shaft CHRYSLER CARAVAN 2002 Service Manual

(7) Install throttle valve lever/shaft (Fig. 323).
(8) Install manual valve shaft/lever to throttle
valve shaft (Fig. 324). Align manual valve lever to
manual valve.(9) Remove throttle valve shaft-to-manual valve
shaft seal, washer, and e-clip (Fig. 325). Verify that
manual valve lever is engaged with manual valve.
(10) Install and verify proper location of check
balls (Fig. 326).
Fig. 323 Install Throttle Valve Lever Assembly
1 - THROTTLE VALVE LEVER ASSEMBLY
2 - MANUAL VALVE
3 - VALVE BODY
Fig. 324 Install Manual Valve Lever
1 - THROTTLE VALVE LEVER ASSEMBLY
2 - MANUAL VALVE LEVER ASSEMBLY
3 - VALVE BODY
Fig. 325 Throttle Shaft E-Clip, Washer, and Seal
1 - MANUAL VALVE LEVER ASSEMBLY
2 - OIL SEAL
3 - ªEº CLIP
4 - THROTTLE VALVE LEVER ASSEMBLY
5 - WASHER
Fig. 326 Steel Ball Locations
1 - MANUAL VALVE
2 - STEEL BALLS (8)
3 - STEEL BALLS
21 - 156 31TH AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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Fig. 1 41TE Transaxle
1 - CASE 7 - LOW/REVERSE CLUTCH 13 - DIFFERENTIAL
2 - INPUT SPEED SENSOR 8 - OUTPUT SPEED SENSOR 14 - OIL PUMP
3 - UNDERDRIVE CLUTCH 9 - PLANETARY GEAR SET 15 - TORQUE CONVERTER
4 - OVERDRIVE CLUTCH 10 - OUTPUT SHAFT GEAR 16 - TORQUE CONVERTER CLUTCH
5 - REVERSE CLUTCH 11 - TRANSFER SHAFT
6 - 2/4 CLUTCH 12 - TRANSFER SHAFT GEAR
RS41TE AUTOMATIC TRANSAXLE21 - 163
41TE AUTOMATIC TRANSAXLE (Continued)
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TEST SIX-SELECTOR IN REVERSE
(1) Attach gauges to the reverse and LR clutch
tap.
(2) Move selector lever to the (R) position.
(3) Read reverse clutch pressure with output sta-
tionary (foot on brake) and throttle opened to achieve
1500 rpm.
(4) Reverse and LR clutch pressure should read
165 to 235 psi.
(5) This test checks the reverse clutch hydraulic
circuit.
TEST RESULT INDICATIONS
(1) If proper line pressure is found in any one test,
the pump and pressure regulator are working prop-
erly.(2) Low pressure in all positions indicates a defec-
tive pump, a clogged filter, or a stuck pressure regu-
lator valve.
(3) Clutch circuit leaks are indicated if pressures
do not fall within the specified pressure range.
(4) If the overdrive clutch pressure is greater than
5 psi in Step 4 of Test Three, a worn reaction shaft
seal ring or a defective solenoid assembly is indi-
cated.
(5) If the underdrive clutch pressure is greater
than 5 psi in Step 4 of Test Two A, a defective sole-
noid assembly or TCM is the cause.
PRESSURE CHECK SPECIFICATIONS
Pressure Taps
Gear
Selector
PositionActual GearUnderdrive
ClutchOverdrive
ClutchReverse
ClutchTorque
Converter
Clutch Off2/4 ClutchLow/
Reverse
Clutch
Park *
PARK 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
REVERSE *
REVERSE 0-2 0-7 165-235 50-100 0-2 165-235
0 mph
NEUTRAL *
NEUTRAL 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
L#
FIRST 110-145 0-5 0-2 60-110 0-2 115-145
20 mph
3#
SECOND 110-145 0-5 0-2 60-110 115-145 0-2
30 mph
3#
DIRECT 75-95 75-95 0-2 60-90 0-2 0-2
45 mph
OD #
OVERDRIVE 0-2 75-95 0-2 60-90 75-95 0-2
30 mph
OD #
OVERDRIVE
WITH TCC0-2 75-95 0-2 0-5 75-95 0-2
50 mph
* Engine speed at 1500 rpm
# CAUTION: Both front wheels must be turning at the same speed.
RS41TE AUTOMATIC TRANSAXLE21 - 167
41TE AUTOMATIC TRANSAXLE (Continued)
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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. 5) (Fig. 6). 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. 7).
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. 5 Air Pressure Test Plate
1 - TOOL 6056
2 - ACCUMULATORS
Fig. 6 Testing Reverse Clutch
1 - TOOL 6056
2 - AIR NOZZLE
21 - 168 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(3) Remove coolant recovery bottle (Fig. 10).
(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. 11).
(7) Disconnect transmission range sensor (TRS)
connector (Fig. 11).
(8) Disconnect solenoid/pressure switch assembly
connector (Fig. 11).
(9) Disconnect gear shift cable from manual valve
lever and upper mount bracket (Fig. 12).
(10) Disconnect crankshaft position sensor (if
equipped). Remove sensor from bellhousing.
(11) Reposition leak detection pump harness and
hoses.
(12) Remove rear mount bracket-to-transaxle case
bolts (Fig. 13).
(13) Remove transaxle upper bellhousing-to-block
bolts.
(14) Raise vehicle on hoist.
(15) Remove transaxle oil pan and drain fluid into
suitable container.
(16) Remove front wheel/tire assemblies.
(17) Remove left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - REMOVAL)
Fig. 10 Coolant Recovery Bottle
1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL
Fig. 11 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. 12 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 170 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(12) Remove low/reverse accumulator plug (Fig.
26).
(13) Remove low/reverse accumulator piston using
petrolatum and a suitable tool (Fig. 27).
(14) Remove low/reverse accumulator (Fig. 28).
(15) Measure input shaft end play. Place transaxle
so input shaft is vertical. Set up end play set and
dial indicator as shown in (Fig. 29).Input shaft end
play should be within 0.13-0.64 mm (0.005-0.025
in.)If outside of this range, a #4 thrust plate change
is required. Record indicator reading for referenceupon reassembly.
Fig. 26 Remove Low/Reverse Accumulator Plug
(Cover)
1 - ADJUSTABLE PLIERS
2 - PLUG
Fig. 27 Remove Low/Reverse Accumulator Piston
1 - SEAL RINGS
2 - PISTON
3 - PISTON
4 - PETROLATUM
5 - SUITABLE TOOL
Fig. 28 Remove Low/Reverse Accumulator
1 - ACCUMULATOR PISTON
2 - SEAL RINGS
3 - RETURN SPRINGS
4 - (NOTE NOTCH)
Fig. 29 Measure Input Shaft End Play Using End
Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
RS41TE AUTOMATIC TRANSAXLE21 - 175
41TE AUTOMATIC TRANSAXLE (Continued)
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(16) Remove oil pump-to-case bolts (Fig. 30).
CAUTION: Be sure input speed sensor is removed
before removing oil pump.
(17) Install pullers Tool C-3752 as shown in (Fig.
31).(18) Remove oil pump assembly (Fig. 32) (Fig. 33).
Fig. 33 Oil Pump Removed
1 - OIL PUMP
2 - GASKET
Fig. 30 Remove Pump Attaching Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 31 Install Tool C-3752
1 - PULLERS TOOL C-3752
2 - PUMP
Fig. 32 Remove Oil Pump
1 - ªPUSH INº ON INPUT SHAFT WHILE REMOVING PUMP
21 - 176 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(23) Remove #4 thrust plate (Fig. 38).
(24) Remove front sun gear assembly and #4
thrust washer (Fig. 39).(25) Remove front carrier/rear annulus assembly
and #6 needle bearing (Fig. 40).
(26) Remove rear sun gear and #7 needle bearing
(Fig. 41).
NOTE: The number 7 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. 42). A small amount of petrolatum can be
used to hold the bearing to the rear sun gear.
Fig. 38 No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 39 Remove Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
Fig. 40 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. 41 Remove Rear Sun Gear
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
21 - 178 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(38) Using Tool 6259, remove transfer shaft gear-
to-shaft nut and coned washer (Fig. 54) (Fig. 55).(39) Using tool L-4407A, remove transfer shaft
gear (Fig. 56).
(40) Remove transfer gear shim (select) (Fig. 57).
Fig. 54 Remove Transfer Shaft Gear Nut
1 - TRANSFER SHAFT GEAR
2 - OUTPUT GEAR
3 - SPECIAL TOOL 6259
Fig. 55 Transfer Shaft Gear Nut and Coned Washer
1 - TRANSFER SHAFT
2 - LOCK WASHER
3 - NUT
Fig. 56 Remove Transfer Shaft Gear
1 - SPECIAL TOOL L4407-6
2 - TRANSFER SHAFT GEAR
3 - SPECIAL TOOL L4407A
Fig. 57 Remove Transfer Shaft Gear and (Select)
Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM (SELECT)
21 - 182 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(41) Remove bearing cup retainer (Fig. 58).
(42) Remove transfer gear bearing cone using
setup shown in (Fig. 59).(43) Remove transfer shaft bearing cup from
retainer using Tool 6062 (Fig. 60).
(44) Using Tool 6051, remove transfer shaft bear-
ing snap ring (Fig. 61).
Fig. 58 Remove Bearing Cup Retainer
1 - ALIGN INDEXING TAB TO SLOT
2 - BEARING CUP RETAINER
Fig. 59 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
Fig. 60 Remove Transfer Shaft Bearing Cup
1 - WRENCHES
2 - TOOL 6062
3 - TRANSFER SHAFT BEARING CUP RETAINER
Fig. 61 Remove Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS TOOL 6051
2 - TRANSFER SHAFT BEARING SNAP RING
3 - TRANSFER SHAFT
RS41TE AUTOMATIC TRANSAXLE21 - 183
41TE AUTOMATIC TRANSAXLE (Continued)
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