Chrysler Repair: A604 41te trany rebuild: air pressure tests, dodge minivan, input shaft


Question
Hello my name is Dave and I had trany problems with my  97 dodge minivan 3.3 engine with a604 tans. with OD The trany would go thru 1st and 2nd then just spin like I had put in neutral ,after that it goes into limp mode ,I checked for codes and that said incorrect 3 gear speed ratio so I replaced input and output sensors still the same so I replaced the speed sensor  oh I did check the wiring for breaks and all checked out ,finally I replaced the control mod ,same thing so then I took on a real challenge and decided to rebuild it myself, I've got it finished and made a plate to do an air pressure test but the manual isn't real clear on whether the input shaft should turn freely or not while putting the 30lbs of air to each specified port or in one test for the underdrive clutch if I'm supposed to put air to all three ports at the same time or what .I would like to make sure It works before I put back in ,are there any other tests I can do before I install it ? Ihave read thru most of your answers and hope you have some expertise on rebuilding  thanks  dodge diehard Dave

Answer
Hi Dave,
It appears to me that the tests of the overdrive, reverse, 2/4, and low/reverse clutches are done by injecting pressure through a single hole and then observing the motion of the respective pistons when the air is applied and when it is removed.
The underdrive clutch can't be seen so it is checked by function. You apply air to the low/reverse and 2/4 clutches. This locks up the output shaft. Then put a piece of rubber hose around the input shaft and a clamp-on plier to turn the input shaft. Then apply pressure to the underdrive clutch and see if the input shaft will not rotate using hand pressure. Then release the pressure on the underdrive clutch and verify that the shaft will rotate.
I don't have any other suggestions for testing before installation. Best of luck.
Roland