Sonnax Chrysler Info from Bob Sonnax :The following information is compiled from post-rebuild drive-ability complaints, which may or may not be related to the converter ..
Converter Related "Tech"
by Bob Warnke
These Domestic unit complaints are categorized by vehicle application:
Daimler/ Chrysler, GM & Ford
Example: 670-1 identifies the transmission.
At as first correction:
• A,B,C, place the complaint in an order.
• "t" notes a concern as transmission related, c = converter related , v =vehicle related.
Compiled for Sonnax and Rebuilders by Bob Warnke, from Tech. calls and recorded sources. Rev. 05-15-02
Daimler/Chrysler Converter Conditions:
• No TCC apply
• Engine stalls on engagement
• TCC shudder
• At: Pump warpage, pump volume low are the most common problems.
• Bt: Installing a stronger TCC control spring will delay apply and often reduce shudder complaints.
• Cv: Bypass the cooler and re-test. If the problem is gone, the cooler may be restricted. If the problem still exists, check cooler flow to verify pump output.
• Dv: Chrysler has a TCC bypass wiring harness to prevent TCC solenoid control. Using this will reduce gas mileage! An alternative that ends with same results, is to block TCC apply valve toward solenoid.
• Ec: If you have low flow when-ever TCC is not applied and a large increase in flow with TCC electrical signal, the converter cover bushing may be too restrictive.
604-1 ( 41TE & 42LE)
• Harsh TCC apply or shudder
• TCC piston contacting the cover, piston warpage
• Converter friction material in the pan
• Ac: Bond TCC lining to cover or piston. Use a 400 degree bonding temp. with flow time of 10 minutes and 150-240 press psi. Use abrasive to grit blast the bonding surface. Aluminum oxide of 80 grit will result in a surface finish of Ra 75-150. The friction contact surface should be held to 25 Ra or better. The above suggestion is from Chrysler remanufacturing standards
• Bt : Replace the pressure regulator-reducing sleeve. (Sonnax part number 92835-07), was designed to insure converter feed
• Ct: Resurface the case and valve body until flat, with a stone or file and re-clean
• Dt: Remove both TCC control valves retained by the wide plate, verify their full stroke
• Et: To regulate TCC apply psi, install the Sonnax part # 92835-03K. This valve limits the maximum apply psi. to prevent piston fatigue and lining failure
• Ft: Resurface the pump stator, and recess the bolt threads. Push out stator tube & apply 518 Lock-tite to spline area. Re-press to OE position.
• Gc: Verify the converter cover bushing centers the turbine/input shaft. This is required to prevent sealing ring cross leakage.
• Hv: Verify cooler flow (at operating temperature) is at least .8 GPM at idle in OD, 1.7 TCC off and 1.9-2.0 TCC applied. See the Sonnaflow charts for further examples.
• Ic: Also refer to 604-3 suggestions
• Code 38, TCC shudder
• At: Excessive pump bushing to converter hub clearance. Strive for under .003", over.005" often is a problem
• Bt: Pump volume low due to excessive pump clearance. Set gear pocket depth clearance to a maximum of .002"
• Ct: '91 and latter units; defective/open flow by-pass valve. The Chrysler by-pass valve under the pump may stick open, which reduces pumps ability to keep TCC applied. See Sonnax# 92836-01K
• Dt: Verify cooler flow and pump quality with SonnaFlow. See 604-1Hv specifications
• Ec: Poor oil flow past the converter's front cover bushing, which supports the turbine hub.
• Ft: TCC valves hung up in valve body
• Gt: Filter o-ring can suck air, place an AXOD accumulator spring around a magnet and place it between oil pan and filter near o-ring area.
• Hc: Poor converter lining material or surfaces. See also 604-1 for specifics
• It: Either valve under the wide retainer sticking
• Jt: TCC feed hole plugged in the plate with gasket material
• TCC engine stall, stumble, premature apply or lining overheat
• Ac: Turbine cover bushing moved inward and restricting release oil flow from venting
• Bc: No or restricted oil flow past a turbine to cover bearing placed at that location
• Cc: Poor cover surface, excess piston to cover run-out
• Dc: urbine hub to piston o-ring leaking or piston to turbine hub score
• Ec: Balance piston and turbine as an assembly
• Fc: Re-true the cover and piston surfaces and remove component run-out
• Gc: Set piston travel to .025" to .035"
• Hv: Verify flex plate bolts have not dimpled the converter cover
• Ic: Piston damper spring contact with turbine or cover
• Jt: See also 604-1,B,D,F,H
• Kv: Cooler circuit restriction
• Repeated transmission or converter overheat
• Av: Can be caused by disabled engine temperature sensor.
• Bv: Defective TPS
• TCC cycling at light throttle between 32-40 mph.
• At: Use 7176 Chrysler oil
• Bv: Reflash or install latest updated controller
• Ct: Bond lining to piston or cover, do not use floating friction clutch.
• Dt: Install pressure control sleeve # 92835-07
• Et: Inspect TCC valves for complete stroke
• Ft: Install a #99 plate ID. valve body, available from OEM.
• Gv: Defective thermostatic elements, engine or transmission & front/input speed sensors or connectors.
• TCC shudder or Erratic cycling
• Av: Probe the connector ground for erratic electronic control. Isolate possible distributor bushing, TPS or sensitive/dirty mass air flow sensor
• Bt: TCC valve bore badly worn
• Ct: If converter is marginal, a 94 or latter body with boost tube will raise converter apply psi by approx. 10% over line psi. when in 4 th and/or TCC applied.
• No TCC after transmission rebuild
• Slow converter fill or repeated lube failure
• At: Mismatced pump halves; large (44RE) and small (42RE) suction ports
• Bt: Mismatched large suction port case with small port valve body
• Ct: This condition can be found quickly as very low SonnaFlow.
• Dt: Switch valve stuck open towards spring
• Et: Separator plate not algned properly, bolt torque pulls plate away from switch valve.
• Delayed engagement together with ballooned converter
• At: Worn pressure regulator reducing valve, aggressively drilled line to lube
• TCC cycling on-off, erratic TCC at hot or cold ranges
• Av: Temperature sensor wiring/terminals defective. (element harness in wiring loom or in cooler line) Transmission operating too hot (TCC & 4 th canceled). Inspect cooler, lines and operating conditions at load.
• Bv: A cooler that returns fluid at a very cool temp. causes pan or line sensor to cancel TCC and 4 th .
• Excessive TCC slip, repeated converter lining failure, codes 740 etc.
• Av: Radiator, trans cooler, inter-cooler, cooler lines restricted. Note: A good pump with the large diameter cooler lines will Sonnaflow up to 2.9 GPM at TCC apply and 1.6-1.9 TCC off. Refer to the various Sonnaflow charts.
• Bt: Excessive line pressure, elevates
• Cv: High loads, high input torque
• Rapid or repeated converter friction failure
• Soft TCC, No TCC apply or clutch not releasing
• Ac: Bond lining where OE was floating (see 604-1AC)
• Bc: Alter converter stall on diesel units. Contact Torque Converter Rebuilders Association (TCRA) for stator modification which improves lining life
• Ct: Adjust line to maximum of 80 psi. (idle drive) install Sonnax switch valve # 22771A-01K, follow directions on exhaust slot modifications
• Dv: Verify cooler flow minimum is .7 gpm idle in drive, 1.6 gpm TCC off cruise and 1.8-2.1 gpm TCC applied.
• Et: Install a quality teflon seal on the turbine shaft, air check circuit from the end of input through case port for cross leakage.
• Fc: Verify the turbine to cover bushing/bearing is centering the turbine correctly
• Gt: Resurface the pump stator, and recess the bolt holes in pump body.
• Ht: Set up pump pocket to gear side clearance at max. of .0015" or replace the pump assembly. Pump tolerance critical!
• It: OE had some turbine shafts with feed hole too small. Inspect or update
• Jv: Cover may be distorted from torque stress. Install Sonnax billet cover
• Sensitive TCC in-out
• Av: Defective TPS, suggest automatic replacement after 50k.
• Bt: Open the exhaust slot in the separator plate, See instructions with Sonnax # 22771A-01
• Cv: Additional transmission cooler may reduce return oil temperature to a degree that thermal pan sensor disengages TCC.
• Dv: TCC cycling or sensitive below 65 mph. Vehicle may need TCM updates (replacement) to eliminate sensitive program of TPS and VSS.
• TCC stalls engine in reverse
• Av: Verify cooler flow is not restricted with Sonnaflow (see 47Re-1 Dv for specs)
• Bt: Problem generally related to release oil flow. Open the release exhaust circuit outer circuit of switch valve.
• Ct: Reseal the turbine shaft rings at the stator, air check flow of input shaft
• Dt: Insure oil flow of release circuit in the converter is not restricted