clutch CHRYSLER CARAVAN 2002 Service Manual

(30) Remove 2/4 clutch pack (Fig. 46).Tag 2/4
clutch pack for reassembly identification.
(31) Remove tapered snap ring (Fig. 47).(32) Remove low/reverse reaction plate (Fig. 48).
(33) Remove one low/reverse clutch disc (Fig. 49).
Fig. 46 Remove 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
Fig. 47 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
Fig. 48 Remove Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Fig. 49 Remove One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
21 - 180 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(34) Remove low/reverse reaction plate snap ring
(Fig. 50).
(35) Remove low/reverse clutch pack (Fig. 51).(36) Remove transfer gear cover-to-case bolts (Fig.
52).
(37) Remove transfer gear cover (Fig. 53).
Fig. 50 Remove Low/Reverse Reaction Plate Snap
Ring
1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
Fig. 51 Remove Low/Reverse Clutch Pack
1 - CLUTCH PLATES (5)
2 - CLUTCH DISCS (5)
Fig. 52 Remove Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
Fig. 53 Remove Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPARTATF RTV (MS-GF41) AS
SHOWN
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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
RS41TE AUTOMATIC TRANSAXLE21 - 187
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
21 - 188 41TE AUTOMATIC TRANSAXLERS
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
RS41TE AUTOMATIC TRANSAXLE21 - 189
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
21 - 190 41TE AUTOMATIC TRANSAXLERS
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
RS41TE AUTOMATIC TRANSAXLE21 - 191
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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(38) Install low/reverse clutch pack (Fig. 125).
Leave uppermost disc out until snap ring is installed.
(39) Install low/reverse reaction plate flat snap
ring (Fig. 126).(40) Install remaining low/reverse clutch disc (Fig.
127).
(41) Install low/reverse reaction plate with flat
side up (Fig. 128).
Fig. 125 Install Low/Reverse Clutch Pack
1 - CLUTCH PLATES (5)
2 - CLUTCH DISCS (5)
Fig. 126 Install Low/Reverse Reaction Plate Snap
Ring
1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
Fig. 127 Install One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
Fig. 128 Install Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
RS41TE AUTOMATIC TRANSAXLE21 - 203
41TE AUTOMATIC TRANSAXLE (Continued)
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(42) Install tapered snap ring (with tapered side
up) as shown in (Fig. 129) (Fig. 130).
(43) Set up dial indicator as shown in (Fig. 131) 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. 132), staggering
clutch plate pads as shown in (Fig. 133).Fig. 129 Tapered Snap Ring Instructions
Fig. 130 Snap Ring Installed
1 - SCREWDRIVER
2 - TAPERED SNAP RING (INSTALL AS SHOWN)
Fig. 131 Check Low/Reverse Clutch Clearance
1 - DIAL INDICATOR
2 - DIAL INDICATOR TIP TOOL 6268
3 - HOOK TOOL
Fig. 132 Install 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
21 - 204 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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