General Purpose Interface Bus Cable Assembly
CH6000A Scan Tool (DRBIIIŽ)
CH7000A/7001A J1962 Cable with red DRBIIIŽ connector
TechCONNECT Workstation
NOTE: An updated J1962 cable has been released. This cable has a red colored
connector at the DRBIIIŽ connection. Use this cable whenever a flash is
being performed.
FLASH REPAIR PROCEDURE:
NOTE: Whenever a controller is programmed, the software in the DRBIIIŽ; must be
programmed with the latest revision level available.
NOTE: If this flash process is interrupted/aborted, the flash should be restarted and
then follow the directions on the DRBIIIŽ.
1. Before beginning the reprogramming procedure, remove any old flash reprogramming
files from the DRBIIIŽ memory. To clear the memory from the MAIN MENU:
a. Simultaneously press the “MORE” and “YES” keys.
b. A screen will appear requesting a “COLD BOOT”.
c. Follow the on screen instructions by selecting the “F4” key.
d. When the DRBIIIŽ reboots to the MAIN MENU, proceed to Step #2
2. With the ignition switch in the “RUN” position, determine the original part number of the
PCM currently in the vehicle. Using the DRBIIIŽ select:
a. "DRBIIIŽ Standalone"
b. "1998 - 2007 Diagnostics"
21-015-07 -2-
c. "All (Except Below)"
d. “Engine”
e. “Module Display”
f. Record the “PCM part #” on the repair order for later reference.
3. Connect the DRBIIIŽ to TechCONNECT. Open TechTOOLS and verify that the
"DRBIIIŽ Status: Connected" message is in the upper right corner of the TechTOOLS
screen.
4. Enter the “PCM part #” recorded in Step #2 in the “Parts Criteria” area and select
“Show Updates”. TechTOOLS will populate the appropriate calibration.
5. Select the calibration.
6. Select the “DRBIII” radio button which is next to the “Download/Update” button.
7. Select the “Download/Update” button.
8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and
follow the instructions on TechCONNECT. When the flash process is complete,
proceed to Step #9.
9. Disconnect the DRBIIIŽ from TechCONNECT.
10. Open the hood, install a battery charger and verify that charging rate provides
approximately 13.5 volts.
11. Connect the DRBIIIŽ to the vehicle.
12. Download the flash from the DRBIIIŽ to the vehicle. Using the DRBIIIŽ select:
a. “Vehicle Flash”
b. Follow the directions on the DRBIIIŽ screen. When the flash process is finished,
complete the remaining steps.
NOTE: Due to the PCM programming procedure, a DTC may be set in other modules
(TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's
may cause the MIL to illuminate. Check all modules using “Module Scan”,
record the DTC's, and erase these DTC's prior to returning the vehicle to the
customer. Erase any DTC's in the PCM only after all other modules have had
their DTC's erased.
13. With the DRBIIIŽ perform Quicklearn procedure.
NOTE: The following step is required by U.S. law.
14. Type the necessary information on the “Authorized Modification Label” p/n
04275086AB and attach near the VECI label (Fig. 1).
-3- 21-015-07
Fig. 1 AUTHORIZED MODIFICATION LABEL
1 - POWERTRAIN CONTROL MODULE P/N (INSERT P/N) USED
2 - CHANGE AUTHORITY: TSB XX-XXX-XX
3 - DEALER CODE: XXXXX
4 - DATE: XX-XX-XX
TORQUE CONVERTER REPLACEMENT:
1. Following the procedures in DealerCONNECT>TechCONNECT, replace the torque
converter with pn 05093926AB.
2. Enable Torque Converter Break In with the DRBIIIŽ.
a. Select TCC Break In View.
b. Select Break In.
NOTE: The torque converter includes new friction material (EMCC1) that must be
operated with the latest software calibration described by this bulletin.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: Description Amount
18-19-06-A1 Reprogram Powertrain Control Module (B) 0.7 Hrs.
21-33-01-98 Torque Converter - Replace, Includes Reprogram
Powertrain Module (B)
4.7 Hrs.
FAILURE CODE:
ZZ Service Action
21-015-07 -4-