'96 Grand Caravan 41TE Pan Removal Help

[benjamming]

The vehicle is a '96 Dodge Grand Caravan with 3.3L engine & 4-speed 41TE transmission. It has 134k miles on it. I don't think the transmission pan has ever been removed since it was installed at the factory.

The problem is that I've only been able to remove 3 of the 14 pan bolts (9.8 bolt with 10mm head). These bolts are all on the driver side where the ambient heat would appear to be less. I've used penetrating spray 3-4 times over the course of a day to no avail. Will that stuff soak through the factory applied RTV sealant? I'm using a 3/8 ratchet & socket cracking one chrome socket. I've used a 10mm combination wrench & can see some flexing in the wrench but still no luck. I can use a 1/2" ratchet, but I don't want to snap off the bolt heads & have to use bolt extractors, etc.

Would a 1/2" air impact set on low pressure help or hurt?

Is a propane torch next?

Thanks.

 

[tomcat27]

I can echo the same problem with same vehical (the steel bolts fuse to the aluminum) but I can offer no great assistance. you likely will not snap the bolts but rather strip them as I did... maybe heat would help. worst case (if you damage them) is to heli-coil them. hopefully someone can offer a better solution

 

[Chris142]

Penetrant won't get through the silicone. What brand of socket did you break?

 

[dishdude]

This might be one of those situations where you are better off just leaving it alone.

 

[hounddog]

Heat

 

[NHGUY]

Heat cherry red,then cool,then red again....and cool a little before twisting.You are bound to break a couple.

 

[SwampSurvivor]

How many miles are on the van? I'd pump out the old fluid through the line, then refill through the dipstick. That Chrysler transmission probably doesn't have too many more miles left in it anyway.

 

[meep]

same vehicle, same challenge, sort of.

I've had to beat the pan so hard to get them off that I'd have to re-bend the surfaces to straight before putting back on.

i'd either gently try an impact, or better yet do this---

buy this: http://www.amazon.com/Mityvac-7201-Fluid...eywords=mityvac

pull the fluid out. and then replace it.

NOTE---- I've gone through this with the 41te in my sig. about 9 months, or 2000 miles after replacing all of the oem (assumed) ATF+4 with new ATF+4, changing the filters and adding a magnefine, I started having trouble with the OD solenoid. As in, barely driveable. I had to replace the solenoid pack and now it seems to be ok, though I might say the line pressure seems a little low. I'm not one to tout "Don't change old ATF fluid!!" but I do think my complete change on ours probably freed up some debris. Sometimes it's hard to win.

 

[benjamming]

Socket was Wright Tools deep 1/4"

How does beating the pan help loosen the bolts?

I'm good with sucking out the fluid (much less mess on these units w/o a drain plug), but I'm sure that filter is way past full!

 

[RiceCake]

I have the exact same transmission. Never had the problem you're having but I can tell you that fitting a combination wrench to a bolt, tightly, so it can't slip off, holding it tight to take up any slack, and then striking the end wrench with a hammer works wonders (or even striking it with the heel of your palm for what its worth).

An impact would work but I've yet to need it for anything but the most extremely large bolts, and on a transmission it sounds rather nutty.

That's what I'd do. DIY hammer wrench.

Personally I hate with every inch of my life watching someone lean on a socket with all their weight and either strip a bolt or fall over onto themselves. Jerk your tools, as long as you're not a total spanner and slip off and round off the bolt usually you can break any bolt free easily.

 

[meep]

ben-- sorry - I wasn't clear. I've struggled to get the pans off of 2 of these.... but for me it wasn't the bolts. I can't imagine snapping a 10mm socket without first snapping/rounding the bolt. For me... i could get the bolts off but the pans would be seized on.

FWIW, the first 41TE I serviced had 60k on it, and the old filter came out looking new. The 2nd one I did on a unit with 83,000, and it too looked mostly new, possibly had a "stained" appearance.

I don't really know if they catch much. When I did the 2nd one, I added a $16 magnefine from rock auto, I believe 5/16" size. With that in place, I doubt I'll need to open it up again.

good luck,
m

 

[benjamming]

Thanks for all the help. I got the pan bolts off with the impact. Pan was stuck some but came off with a hammer. Magnet was a big ball of fuzz. Filter didn't have chunks of transmission so happy about that. Took a lot of scraping to get all the RTV removed & clean for the new rubber gasket. I torqued to 12ft-lbs. No leaks. I filled back up with AMSOIL ATF - 4 qts.

Should fluid level be checked while running or right after shut down?

 

[PTBH04]

while running, fully warmed up, and in park.