CHRYSLER VOYAGER 2005 Service Manual

End Play Shim Needed Part Number End Play Shim Needed Part Number
0.36mm
(0.014 in.)4.34mm
(0.171 in.)4412828AB1.07mm
(0.042 in.)3.62mm
(0.143 in.)4412810AB
0.38mm
(0.015 in.)4.30mm
(0.169 in.)4412827AB1.08mm
(0.043 in.)3.62mm
(0.143 in.)4412810AB
0.41mm
(0.016 in.)4.30mm
(0.169 in.)4412827AB1.12mm
(0.044 in.)3.58mm
(0.141)4412809AB
0.43mm
(0.017 in.)4.26mm
(0.168 in.)4412826AB1.14mm
(0.045 in.)3.54mm
(0.139 in.)4412808AB
0.46mm
(0.018 in.)4.22mm
(0.166 in.)4412825AB1.17mm
(0.046 in.)3.54mm
(0.139 in.)4412808AB
0.48mm
(0.019 in.)4.22mm
(0.166 in.)4412825AB1.19mm
(0.047 in.)3.50mm
(0.138 in.)4412807AB
0.50mm
(0.020 in.)4.18mm
(0.165 in.)4412824AB1.22mm
(0.048 in.)3.46mm
(0.136 in.)4412806AB
0.53mm
(0.021 in.)4.18mm
(0.165 in.)4412824AB1.24mm
(0.049 in.)3.46mm
(0.136 in.)4412806AB
0.56mm
(0.022 in.)4.14mm
(0.163 in.)4412823AB1.27mm
(0.050 in.)3.42mm
(0.135 in.)4412805AB
0.58mm
(0.023 in.)4.10mm
(0.161 in.)4412822AB1.30mm
(0.051 in.)3.38mm
(0.133 in.)4412804AB
0.61mm
(0.024 in.)4.10mm
(0.161 in.)4412822AB1.32mm
(0.052 in.)3.38mm
(0.133 in.)4412804AB
0.64mm
(0.025 in.)4.06mm
(0.160 in.)4412821AB1.35mm
(0.053 in.)3.34mm
(0.132 in.)4412803AB
0.66mm
(0.026 in.)4.02mm
(0.158 in.)4412820AB1.37mm
(0.054 in.)3.34mm
(0.132 in.)4412803AB
0.69mm
(0.027 in.)4.02mm
(0.158 in.)4412820AB1.40mm
(0.055 in.)3.30mm
(0.130 in.)4412802AB
0.71mm
(0.028 in.)3.98mm
(0.157 in.)4412819AB1.45mm
(0.057 in3.26mm
(0.128 in.)4412801AB
0.74mm
(0.029 in.)3.94mm
(0.155 in.)4412818AB1.47mm
(0.058 in.)2.22mm
(0.127 in.)4505570AB
21 - 40 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(32) Install the transfer shaft gear using Tool 6261
(Fig. 119).
CAUTION: Install a NEW retaining nut, as the origi-
nal nut MUST NOT be reused.
(33) Install the new retaining nut and washer.
(34) Using Tool 6259, torque transfer gear retain-
ing nut to 271 N´m (200 ft. lbs.) (Fig. 120).(35) Measure transfer shaft end play.Transfer
shaft end play should be within 0.05-0.10 mm
(0.002-0.004 in.).If the end play is too high, install a
0.04 mm (0.0016 in.) thicker shim. If the end play is
too low, install a 0.04 mm (0.0016 in.) thinner shim.
Repeat until 0.05-0.10 mm (0.002-0.004 in.) end play
is obtained.
(36) Install a bead of MopartATF RTV (MS-GF41)
to transfer gear cover (Fig. 121).
(37) Install transfer gear cover-to-case bolts and
torque to 20 N´m (175 in. lbs.) torque (Fig. 122).
Fig. 119 Install Transfer Shaft Gear
1 - WRENCHES
2 - SPECIAL TOOL 6261
3 - OUTPUT GEAR
4 - TRANSFER SHAFT GEAR
Fig. 120 Tighten Nut to 271 N²m (200 ft. lbs.)
1 - TRANSFER SHAFT GEAR
2 - 200 FT. LBS.
3 - TORQUE WRENCH
4 - SPECIAL TOOL 6259
Fig. 121 Install Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPARTATF RTV (MS-GF41) AS SHOWN
Fig. 122 Install Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
RS40TE AUTOMATIC TRANSAXLE21-41
40TE AUTOMATIC TRANSAXLE (Continued)

(38) Install low/reverse clutch pack (Fig. 123).
Leave uppermost disc out until snap ring is installed.
(39) Install low/reverse reaction plate flat snap
ring (Fig. 124).(40) Install remaining low/reverse clutch disc (Fig.
125).
(41) Install low/reverse reaction plate with flat
side up (Fig. 126).
Fig. 123 Install Low/Reverse Clutch
1 - CLUTCH PLATE
2 - CLUTCH DISC
Fig. 124 Install Low/Reverse Reaction Plate Snap
Ring
1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
Fig. 125 Install One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
Fig. 126 Install Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
21 - 42 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(42) Install tapered snap ring (with tapered side
up) as shown in (Fig. 127) (Fig. 128).
(43) Set up dial indicator as shown in (Fig. 129) to
measure low/reverse clutch clearance. Press down on
clutch pack with finger and zero dial indicator.Low/
Reverse clutch pack clearance is 0.89-1.47 mm
(0.035-0.058 in.). Set up indicator and record mea-
surement in four (4) places. Take average of readings
and select the proper low/reverse reaction plate to
achieve specifications.
LOW/REVERSE REACTION PLATE CHART
PART NUMBER THICKNESS
4799846AA 5.88 mm (0.232 in.)
4799847AA 6.14 mm (0.242 in.)
4799848AA 6.40 mm (0.252 in.)
4799849AA 6.66 mm (0.262 in.)
4799855AA 6.92 mm (0.273 in.)
(44) Install 2/4 clutch pack (Fig. 130).
Fig. 127 Tapered Snap Ring Instructions
Fig. 128 Snap Ring Installed
1 - SCREWDRIVER
2 - TAPERED SNAP RING (INSTALL AS SHOWN)
Fig. 129 Check Low/Reverse Clutch Clearance
1 - DIAL INDICATOR
2 - DIAL INDICATOR TIP TOOL 6268
3 - HOOK TOOL
Fig. 130 Install 2/4 Clutch
1 - CLUTCH DISC
2 - CLUTCH PLATE
RS40TE AUTOMATIC TRANSAXLE21-43
40TE AUTOMATIC TRANSAXLE (Continued)

NOTE: The 2/4 Clutch Piston has bonded seals
which are not individually serviceable. Seal replace-
ment requires replacement of the piston assembly.
(45) Orient 2/4 clutch return spring to retainer as
shown in (Fig. 131), and install to transaxle (Fig.
132).(46) Using tool 5058, compress 2/4 clutch return
spring just enough to install snap ring (Fig. 133).
(47) Install snap ring.
(48) Set up dial indicator as shown in (Fig. 134)
and measure 2/4 clutch clearance. Press down on
clutch pack with finger and zero dial indicator.2/4
clutch pack clearance is 0.76-2.64 mm
(0.030-0.104 in.).Set up indicator and record mea-
surement in four (4) places. Take average of read-
ings. If clearance is outside this range, the clutch is
assembled improperly.There is no adjustment for
2/4 clutch clearance.
Fig. 131 Proper Orientation of 2/4 Clutch Retainer
and Spring
1 - NOTE POSITION
2 - RETURN SPRING
3 - 2/4 CLUTCH RETAINER
Fig. 132 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 133 Install 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
Fig. 134 Check 2/4 Clutch Clearance
1 - DIAL INDICATOR
2 - HOOK TOOL
3 - DIAL INDICATOR TIP TOOL 6268
21 - 44 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(49) Install rear sun gear and #7 needle bearing
(Fig. 136).
NOTE: The number seven needle bearing has three
anti-reversal tabs and is common with the number
five and number two position. The orientation
should allow the bearing to seat flat against the
rear sun gear (Fig. 135). A small amount of petrola-
tum can be used to hold the bearing to the rear sun
gear.(50) Install front carrier/rear annulus assembly
and #6 needle bearing (Fig. 137).
(51) Install front sun gear assembly and #4 thrust
washer (Fig. 138).
Fig. 135 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 136 Install Rear Sun Gear and #7 Needle
Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 137 Install Front Carrier/Rear Annulus
Assembly
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 138 Install Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
RS40TE AUTOMATIC TRANSAXLE21-45
40TE AUTOMATIC TRANSAXLE (Continued)

(52)DETERMINING #4 THRUST PLATE
THICKNESS / INPUT SHAFT END PLAY:
(a) Select the thinnest #4 thrust plate thickness
and install to input clutch assembly (Fig. 139). Use
petrolatum to retain.
(b) Install input clutch assembly into position
and verify that it is completely seated by viewing
through input speed sensor hole. If view through
input speed sensor hole is not as shown in (Fig.
140), the input clutch assembly is not seated prop-
erly.
(c) Remove oil pump o-ring (Fig. 141).Be sure
to reinstall oil pump o-ring after selecting the
proper #4 thrust plate.
(d) Install pump and gasket to transmission.
Install and torque bolts.(e) Set up input shaft for measurement with
Indicator Set C3339 and End Play Set 8266 as
shown in (Fig. 142).
(f) Measure the input shaft end play with the
transaxle in the vertical position.Input shaft end
play must be within 0.005 to 0.025 inch.For
example, if end play reading is 0.055 inch, select
No. 4 Thrust Plate which is 0.071 to 0.074 thick.
This should provide an input shaft end play read-
ing of 0.020 inch which is within specifications.
(g) Refer to the No. 4 thrust plate chart to select
the proper No. 4 thrust plate:
Fig. 139 Select Thinnest No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 140 View Through Input Speed Sensor Hole
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
Fig. 141 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 142 Measure Input Shaft End Play
Using Tool 8266ÐTypical
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
21 - 46 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

NO. 4 THRUST PLATE CHART
PART NUMBER THICKNESS
4431665AB 1.60mm (0.063 in.)
3836237AB 1.73mm (0.068 in.)
4431666AB 1.80mm (0.071 in.)
3836238AB 1.96mm (0.077 in.)
4431667AB 2.03mm (0.080 in.)
3836239AB 2.16mm (0.085 in.)
4431668AB 2.24mm (0.088 in.)
3836240AB 2.39mm (0.094 in.)
4431669AB 2.46mm (0.097 in.)
3836241AB 2.62mm (0.103 in.)
4446670AB 2.67mm (0.105 in.)
4446671AB 2.90mm (0.114 in.)
(53) Install input clutch assembly (Fig. 143).(54) Install #1 caged needle bearing (Fig. 144).
CAUTION: The cooler bypass valve must be
replaced if transaxle failure has occurred. Do not
attempt to reuse or clean old valve.
(55) Install cooler bypass valve with o-ring end
towards rear of case (Fig. 145).
Fig. 143 Install Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 144 Install No. 1 Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 145 Install Cooler Bypass Valve
1 - COOLER BYPASS VALVE
RS40TE AUTOMATIC TRANSAXLE21-47
40TE AUTOMATIC TRANSAXLE (Continued)

(56) Install oil pump gasket (Fig. 146).
(57) Install oil pump assembly (Fig. 147).(58) Install oil pump-to-case bolts and torque to 27
N´m (20 ft. lbs.) (Fig. 148).
(59) Install low/reverse accumulator (Fig. 149).
Fig. 146 Install Oil Pump Gasket
1 - PUMP GASKET
Fig. 147 Install Oil Pump
1 - OIL PUMP
2 - GASKET
Fig. 148 Install Pump-to-Case Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 149 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
21 - 48 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(60) Install low/reverse accumulator plug (Fig.
150).
(61) Install low/reverse accumulator snap ring
(Fig. 151).NOTE: Depending on engine application, some
accumulators will have two springs, and others will
have one spring. The springs are color-coded for
application and year.
(62) Install underdrive and overdrive accumulators
and springs (Fig. 152).
(63) Install valve body to transaxle (Fig. 153).
Rotate manual valve shaft fully clockwise to ease
installation. Make sure park rod rollers are posi-
tioned within park guide bracket.
Fig. 150 Install Low/Reverse Accumulator Plug
1 - ADJUSTABLE PLIERS
2 - PLUG
Fig. 151 Install Low/Reverse Accumulator Snap
Ring
1 - SNAP RING
2 - PLUG
Fig. 152 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 153 Valve Body Removal/Installation
1 - VALVE BODY
RS40TE AUTOMATIC TRANSAXLE21-49
40TE AUTOMATIC TRANSAXLE (Continued)