lock CHRYSLER VOYAGER 2001 Service Manual

STATOR
The stator assembly (Fig. 232) is mounted on a sta-
tionary shaft which is an integral part of the oil
pump. The stator is located between the impeller and
turbine within the torque converter case (Fig. 233).
The stator contains an over-running clutch, which
allows the stator to rotate only in a clockwise direc-
tion. When the stator is locked against the over-run-
ning clutch, the torque multiplication feature of the
torque converter is operational.
TORQUE CONVERTER CLUTCH (TCC)
The TCC (Fig. 234) was installed to improve the
efficiency of the torque converter that is lost to the
slippage of the fluid coupling. Although the fluid cou-
pling provides smooth, shock±free power transfer, it
is natural for all fluid couplings to slip. If the impel-
ler and turbine were mechanically locked together, a
zero slippage condition could be obtained. A hydraulic
piston was added to the turbine, and a friction mate-
rial was added to the inside of the front cover to pro-
vide this mechanical lock-up.
Fig. 231 Turbine
1 - TURBINE VANE
2 - ENGINE ROTATION
3 - INPUT SHAFT4 - PORTION OF TORQUE CONVERTER COVER
5 - ENGINE ROTATION
6 - OIL FLOW WITHIN TURBINE SECTION
21 - 122 AUTOMATIC - 31THRS
TORQUE CONVERTER (Continued)

OPERATION
The converter impeller (Fig. 235) (driving member),
which is integral to the converter housing and bolted
to the engine drive plate, rotates at engine speed.
The converter turbine (driven member), which reacts
from fluid pressure generated by the impeller, rotates
and turns the transmission input shaft.
TURBINE
As the fluid that was put into motion by the impel-
ler blades strikes the blades of the turbine, some of
the energy and rotational force is transferred into the
turbine and the input shaft. This causes both of them
(turbine and input shaft) to rotate in a clockwise
direction following the impeller. As the fluid is leav-
ing the trailing edges of the turbine's blades it con-
tinues in a ªhinderingº direction back toward the
impeller. If the fluid is not redirected before it strikes
the impeller, it will strike the impeller in such a
direction that it would tend to slow it down.
Fig. 232 Stator Components
1 - CAM (OUTER RACE)
2 - ROLLER
3 - SPRING
4 - INNER RACE
Fig. 233 Stator Location
1-STATOR
2 - IMPELLER
3 - FLUID FLOW
4 - TURBINE
Fig. 234 Torque Converter Clutch (TCC)
1 - IMPELLER FRONT COVER
2 - THRUST WASHER ASSEMBLY
3 - IMPELLER
4-STATOR
5 - TURBINE
6 - PISTON
7 - FRICTION DISC
RSAUTOMATIC - 31TH21 - 123
TORQUE CONVERTER (Continued)

STATOR
Torque multiplication is achieved by locking the
stator's over-running clutch to its shaft (Fig. 236).
Under stall conditions (the turbine is stationary), the
oil leaving the turbine blades strikes the face of the
stator blades and tries to rotate them in a counter-
clockwise direction. When this happens the over±run-
ning clutch of the stator locks and holds the stator
from rotating. With the stator locked, the oil strikes
the stator blades and is redirected into a ªhelpingº
direction before it enters the impeller. This circula-
tion of oil from impeller to turbine, turbine to stator,
and stator to impeller, can produce a maximum
torque multiplication of about 2.4:1. As the turbine
begins to match the speed of the impeller, the fluid
that was hitting the stator in such as way as to
cause it to lock±up is no longer doing so. In this con-
dition of operation, the stator begins to free wheel
and the converter acts as a fluid coupling.
Fig. 235 Torque Converter Fluid Operation
1 - APPLY PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD3 - RELEASE PRESSURE
4 - THE PISTON MOVES SLIGHTLY REARWARD
Fig. 236 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
21 - 124 AUTOMATIC - 31THRS
TORQUE CONVERTER (Continued)

(7) Install output shaft gear onto shaft. Use Tool
L-4439 to get gear started (Fig. 258).
(8) Install Tool L-4434 and C-4658. Install washer
and nut (Fig. 259).
(9) Torque output shaft retaining nut to 271 N´m
(200 ft. lbs.) (Fig. 260).
(10) Set up Tool L-4432 and C-4658 as shown in
(Fig. 261). Install dial indicator and measure output
shaft end play.
(11) Using an in. lb. torque wrench, measure out-
put shaft bearing turning torque (Fig. 262).
(12) Install stirrup and strap. Install bolts but do
not tighten.
NOTE: Once the stirrup assembly is positioned
onto the output gear, it is necessary to ªclockº the
stirrup against the flats of the output gear retaining
nut.(13) Rotate stirrup clockwise against flats of gear
retaining nut (Fig. 263).
(14) Torque stirrup and strap bolts to 23 N´m (200
in. lbs..) (Fig. 264).
(15) Bend tabs of strap up against ªflatsºof retain-
ing bolts to prevent bolts from backing out of gear in
the event they come loose.
(16) Install transfer shaft and gear. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/TRANSFER SYSTEM - INSTALLATION)
(17) Assemble transaxle geartrain. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC - 31TH
- ASSEMBLY)
Fig. 257 Output Shaft and (Select) Shims in Position
1 - BEARING CUP
2 - (SELECT) SHIM
3 - OUTPUT SHAFT ASSEMBLY
Fig. 258 Start Output Shaft Gear onto Output Shaft
1 - OUTPUT SHAFT GEAR
2 - OUTPUT SHAFT
3 - SPECIAL TOOL L-4439
Fig. 259 Holding Output Shaft Gear
1 - OUTPUT SHAFT
2 - SCREW (2)
3 - SPECIAL TOOL L-4434 AND C-4658
4 - WASHER
5 - NUT
Fig. 260 Tighten Output Shaft Retaining Nut
1 - OUTPUT SHAFT GEAR
2 - SPECIAL TOOL L-4434 AND C-4658
3 - SCREW (2)
RSAUTOMATIC - 31TH21 - 131
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)

ADJUSTMENT - OUTPUT SHAFT BEARING
(1) With output shaft gear removed, install a 13.65
mm (0.537 inch) and a 1.34 mm (0.053 inch) gauging
shims on the planetary rear annulus gear hub using
grease to hold the shims in place. The 13.65 mm
shim has a larger inside diameter and must be
installed over the output shaft first. The 1.34 mm
shim pilots on the output shaft.
(2) Install output shaft gear and bearing assembly,
torque to 271 N´m (200 ft. lbs.).
(3) To measure bearing end play:
(4) Attach Tool L-4432 to the output shaft gear.(5) Mount a steel ball with grease into the end of
the output shaft.
(6) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
(7) Using a dial indicator, mounted to the trans-
axle case, measure output shaft end play.
(8) Once bearing end play has been determined,
refer to the output shaft bearing shim chart.
(9) The 12.65 mm (0.498 inch), 13.15 mm (0.518
inch) or 13.65 mm (0.537 inch) shims are always
installed first.These shims have lubrication slots
which are necessary for proper bearing lubrica-
tion.
Fig. 261 Checking Output Shaft End Play
1 - SPECIAL TOOL L-4432 AND C-4658
2 - SCREW (2)
3 - OUTPUT SHAFT GEAR
4 - STEEL BALL (GREASE IN PLACE)
5 - SPECIAL TOOL L-4438
6 - DIAL INDICATOR
Fig. 262 Checking Bearing Turning Torque
1 - OUTPUT SHAFT GEAR
2 - TORQUE WRENCH
Fig. 263 Turn Stirrup Clockwise Against Flats of
Retaining Nut
1 - TURN STIRRUP CLOCKWISE
2 - STRAP
Fig. 264 Tighten Strap Retaining Nuts
1 - STRAP
2 - OUTPUT GEAR
3 - STIRRUP
21 - 132 AUTOMATIC - 31THRS
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)

(14) Using Tool L-4434 and adapter C-4658 (Fig.
293), torque transfer shaft gear retaining nut to 271
N´m (200 ft. lbs.).
(15) Measure transfer shaft end play. Set up Tool
L-4432 and C-4658 as shown in (Fig. 294). Measure
end play with dial indicator.
(16) Position stirrup and strap on transfer gear.
(17) Install bolts but do not tighten.
(18) Rotate stirrup clockwise until it contacts
transfer gear retaining nut flat.(19) Torque stirrup and strap-to-transfer gear bolts
to 23 N´m (200 in. lbs.).
(20) Bend tabs of strap up against ªflatsº of retain-
ing bolts.
(21) Install a bead of Moparž Silicone Rubber
Adhesive Sealant to transfer gear cover (Fig. 295).
Immediately install to transaxle case.
(22) Install and torque transfer gear cover-to-case
bolts (Fig. 296) to 19 N´m (165 in. lbs.) .
Fig. 293 Tighten Transfer Shaft Gear Retaining Nut
to 271 N´m (200 ft. lbs.)
1 - TRANSFER SHAFT GEAR
2 - TORQUE WRENCH
3 - SPECIAL TOOL L-4434 AND ADAPTER C-4658
Fig. 294 Measuring Transfer Shaft End-Play
1 - SPECIAL TOOL L-4432 AND C-4658
2 - TRANSFER SHAFT GEAR
3 - STEEL BALL (USE GREASE TO HOLD IN PLACE)
4 - DIAL INDICATOR
5 - SCREW (2)
Fig. 295 Install Rear Cover
1 - OUTPUT SHAFT GEAR
2 - USE MOPAR SILICONE RUBBER ADHESIVE SEALER
3 - REAR COVER
4 - TRANSFER SHAFT GEAR
Fig. 296 Rear Cover Bolts
1 - REAR COVER
2 - REAR COVER BOLTS (10)
RSAUTOMATIC - 31TH21 - 141
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)

HYDRAULIC CONTROL PRESSURE
ADJUSTMENTS
LINE PRESSURE
An incorrect throttle pressure setting will cause
incorrect line pressure readings even though line
pressure adjustment is correct. Always inspect and
correct throttle pressure adjustment before adjusting
the line pressure.
The approximate adjustment for line pressure is
1-5/16 inches, measured from valve body to inner
edge of adjusting nut. However, due to manufactur-
ing tolerances, the adjustment can be varied to
obtain specified line pressure.
The adjusting screw may be turned with an Allen
wrench. One complete turn of adjusting screw
changes closed throttle line pressure approximately
1-2/3 psi. Turning adjusting screw counterclockwise
increases pressure, and clockwise decreases pressure.
THROTTLE PRESSURE
Throttle pressures cannot be tested accurately;
therefore, the adjustment should be measured if a
malfunction is evident.
(1) Insert gauge pin of Tool C-3763 between the
throttle lever cam and kickdown valve.
(2) By pushing in on tool, compress kickdown
valve against its spring so throttle valve is com-
pletely bottomed inside the valve body.
(3) While compressing spring, turn throttle lever
stop screw with adapter C-4553. Turn until head of
screw touches throttle lever tang, with throttle lever
cam touching tool and throttle valve bottomed. Be
sure adjustment is made with spring fully com-
pressed and valve bottomed in the valve body.
VEHICLE SPEED SENSOR/
PINION GEAR
REMOVAL
(1) Remove harness connector from sensor (Fig.
340) . Be sure weather seal stays on harness connec-
tor.
(2) Remove bolt securing the sensor in the exten-
sion housing (Fig. 340) .
(3) Carefully pull sensor and pinion gear assembly
out of extension housing.
(4) Remove pinion gear from sensor (Fig. 340) .
(5) Inspect pinion gear for damage (missing teeth,
etc.) and replace as necessary.
NOTE: When removing vehicle speed sensor for
any reason, a new o-ring MUST be used.
INSTALLATION
(1) Install vehicle speed sensor and pinion gear to
extension housing with new o-ring (Fig. 340).
(2) Install bolt and torque to 7 N´m (60 in. lbs.).
(3) Connect connector.
(4) Lower vehicle.
Fig. 339 Transaxle Oil Pan Bolts
1 - TRANSAXLE OIL PAN
2 - OIL PAN BOLTS
Fig. 340 Vehicle Speed Sensor Removal/Installation
1 - CONNECTOR
2 - SPEEDO PINION
3 - O-RING
4 - SENSOR
RSAUTOMATIC - 31TH21 - 157
VALVE BODY (Continued)

AUTOMATIC - 41TE
TABLE OF CONTENTS
page page
AUTOMATIC - 41TE
DESCRIPTION..........................159
OPERATION............................159
DIAGNOSIS AND TESTING................159
41TE TRANSAXLE GENERAL DIAGNOSIS . . . 159
ROAD TEST..........................161
HYDRAULIC PRESSURE TESTS..........162
CLUTCH AIR PRESSURE TESTS..........164
TORQUE CONVERTER HOUSING FLUID
LEAKAGE............................164
REMOVAL.............................165
DISASSEMBLY..........................169
ASSEMBLY............................186
INSTALLATION..........................209
SCHEMATICS AND DIAGRAMS.............212
SPECIFICATIONS........................225
SPECIAL TOOLS........................227
ACCUMULATOR
DESCRIPTION..........................232
OPERATION............................233
AUTOSTICK SWITCH
DESCRIPTION..........................233
OPERATION............................233
DRIVING CLUTCHES
DESCRIPTION..........................234
OPERATION............................234
FINAL DRIVE
DESCRIPTION..........................234
OPERATION............................234
DISASSEMBLY..........................235
ASSEMBLY............................240
ADJUSTMENTS.........................243
FLUID
STANDARD PROCEDURE.................246
FLUID LEVEL AND CONDITION CHECK.....246
FLUID AND FILTER SERVICE.............246
GEAR SHIFT CABLE
REMOVAL.............................248
INSTALLATION..........................250
ADJUSTMENTS.........................251
HOLDING CLUTCHES
DESCRIPTION..........................251
OPERATION............................251
INPUT CLUTCH ASSEMBLY
DISASSEMBLY..........................252
ASSEMBLY............................259
OIL PUMP
DESCRIPTION..........................269
OPERATION............................269STANDARD PROCEDURE.................269
OIL PUMP VOLUME CHECK..............269
DISASSEMBLY..........................270
ASSEMBLY............................271
PLANETARY GEARTRAIN
DESCRIPTION..........................271
OPERATION............................271
SEAL - OIL PUMP
REMOVAL.............................271
INSTALLATION..........................272
SHIFT INTERLOCK SOLENOID
DESCRIPTION..........................272
OPERATION............................273
DIAGNOSIS AND TESTING................274
BRAKE/TRANSMISSION SHIFT INTERLOCK
SOLENOID...........................274
REMOVAL.............................274
INSTALLATION..........................275
SOLENOID/PRESSURE SWITCH ASSEMBLY
DESCRIPTION..........................276
OPERATION............................276
REMOVAL.............................277
INSTALLATION..........................277
SPEED SENSOR - INPUT
DESCRIPTION..........................278
OPERATION............................278
REMOVAL.............................279
INSTALLATION..........................279
SPEED SENSOR - OUTPUT
DESCRIPTION..........................280
OPERATION............................280
REMOVAL.............................280
INSTALLATION..........................281
TORQUE CONVERTER
DESCRIPTION..........................281
OPERATION............................284
REMOVAL.............................286
INSTALLATION..........................286
TRANSMISSION CONTROL RELAY
DESCRIPTION..........................287
OPERATION............................287
TRANSMISSION RANGE SENSOR
DESCRIPTION..........................287
OPERATION............................287
REMOVAL.............................288
INSTALLATION..........................288
TORQUE REDUCTION LINK (TRD)
DESCRIPTION..........................289
OPERATION............................289
21 - 158 AUTOMATIC - 41TERS

DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS
Inoperative clutches can be located using a series
of tests by substituting air pressure for fluid pressure
(Fig. 4) (Fig. 5). The clutches may be tested by apply-
ing air pressure to their respective passages. The
valve body must be removed and Tool 6056 installed.
To make air pressure tests, proceed as follows:
NOTE: The compressed air supply must be free of
all dirt and moisture. Use a pressure of 30 psi.
Remove oil pan and valve body. See Valve body
removal.
OVERDRIVE CLUTCH
Apply air pressure to the overdrive clutch apply
passage and watch for the push/pull piston to move
forward. The piston should return to its starting
position when the air pressure is removed.
REVERSE CLUTCH
Apply air pressure to the reverse clutch apply pas-
sage and watch for the push/pull piston to move rear-
ward. The piston should return to its starting
position when the air pressure is removed.
2/4 CLUTCH
Apply air pressure to the feed hole located on the
2/4 clutch retainer. Look in the area where the 2/4
piston contacts the first separator plate and watch
carefully for the 2/4 piston to move rearward. The
piston should return to its original position after the
air pressure is removed.
LOW/REVERSE CLUTCH
Apply air pressure to the low/reverse clutch feed
hole (rear of case, between 2 bolt holes). Then, look
in the area where the low/reverse piston contacts the
first separator plate. Watch carefully for the piston to
move forward. The piston should return to its origi-
nal position after the air pressure is removed.
UNDERDRIVE CLUTCH
Because this clutch piston cannot be seen, its oper-
ation is checked by function. Air pressure is applied
to the low/reverse and the 2/4 clutches. This locks the
output shaft. Use a piece of rubber hose wrapped
around the input shaft and a pair of clamp-on pliers
to turn the input shaft. Next apply air pressure to
the underdrive clutch. The input shaft should not
rotate with hand torque. Release the air pressure
and confirm that the input shaft will rotate.
DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE
When diagnosing converter housing fluid leaks,
three actions must be taken before repair:
(1) Verify proper transmission fluid level.
(2) Verify that the leak originates from the con-
verter housing area and is transmission fluid.
(3) Determine the true source of the leak.
Fluid leakage at or around the torque converter
area may originate from an engine oil leak (Fig. 6).
The area should be examined closely. Factory fill
fluid is red and, therefore, can be distinguished from
engine oil.
Some suspected converter housing fluid leaks may
not be leaks at all. They may only be the result of
residual fluid in the converter housing, or excess
fluid spilled during factory fill, or fill after repair.
Fig. 4 Air Pressure Test Plate
1 - TOOL 6056
2 - ACCUMULATORS
Fig. 5 Testing Reverse Clutch
1 - TOOL 6056
2 - AIR NOZZLE
21 - 164 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)

(4) Remove fluid level indicator/tube assembly.
Plug opening to prevent debris from entering trans-
axle.
(5) Using a blade or suitable hose cutter, cut trans-
axle oil cooler lines off flush with fittings. Plug lines
and fittings to prevent debris from entering transaxle
or cooler circuit. A service splice kit will be installed
upon reassembly.
(6) Disconnect input and output shaft speed sensor
connectors (Fig. 10).
(7) Disconnect transmission range sensor (TRS)
connector (Fig. 10).
(8) Disconnect solenoid/pressure switch assembly
connector (Fig. 10).
(9) Disconnect gear shift cable from manual valve
lever and upper mount bracket (Fig. 11).
(10) Disconnect crankshaft position sensor (if
equipped).
(11) Reposition leak detection pump harness and
hoses.
(12) Remove wiper module assembly to gain access
to and remove rear mount bracket bolts. (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - REMOVAL)
(13) Remove rear mount bracket-to-transaxle case
bolts (Fig. 12).
(14) Remove transaxle upper bellhousing-to-block
bolts.
(15) Raise vehicle on hoist.
(16) Remove transaxle oil pan and drain fluid into
suitable container.
(17) Remove front wheel/tire assemblies.
Fig. 9 Coolant Recovery Bottle
1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY/RESERVE CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL
Fig. 10 Component Connector LocationÐTypical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 11 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 166 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)