Downshift clunk

[Caravan05850]

My 2000 caravan is sometimes making a clunking noise when it downshifts at low speeds. What could be the cause of this?

[s38638i]

check your trans fluid, make sure it is full, could have trans leak, vans are very common for having the cooler lines and the trans solenoid leaking, if fluid is very low the trans module will probably need to be quicklearned with the drb scan tool at a chrysler dealership

[Caravan05850]

No the fluid is not low. It has always leaked a little at the hose ends and more recently the leak has gotten worse from somewhere else, so I always check it and add fluid every now and then (ATF4). The mileage is now about 113,000 and I haven't changed the fluid or filter since about 50,000 miles, although the fluid stays somewhat new as I have to add a quart every now and then. The dealership told me once not too long ago that I needed a new solenoid pack. I guess I'll get underneath the van this weekend and wipe everything down so I can narrow down where the bigger leak is coming from. Initial view would seem to indicate it is from the pan gasket, but its hard tell tell for sure until I clean everything off.

[s38638i]

the solenoid will leak down and then makes it look like the pan gasket, if you haven
t done a trans flush for a while you could get the new solenoid and do the flush at the same time, then when the tech replace the solenoid pack they will have to quicklearn it and it should take care of your problem

[Caravan05850]

I would most likely replace the solenoid pack myself. Is there any way I can get around the quicklearn procedure?

Also, if it is just the gasket on the solenoid pack that is bad, why can't I just replace the gasket or make one out of RTV?

[s38638i]

the solenoid probably is ok but i;m not sure if you can get the gasket alone or not i know when we put them in at work the new solenoid comes with one in the box, you will need to go to the dealership to do the quicklearn though, if you know someone there the will do it for free hopefully cause it only takes about 15 sec. or if you don't know anyone then you can try to talk to the service writer about it and see what he can do. if you need any help doing the solenoid then pm me or keep writing on this thread and ill try to check it.

[s38638i]

i forgot to say that you probably can't make one out of rtv b/c it may squish into the holes under the solenoid and mess it up

[StandOnCliff]

Never use RTV inside a transmission. Only do so if you want that transmission to go bad.RTV in time will let go and clog valves and such.

[Caravan05850]

Ok, so I just called a dealership and the gasket is available for $3.51, however, they said the quicklearn would take an hour so it would be $75.00 for the quicklearn to be performed.

1). What does the quicklearn do and will the tranny eventually relearn itself if I don't do the quicklearn?

2). How hard is it to remove and reinstall the solenoid pack? I am a pretty good DIYer, I've changed engines in other cars and such. Seems like its held on by some bolts with connectors?

3). Where is the solenoid pack located? Drivers side or passenger side?

Thanks for your help.

[s38638i]

i don't believe it will learn itself, the quicklearn just runs your trans through the gears, when i do it on the drb you push the brake, put in neutral, then drive while holding the brake still and then it is done. it took me longer to type this then the quicklearn takes. for the location if your are sitting in the drivers seat it is right in front of you. open the hood and look down right below the dipstick for the trans and you will see an aluminum piece bolts to the trans. for removal you need to unhook the cooler lines and the connector for the speed sensor then then sensor itself the it has 3, 10mm bolts holding it to the trans. remove the bolts and you might need a prybar an pry a little and the solenoid comes off then clean the gasket off the trans and then the solenoid if replacing the gasket only. MAKE SURE YOU CLEAN ALL DIRT FROM THE SOLENOID BEFORE REMOVAL or all the gravel, etc. will fall into the pan.

[Caravan05850]

Got it.

BTW, does the transmission work on a limited basis until I get it to the dealership for the quicklearn?

[StandOnCliff]

It'll work,but shift rough.
No guarantees this will be sufficient but give it a try:
Transaxle must be warmed up.
Maintain constant throttle opening during shifts
Do not move accelerator pedal during upshifts
Accelerate vehicle with throttle opening angle in the range of 10 to 50 degress
Make 15-20: 1-2,2-3, 3-4 upshifts. Accelerate from stop to about 45 mph each time at a moderate throttle opening angle.

With vehicle speed below 25 mph make 5 to 8 wide open throttle kick downs from to either third or second gear from 4th gear (4-3 or 4-2 for example).
Do the same with vehicle speeds above 25 mph do the same kick downs with part to wide open throttle position. Allow for 5 seconds or more in 4th, preferably at road load throttle prior to performing kick downs.

This should optimize shift quality. It still should go in for a quick learn procedure.

[s38638i]

you should be able to drive it there, but it will clunk loudly when slowing down

[acton mike]

what sometimes sounds like and feels like a harsh downshift is actually a worn out engine/transmission mount found at the front of the engine/trans at the bottom of the rad support; it allows the engine/gearbox to rock back and forth check it out before you go crazy on the transmission