CHRYSLER VOYAGER 2002 Service Manual

(45) Using tool 5049A, remove transfer shaft from
transaxle (Fig. 62).
(46) Slip bearing cup retainer and oil baffle off of
shaft (Fig. 63).(47) Using tool P-334, press transfer shaft bearing
cone off of shaft (Fig. 64).
(48) Bend output gear retaining strap ears flat to
allow bolt removal.
(49) Remove output shaft stirrup strap bolts (Fig.
65).
Fig. 62 Remove Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
Fig. 63 Bearing Cup Removed
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
Fig. 64 Remove Transfer Shaft Bearing Cone
1 - ARBOR PRESS RAM
2 - TRANSFER SHAFT
3 - TOOL P-334
4 - BEARING CONE
Fig. 65 Remove Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
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41TE AUTOMATIC TRANSAXLE (Continued)
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(50) Remove stirrup and strap (Fig. 66).
(51) Using Tool 6259 (Fig. 67), remove output shaft
gear-to-shaft bolt and washer (Fig. 68).(52) Using Tool L4407A, and button 6055, remove
output gear from shaft (Fig. 69).
Fig. 66 Remove Stirrup Strap
1 - OUTPUT GEARBOLT
2 - RETAINING STRAP
3 - STIRRUP
Fig. 67 Remove Output Gear Bolt
1 - OUTPUT GEAR
2 - TOOL 6259
Fig. 68 Output Gear Bolt and Washer
1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
Fig. 69 Remove Output Gear
1 - OUTPUT GEAR
2 - BUTTON TOOL 6055
3 - WRENCHES
4 - TOOL L4407A
5 - BOLTS TOOL L4407±6
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41TE AUTOMATIC TRANSAXLE (Continued)
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(53) Remove output gear bearing shim (select)
(Fig. 70).
(54) Using setup as shown in (Fig. 71), remove
output gear bearing cone.(55) Remove rear carrier assembly from transaxle
(Fig. 72).
(56) Remove rear carrier assembly bearing cone
using setup shown in (Fig. 73).
Fig. 70 Output Gear and (Select) Shim
1 - REAR CARRIER ASSEMBLY
2 - SHIM (SELECT)
3 - OUTPUT GEAR
Fig. 71 Remove Bearing Cone
1 - TOOL 5048 WITH JAWS 5048±5 AND BUTTON L-4539±2
2 - WRENCHES
3 - OUTPUT GEAR
Fig. 72 Remove Rear Carrier Assembly
1 - REAR CARRIER ASSEMBLY
Fig. 73 Remove Rear Carrier Bearing Cone
1 - TOOL 5048 WITH JAWS 5048±3 AND BUTTON 6055
2 - WRENCHES
3 - REAR CARRIER ASSEMBLY
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41TE AUTOMATIC TRANSAXLE (Continued)
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(57) Install low/reverse spring compressor tool as
shown in (Fig. 74) (Fig. 75).(58) Compress low/reverse piston return spring
and remove snap ring (Fig. 76).
(59) Remove low/reverse spring compressor tool
and low reverse piston return spring (Fig. 77).
Fig. 74 Low/Reverse Spring Compressor Tool
1 - TOOL 6057
2 - TOOL 5059
3 - TOOL 5058±3
Fig. 75 Compressor Tool in Use
1 - LOW/REVERSE CLUTCH RETURN SPRING
2 - SNAP RING (INSTALL AS SHOWN)
3 - TOOL 6057
4 - TOOL 5059
5 - TOOL 5058±3
Fig. 76 Remove Snap Ring
1 - SNAP RING OPENING MUST BE BETWEEN SPRING
LEVERS (AS SHOWN)
2 - SNAP RING PLIERS
3 - TOOL 6057
Fig. 77 Low/Reverse Piston Return Spring
1 - LOW/REVERSE PISTON RETURN SPRING
2 - PISTON
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41TE AUTOMATIC TRANSAXLE (Continued)
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(60) Using a suitable punch , drive out park guide
bracket pivot shaft plug (Fig. 78).
(61) Using ordinary pliers, remove pivot shaft and
guide bracket assembly (Fig. 79).(62) Inspect guide bracket components for exces-
sive wear and replace if necessary (Fig. 80).
(63) Remove low/reverse clutch piston (Fig. 81).
Fig. 78 Remove Anchor Shaft and Plug
1 - GUIDE BRACKET ANCHOR SHAFT
2 - PIVOT SHAFT
3 - ANCHOR SHAFT PLUG
Fig. 79 Pivot Shaft and Guide Bracket
1 - ANTIRACHET SPRING
2 - GUIDE BRACKET
3 - PIVOT SHAFT
4-PAWL
Fig. 80 Guide Bracket Disassembled
1 - ANTIRATCHET SPRING
2 - GUIDE BRACKET
3 - SPLIT SLEEVE
4 - SPACER
5-PAWL
6 - STEPPED SPACER
Fig. 81 Remove Low/Reverse Clutch Piston
1 - LOW/REVERSE CLUTCH PISTON
2 - D-RING SEAL
3 - D-RING SEAL
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41TE AUTOMATIC TRANSAXLE (Continued)
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(64) Remove low/reverse piston retainer-to-case
screws (Fig. 82).
(65) Remove low/reverse piston retainer (Fig. 83).(66) Remove low/reverse piston retainer-to-case
gasket (Fig. 84).
(67) Using a hammer and suitable drift, drive out
inner output bearing cup (Fig. 85).
Fig. 82 Remove Piston Retainer Attaching Screws
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - SCREWDRIVER
3 - TORX-LOC SCREWS
Fig. 83 Remove Piston Retainer
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - GASKET
Fig. 84 Remove Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Fig. 85 Remove Output Bearing Inner Cup
1 - OUTPUT BEARING CUPS (REPLACE IN PAIRS)
2 - HAMMER
3 - BRASS DRIFT
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41TE AUTOMATIC TRANSAXLE (Continued)
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(68) Using tool 6062, remove outer output bearing
cup (Fig. 86).
ASSEMBLY
CAUTION: If transaxle failure has occurred, it is
necessary to flush the transaxle oil cooler and lines
to remove debris and particles that could contami-
nate and/or fail a new or rebuilt unit. (Refer to 7 -
COOLING/TRANSMISSION - STANDARD PROCE-
DURE)
CAUTION: The cooler bypass valve must be
replaced if transaxle failure has occurred. Do not
attempt to reuse or clean old valve.
NOTE: If transaxle is being overhauled (clutch
and/or seal replacement), the TCM Quick Learn pro-
cedure must be performed. (Refer to 8 - ELECTRI-
CAL/ELECTRONIC CONTROL MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
(1) Install both output bearing cups using Tool
5050 (Fig. 87).
(2) Install low/reverse piston retainer gasket (Fig.
88). Make sure gasket holes line up with case.
Fig. 86 Remove Output Bearing Outer Cup
1 - TOOL 6062
Fig. 87 Install Both Output Bearing Cups
1 - OUTPUT BEARING CUPS
2 - WRENCHES
3 - TOOL 5050
Fig. 88 Install Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
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41TE AUTOMATIC TRANSAXLE (Continued)
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(3) Install low/reverse piston retainer (Fig. 89).
(4) Install low/reverse piston retainer-to-case bolts
(Fig. 90) and torque to 5 N´m (45 in. lbs.).(5) Install low/reverse clutch piston (Fig. 91).
(6) Assemble park guide bracket assembly (Fig.
93) (Fig. 92).
Fig. 89 Install Piston Retainer
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - GASKET
Fig. 90 Install Piston Retainer Attaching Screws
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - SCREWDRIVER
3 - TORX-LOC SCREWS
Fig. 91 Install Low/Reverse Clutch Piston
1 - LOW/REVERSE CLUTCH PISTON
2 - D-RING SEAL
3 - D-RING SEAL
Fig. 92 Guide Bracket Disassembled
1 - ANTIRATCHET SPRING
2 - GUIDE BRACKET
3 - SPLIT SLEEVE
4 - SPACER
5-PAWL
6 - STEPPED SPACER
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41TE AUTOMATIC TRANSAXLE (Continued)
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(7) Install guide bracket into position and insert
pivot shaft (Fig. 94).(8) Install anchor shaft and plug (Fig. 95). Make
sure guide bracket and split sleeve are in contact
with the rear of the transaxle case.
(9)
Install low/reverse piston return spring (Fig. 96).
Fig. 93 Guide Bracket
1 - GUIDE BRACKET
2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN)
3-PAWL
Fig. 94 Pivot Shaft and Guide Bracket
1 - ANTIRACHET SPRING
2 - GUIDE BRACKET
3 - PIVOT SHAFT
4-PAWL
Fig. 95 Install Anchor Shaft and Plug
1 - GUIDE BRACKET ANCHOR SHAFT
2 - PIVOT SHAFT
3 - ANCHOR SHAFT PLUG
Fig. 96 Low/Reverse Piston Return Spring
1 - LOW/REVERSE PISTON RETURN SPRING
2 - PISTON
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41TE AUTOMATIC TRANSAXLE (Continued)
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(10) Install low/reverse spring compressor into
position (Fig. 97). Compress low/reverse piston and
install snap ring as shown in (Fig. 98).(11) Install rear carrier bearing cone using Tool
6053 (Fig. 99).
(12) Install rear carrier assembly to transaxle case
(Fig. 100).
Fig. 97 Compressor Tool in Use
1 - LOW/REVERSE CLUTCH RETURN SPRING
2 - SNAP RING (INSTALL AS SHOWN)
3 - TOOL 6057
4 - TOOL 5059
5 - TOOL 5058±3
Fig. 98 Install Snap Ring
1 - SNAP RING OPENING MUST BE BETWEEN SPRING
LEVERS (AS SHOWN)
2 - SNAP RING PLIERS
3 - TOOL 6057
Fig. 99 Install Rear Carrier Bearing Cone
1 - ARBOR PRESS RAM
2 - TOOL 6053
3 - NEW BEARING CONE
4 - REAR CARRIER ASSEMBLY
Fig. 100 Install Rear Carrier Assembly
1 - REAR CARRIER ASSEMBLY
RS41TE AUTOMATIC TRANSAXLE21 - 193
41TE AUTOMATIC TRANSAXLE (Continued)
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