CHRYSLER VOYAGER 2001 Service Manual

(18) Using Tool 5059A and an arbor press, com-
press UD clutch piston enough to remove snap ring
(Fig. 248) (Fig. 249) .
(19) Remove spring retainer (Fig. 249) .(20) Remove UD clutch piston (Fig. 250) .
(21) Remove input hub tapered snap ring (Fig.
251) .
Fig. 248 UD Spring Retainer Snap Ring
1 - SNAP RING PLIERS
2 - ARBOR PRESS RAM
3 - SNAP RING
4 - SPECIAL TOOL 5059A
Fig. 249 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 250 Underdrive Clutch Piston
1 - PISTON
Fig. 251 Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
RSAUTOMATIC - 41TE21 - 257
INPUT CLUTCH ASSEMBLY (Continued)

(22) Tap on input hub with soft faced hammer and
separate input hub from OD/Reverse piston and
clutch retainer (Fig. 252) (Fig. 253) .(23) Separate clutch retainer from OD/Reverse pis-
ton (Fig. 254) .
(24) Using Tool 6057 and an arbor press, compress
return OD/Reverse piston return spring just enough
to remove snap ring (Fig. 255) (Fig. 256) .
Fig. 252 Tap on Input Hub
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - PLASTIC HAMMER
Fig. 253 Input Hub Removed
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - INPUT CLUTCHES RETAINER
3 - O-RING
4 - SEAL
5 - OVERDRIVE/REVERSE PISTON
Fig. 254 Pull Retainer from Piston
1 - OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
Fig. 255 Remove Snap Ring
1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST
ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
3 - SNAP RING
4 - SPECIAL TOOL 6057
5 - OD/REVERSE PISTON
6 - RETURN SPRING
21 - 258 AUTOMATIC - 41TERS
INPUT CLUTCH ASSEMBLY (Continued)

(25) Remove input shaft to input clutch hub snap
ring (Fig. 257) .(26) Using a suitably sized socket and an arbor
press, remove input shaft from input shaft hub (Fig.
258) .
ASSEMBLY
Use petrolatum on all seals to ease assembly of
components.
(1) Using an arbor press, install input shaft to
input shaft hub (Fig. 259).
Fig. 256 Snap Ring and Return Spring
1 - OD/REVERSE PISTON
2 - RETURN SPRING
3 - SNAP RING
4 - O-RING
Fig. 257 Remove Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SHARP-POINTED TOOL
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 258 Remove Input Shaft
1 - ARBOR PRESS RAM
2 - SOCKET
3 - SEAL
4 - O-RINGS
5 - INPUT SHAFT
6 - SEAL
7 - INPUT SHAFT HUB ASSEMBLY
Fig. 259 Install Input Shaft
1 - INPUT SHAFT
2 - ARBOR PRESS RAM
3 - INPUT SHAFT HUB ASSEMBLY
RSAUTOMATIC - 41TE21 - 259
INPUT CLUTCH ASSEMBLY (Continued)

(2) Install input shaft snap ring (Fig. 260).
(3) Using an arbor press and Tool 6057, Install
OD/Reverse piston return spring and snap ring (Fig.
261) (Fig. 262).(4) Install the OD/Reverse piston assembly to the
input clutch retainer as shown in (Fig. 263).
Fig. 260 Install Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 261 Return Spring and Snap Ring
1 - OD/REVERSE PISTON
2 - RETURN SPRING
3 - SNAP RING
4 - O-RING
Fig. 262 Install Snap Ring
1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST
ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
3 - SNAP RING
4 - SPECIAL TOOL 6057
5 - OD/REVERSE PISTON
6 - RETURN SPRING
Fig. 263 Install OD/Reverse Piston
1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
21 - 260 AUTOMATIC - 41TERS
INPUT CLUTCH ASSEMBLY (Continued)

(5) Install the input hub/shaft assy. to the OD/Re-
verse piston/clutch retainer assy. (Fig. 264).
(6) Install input hub tapered snap ring (Fig. 265).(7) Install UD clutch piston (Fig. 266).
(8) Install UD piston return spring and Tool 5067
as shown in (Fig. 267).
(9) Using Tool 5059A and an arbor press, Install
the UD spring retainer and snap ring. (Fig. 268) (Fig.
269)Compress just enough to install snap ring.
CAUTION: Compress return spring just enough to
install snap ring.
Fig. 264 Install Input Shaft Hub Assembly
1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY
(ROTATE TO ALIGN SPLINES)
2 - OD/REV. PISTON
Fig. 265 Install Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
Fig. 266 Underdrive Clutch Piston
1 - PISTON
Fig. 267 Seal Compressor Special Tool 5067
1 - PISTON RETURN SPRING
2 - SPECIAL TOOL 5067
3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY
RSAUTOMATIC - 41TE21 - 261
INPUT CLUTCH ASSEMBLY (Continued)

(10) Install the UD clutch pack. Leave out upper
disc, until snap ring is installed (Fig. 270).
(11) Install the UD clutch flat snap ring (Fig. 271).
Fig. 268 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 269 Install UD Spring Retainer and Snap Ring
1 - ARBOR PRESS RAM
2 - SNAP RING PLIERS
3 - SNAP RING
4 - OD/REVERSE PISTON
5 - TOOL 5067
6 - TOOL 5059A
Fig. 270 Underdrive Clutch Pack
1 - CLUTCH PLATE
2 - ONE UD CLUTCH DISC
3 - CLUTCH DISC
Fig. 271 UD Clutch Flat Snap Ring
1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
21 - 262 AUTOMATIC - 41TERS
INPUT CLUTCH ASSEMBLY (Continued)

(12) Install the last UD clutch disc (Fig. 272).
(13) Install the OD/UD clutch reaction plate and
snap ring (Fig. 273) (Fig. 274). The OD/UD clutches
reaction plate has a step on both sides. Install the
OD/UD clutches reaction plate tapered step side up.
NOTE: Snap ring ends must be located within one
finger of the input clutch hub. Be sure that snap
ring is fully seated, by pushing with screwdriver,
into snap ring groove all the way around.(14) Seat tapered snap ring to ensure proper
installation (Fig. 275).
(15) Install input clutch assembly to the Input
Clutch Pressure Fixture±Tool 8391 (Fig. 276).
(16) Set up dial indicator on the UD clutch pack as
shown in (Fig. 277).
Fig. 272 Install Last UD Clutch Disc
1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 273 OD/UD Reaction Plate
1 - OD/UD CLUTCH REACTION PLATE (STEP SIDE DOWN)
Fig. 274 Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
Fig. 275 Seating Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER
RSAUTOMATIC - 41TE21 - 263
INPUT CLUTCH ASSEMBLY (Continued)

(17) Using moderate pressure, press down and
hold (near indicator) the UD clutch pack with screw-
driver or suitable tool and zero dial indicator (Fig.
278). When releasing pressure on clutch pack, indica-
tor reading should advance 0.005±0.010.
CAUTION: Do not apply more than 30 psi (206 kPa)
to the underdrive clutch pack.
(18) Apply 30 psi (206 kPa) to the underdrive hose
on Tool 8391 and measure UD clutch clearance. Mea-
sure and record UD clutch pack measurement in four
(4) places, 90É apart.
(19) Take average of four measurements and com-
pare with UD clutch pack clearance specification.
Underdrive clutch pack clearance must be 0.94-
1.50 mm (0.037-0.059 in.).
(20) If necessary, select the proper reaction plate
to achieve specifications:
UNDERDRIVE REACTION PLATE THICKNESS
4659939AB 5.837-5.937 mm (0.230-0.234 in.)
4659940AB 6.147-6.248 mm (0.242-0.246 in.)
4659941AB 6.457-6.557 mm (0.254-0.258 in.)
Fig. 276 Input Clutch Assembly on Pressure Fixture
Tool 8391
1 - INPUT CLUTCH ASSEMBLY
2 - INPUT CLUTCH PRESSURE FIXTURE 8391
Fig. 277 Set Up Dial Indicator to Measure UD Clutch
Clearance
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
Fig. 278 Press Down on UD Clutch Pack and Zero
Dial Indicator
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
21 - 264 AUTOMATIC - 41TERS
INPUT CLUTCH ASSEMBLY (Continued)

(21) Install the OD clutch pack (four frictions/three
steels) (Fig. 279).
(22) Install OD reaction plate waved snap ring
(Fig. 280).(23) Install the OD/Reverse reaction plate with
large step down (towards OD clutch pack) (Fig. 281).
(24) Install OD reaction plate flat snap ring (Fig.
282).
Fig. 279 Install OD Clutch Pack
1 - OVERDRIVE CLUTCH PACK
Fig. 280 Install Waved Snap Ring
1 - OVERDRIVE REACTION PLATE WAVED SNAP RING
2 - SCREWDRIVER
Fig. 281 OD/Reverse Reaction Plate
1 - OVERDRIVE/REVERSE PRESSURE PLATE
2 - (STEP SIDE DOWN)
Fig. 282 Install Flat Snap Ring
1 - ARBOR PRESS RAM
2 - TOOL 5059A
3 - FLAT SNAP RING
RSAUTOMATIC - 41TE21 - 265
INPUT CLUTCH ASSEMBLY (Continued)

(25) Measure OD clutch pack clearance. Set up
dial indicator on top of the OD/Reverse reaction plate
as shown in (Fig. 283).
(26) Zero dial indicator and apply 30 psi (206 kPa)
air pressure to the overdrive clutch hose on Tool
8391. Measure and record OD clutch pack measure-
ment in four (4) places, 90É apart.
(27) Take average of four measurements and com-
pare with OD clutch pack clearance specification.
The overdrive (OD) clutch pack clearance is
1.07-3.25 mm (0.042-0.128 in.).
If not within specifications, the clutch is not
assembled properly. There is no adjustment for the
OD clutch clearance.
(28) Install reverse clutch pack (two frictions/one
steel) (Fig. 284).
(29) Install reverse clutch reaction plate with the
flat side down towards reverse clutch (Fig. 285).
(30) Tap reaction plate down to allow installation
of the reverse clutch snap ring. Install reverse clutch
snap ring (Fig. 286).(31) Pry up reverse reaction plate to seat against
snap ring (Fig. 287).
(32) Set up a dial indicator on the reverse clutch
pack as shown in (Fig. 288).
(33) Using moderate pressure, press down and
hold (near indicator) reverse clutch disc with screw-
driver or suitable tool and zero dial indicator (Fig.
289). When releasing pressure, indicator should
advance 0.005-0.010. as clutch pack relaxes.
Fig. 283 Measure OD Clutch Pack Clearance
1 - DIAL INDICATOR
2 - OD/REVERSE REACTION PLATE
Fig. 284 Install Reverse Clutch Pack
1 - REVERSE CLUTCH PLATE
2 - REVERSE CLUTCH DISCS
Fig. 285 Install Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)
21 - 266 AUTOMATIC - 41TERS
INPUT CLUTCH ASSEMBLY (Continued)