DODGE TOWN AND COUNTRY 2001 Service Manual

(20) Remove cooler bypass valve (Fig. 37).
(21) Remove #1 needle bearing (Fig. 38).(22) Remove input clutch assembly (Fig. 39).
(23) Remove #4 thrust plate (Fig. 40).
Fig. 37 Remove Bypass Valve
1 - COOLER BYPASS VALVE
Fig. 38 Remove Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 39 Remove Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 40 No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
21 - 174 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)
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(24) Remove front sun gear assembly and #4
thrust washer (Fig. 41).
(25) Remove front carrier and rear annulus assem-
bly (Fig. 42).(26) Remove rear sun gear and #7 needle bearing
(Fig. 43).
NOTE: Verify that Tool 5058 is centered properly
over the 2/4 clutch retainer before compressing. If
necessary, fasten the 5058 bar to the bellhousing
flange with any combination of locking pliers and
bolts to center the tool properly.
(27) Setup tool 5058 as shown in (Fig. 44). Com-
press 2/4 clutch return spring (just enough to remove
snap ring) and remove snap ring.
Fig. 41 Remove Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
Fig. 42 Remove Front Carrier and Rear Annulus
Assembly
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 43 Remove Rear Sun Gear
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 44 Remove 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
RSAUTOMATIC - 41TE21 - 175
AUTOMATIC - 41TE (Continued)
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(28) Remove 2/4 clutch retainer (Fig. 45).
(29) Remove 2/4 clutch return spring (Fig. 46).(30) Remove 2/4 clutch pack (Fig. 47).Tag 2/4
clutch pack for reassembly identification.
(31) Remove tapered snap ring (Fig. 48).
Fig. 45 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 46 Remove 2/4 Clutch Return Spring
1 - 2/4 CLUTCH RETURN SPRING
Fig. 47 Remove 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
Fig. 48 Remove Tapered Snap Ring
1 - LOW/REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)
4 - OIL PAN FACE
5 - LONG TAB
21 - 176 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)
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(32) Remove low/reverse reaction plate (Fig. 49).
(33) Remove one low/reverse clutch disc (Fig. 50).(34) Remove low/reverse reaction plate snap ring
(Fig. 51).
(35) Remove low/reverse clutch pack (Fig. 52).
Fig. 49 Remove Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Fig. 50 Remove One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
Fig. 51 Remove Low/Reverse Reaction Plate Snap
Ring
1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
Fig. 52 Remove Low/Reverse Clutch Pack
1 - CLUTCH PLATES (5)
2 - CLUTCH DISCS (5)
RSAUTOMATIC - 41TE21 - 177
AUTOMATIC - 41TE (Continued)
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(36) Remove transfer gear cover-to-case bolts (Fig.
53).
(37) Remove transfer gear cover (Fig. 54).(38) Using Tool 6259, remove transfer shaft gear-
to-shaft nut and coned washer (Fig. 55) (Fig. 56).
Fig. 53 Remove Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
Fig. 54 Remove Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPAR SILICONE RUBBER ADHESIVE
SEALANT AS SHOWN
Fig. 55 Remove Transfer Shaft Gear Nut
1 - TRANSFER SHAFT GEAR
2 - OUTPUT GEAR
3 - SPECIAL TOOL 6259
Fig. 56 Transfer Shaft Gear Nut and Coned Washer
1 - TRANSFER SHAFT
2 - LOCK WASHER
3 - NUT
21 - 178 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)
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(39) Using tool L-4407A, remove transfer shaft
gear (Fig. 57).
(40) Remove transfer gear shim (select) (Fig. 58).(41) Remove bearing cup retainer (Fig. 59).
(42) Remove transfer gear bearing cone using
setup shown in (Fig. 60).
Fig. 57 Remove Transfer Shaft Gear
1 - SPECIAL TOOL L4407-6
2 - TRANSFER SHAFT GEAR
3 - SPECIAL TOOL L4407A
Fig. 58 Remove Transfer Shaft Gear and (Select)
Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM (SELECT)
Fig. 59 Remove Bearing Cup Retainer
1 - ALIGN INDEXING TAB TO SLOT
2 - BEARING CUP RETAINER
Fig. 60 Remove Transfer Gear Bearing Cone
1 - WRENCHES
2 - TOOL 5048 WITH JAWS TOOL 5048±4 AND BUTTON TOOL
L-4539±2
3 - TRANSFER SHAFT GEAR
RSAUTOMATIC - 41TE21 - 179
AUTOMATIC - 41TE (Continued)
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(43) Remove transfer shaft bearing cup from
retainer using Tool 6062 (Fig. 61).
(44) Using Tool 6051, remove transfer shaft bear-
ing snap ring (Fig. 62).(45) Using tool 5049A, remove transfer shaft from
transaxle (Fig. 63).
(46) Slip bearing cup retainer and oil baffle off of
shaft (Fig. 64).
Fig. 61 Remove Transfer Shaft Bearing Cup
1 - WRENCHES
2 - TOOL 6062
3 - TRANSFER SHAFT BEARING CUP RETAINER
Fig. 62 Remove Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS TOOL 6051
2 - TRANSFER SHAFT BEARING SNAP RING
3 - TRANSFER SHAFT
Fig. 63 Remove Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
Fig. 64 Bearing Cup Removed
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
21 - 180 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)
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(47) Using tool P-334, press transfer shaft bearing
cone off of shaft (Fig. 65).
(48) Bend output gear retaining strap ears flat to
allow bolt removal.
(49) Remove output shaft stirrup strap bolts (Fig.
66).(50) Remove stirrup and strap (Fig. 67).
(51) Using Tool 6259 (Fig. 68), remove output shaft
gear-to-shaft bolt and washer (Fig. 69).
Fig. 65 Remove Transfer Shaft Bearing Cone
1 - ARBOR PRESS RAM
2 - TRANSFER SHAFT
3 - TOOL P-334
4 - BEARING CONE
Fig. 66 Remove Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
Fig. 67 Remove Stirrup Strap
1 - OUTPUT GEARBOLT
2 - RETAINING STRAP
3 - STIRRUP
Fig. 68 Remove Output Gear Bolt
1 - OUTPUT GEAR
2 - TOOL 6259
RSAUTOMATIC - 41TE21 - 181
AUTOMATIC - 41TE (Continued)
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(52) Using Tool L4407A, and button 6055, remove
output gear from shaft (Fig. 70).(53) Remove output gear bearing shim (select)
(Fig. 71).
(54) Using setup as shown in (Fig. 72), remove
output gear bearing cone.
Fig. 69 Output Gear Bolt and Washer
1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
Fig. 70 Remove Output Gear
1 - OUTPUT GEAR
2 - BUTTON TOOL 6055
3 - WRENCHES
4 - TOOL L4407A
5 - BOLTS TOOL L4407±6
Fig. 71 Output Gear and (Select) Shim
1 - REAR CARRIER ASSEMBLY
2 - SHIM (SELECT)
3 - OUTPUT GEAR
Fig. 72 Remove Bearing Cone
1 - TOOL 5048 WITH JAWS 5048±5 AND BUTTON L-4539±2
2 - WRENCHES
3 - OUTPUT GEAR
21 - 182 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)
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(55) Remove rear carrier assembly from transaxle
(Fig. 73).
(56) Remove rear carrier assembly bearing cone
using setup shown in (Fig. 74).(57) Install low/reverse spring compressor tool as
shown in (Fig. 75) (Fig. 76).
Fig. 73 Remove Rear Carrier Assembly
1 - REAR CARRIER ASSEMBLY
Fig. 74 Remove Rear Carrier Bearing Cone
1 - TOOL 5048 WITH JAWS 5048±3 AND BUTTON 6055
2 - WRENCHES
3 - REAR CARRIER ASSEMBLY
Fig. 75 Low/Reverse Spring Compressor Tool
1 - TOOL 6057
2 - TOOL 5059
3 - TOOL 5058±3
Fig. 76 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
RSAUTOMATIC - 41TE21 - 183
AUTOMATIC - 41TE (Continued)
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