shaft CHRYSLER CARAVAN 2002 Service Manual

(9) Install ring gear-to-case bolts, with pinion shaft
retainers (Fig. 201), and torque bolts to 95 N´m (70
ft. lbs.).
(10) Using Miller Special Tool L-4410, and C-4171,
install differential bearing to differential (extension
housing side) (Fig. 202).
(11) Using Miller Special Tool 5052 and C-4171,
install differential bearing to differential (bearing
retainer side).(12) Using Miller Special Tool 6061 and C-4171,
install differential bearing race to bearing retainer
(Fig. 203).
(13) Using Miller Special Tool L±4520 and C-4171,
install differential bearing to extension housing.
NOTE: Use MoparTSilicone Rubber Adhesive Seal-
ant, or equivalent, on retainer and extension hous-
ing/adapter plate to seal to case.
(14) Install differential assembly into transaxle
case. Install differential bearing retainer (Fig.
204)and torque retainer-to-case bolts (Fig. 205)to 28
N´m (21 ft. lbs.).
Fig. 201 Ring Gear-to-Case Bolts
1 - DIFFERENTIAL CASE
2 - PINION SHAFT RETAINER
3 - RING GEAR
4 - RING GEAR-TO-CASE BOLT
Fig. 202 Position Bearing Cone Onto DifferentialÐ
Typical
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL BEARING
Fig. 203 Differential Bearing Retainer
1 - DIFFERENTIAL BEARING CUP
2 - DIFFERENTIAL BEARING RETAINER
Fig. 204 Differential Bearing Retainer
1 - DIFFERENTIAL BEARING CUP
2 - DIFFERENTIAL BEARING RETAINER
RS41TE AUTOMATIC TRANSAXLE21 - 245
FINAL DRIVE (Continued)
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(15) Apply a bead of MopartSilicone Rubber
Adhesive Sealant to extension housing/adapter plate
and install into position. Install and torque bolts to
28 N´m (21 ft. lbs.).
(16)
Measure and adjust differential bearing preload.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/FINAL DRIVE - ADJUSTMENTS)
(17) Apply a bead of MopartSilicone Rubber
Adhesive Sealant to differential cover and install to
case (Fig. 206).
(18) Install and torque cover-to-case bolts to 19
N´m (165 in. lbs.) (Fig. 207).
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL BEARING
PRELOAD
NOTE: Perform all differential bearing preload mea-
surements with the transfer shaft and gear removed.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT
USING EXISTING SHIM
(1)Position the transaxle assembly vertically on the
support stand, differential bearing retainer side up.
(2) Install Tool L-4436A into the differential and
onto the pinion mate shaft (Fig. 208).
Fig. 205 Differential Retainer Bolts
1 - DIFFERENTIAL RETAINER BOLTS
Fig. 206 Install Differential Cover
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL COVER
Fig. 207 Differential Cover Bolts
1 - DIFFERENTIAL COVER BOLTS
2 - DIFFERENTIAL COVER
Fig. 208 Tool L-4436 and Torque Wrench
1 - SPECIAL TOOL L-4436±A
2 - TORQUE WRENCH
3 - DIFFERENTIAL BEARING RETAINER
21 - 246 41TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)
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HOLDING CLUTCHES
DESCRIPTION
Two hydraulically applied multi-disc clutches are
used to hold planetary geartrain components station-
ary while the input clutches drive others. The 2/4
and Low/Reverse clutches are considered holding
clutches and are contained at the rear of the trans-
axle case. (Fig. 225) .
OPERATION
NOTE: Refer to the ªElements In Useº chart in Diag-
nosis and Testing for a collective view of which
clutch elements are applied at each position of the
selector lever.
2/4 CLUTCH
The 2/4 clutch is hydraulically applied in second
and fourth gears by pressurized fluid against the 2/4
clutch piston. When the 2/4 clutch is applied, the
front sun gear assembly is held or grounded to the
transaxle case.
LOW/REVERSE CLUTCH
The Low/Reverse clutch is hydraulically applied in
park, reverse, neutral, and first gears by pressurized
fluid against the Low/Reverse clutch piston. When
the Low/Reverse clutch is applied, the front planet
carrier/rear annulus assembly is held or grounded to
the transaxle case.
INPUT CLUTCH ASSEMBLY
DISASSEMBLY
(1) Mount input clutch assembly to Input Clutch
Pressure Fixture (Tool 8391).
(2) Tap down reverse clutch reaction plate to
release pressure from snap ring (Fig. 226).
Fig. 225 2/4 and Low/Reverse Clutches
1 - FRONT PLANET CARRIER/REAR ANNULUS
2 - 2/4 CLUTCH
3 - L/R CLUTCH
4 - REAR PLANET CARRIER/FRONT ANNULUS
5 - REAR SUN GEAR
6 - FRONT SUN GEAR ASSEMBLY
Fig. 226 Tapping Reaction Plate
1 - #4 THRUST PLATE (SELECT)
2 - TAP DOWN REVERSE CLUTCH REACTION PLATE TO
REMOVE OR INSTALL SNAP RING
3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY
4 - REVERSE CLUTCH REACTION PLATE
RS41TE AUTOMATIC TRANSAXLE21 - 255
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(6) Remove the OD/Reverse pressure plate snap
ring (Fig. 231).
(7) Remove OD/Reverse pressure plate (Fig. 232).(8) Remove OD/Reverse pressure plate wave snap
ring (Fig. 233).
(9) Remove OD shaft/hub and OD clutch pack (Fig.
234) (Fig. 235).
NOTE: Tag overdrive clutch pack for reassembly
identification.
Fig. 231 OD/Reverse Pressure Plate Snap Ring
1 - OD/REVERSE PRESSURE PLATE
2 - SCREWDRIVER
3 - OD/REVERSE PRESSURE PLATE SNAP RING
Fig. 232 OD/Reverse Pressure Plate
1 - OD/REVERSE PRESSURE PLATE (STEP SIDE DOWN)
2 - (STEP SIDE DOWN)
Fig. 233 Waved Snap Ring
1 - OVERDRIVE SHAFT ASSEMBLY
2 - OD/REVERSE CLUTCH WAVED SNAP RING
3 - SCREWDRIVER
Fig. 234 Remove OD Clutch Pack
1 - OVERDRIVE SHAFT ASSEMBLY AND OD CLUTCH PACK
2 - #3 THRUST PLATE
3 - #3 THRUST WASHER
4 - UNDERDRIVE SHAFT ASSEMBLY
RS41TE AUTOMATIC TRANSAXLE21 - 257
INPUT CLUTCH ASSEMBLY (Continued)
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(10) Remove and inspect #3 & #4 thrust washers
(Fig. 236).(11) Remove the underdrive shaft assembly (Fig.
237).
(12) Remove the #2 needle bearing (Fig. 238).
Fig. 235 Overdrive Clutch Pack
1 - OVERDRIVE CLUTCH PLATE
2 - OVERDRIVE SHAFT ASSEMBLY
3 - OVERDRIVE CLUTCH DISC
Fig. 236 #3&4 Thrust Washers
1 - #3 THRUST PLATE (3 TABS)
2 - OD SHAFT ASSEMBLY
3 - #4 THRUST PLATE (3 SLOTS)
Fig. 237 Underdrive Shaft Assembly
1 - #3 THRUST WASHER (5 TABS)
2 - UNDERDRIVE SHAFT ASSEMBLY
Fig. 238 No. 2 Needle Bearing
1 - #2 NEEDLE BEARING (NOTE 3 TABS)
21 - 258 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)
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(21) Remove input hub tapered snap ring (Fig.
247).
(22) Tap on input hub with soft faced hammer and
separate input hub from OD/Reverse piston and
clutch retainer (Fig. 248) (Fig. 249).(23) Separate clutch retainer from OD/Reverse pis-
ton (Fig. 250).
Fig. 247 Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
Fig. 248 Tap on Input Hub
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - PLASTIC HAMMER
Fig. 249 Input Hub Removed
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - INPUT CLUTCHES RETAINER
3 - O-RING
4 - SEAL
5 - OVERDRIVE/REVERSE PISTON
Fig. 250 Pull Retainer from Piston
1 - OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
RS41TE AUTOMATIC TRANSAXLE21 - 261
INPUT CLUTCH ASSEMBLY (Continued)
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(24) Using Tool 6057 and an arbor press, compress
return OD/Reverse piston return spring just enough
to remove snap ring (Fig. 251) (Fig. 252).(25) Remove input shaft to input clutch hub snap
ring (Fig. 253).
(26) Using a suitably sized socket and an arbor
press, remove input shaft from input shaft hub (Fig.
254).
Fig. 251 Remove Snap Ring
1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST
ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
3 - SNAP RING
4 - SPECIAL TOOL 6057
5 - OD/REVERSE PISTON
6 - RETURN SPRING
Fig. 252 Snap Ring and Return Spring
1 - OD/REVERSE PISTON
2 - RETURN SPRING
3 - SNAP RING
4 - O-RING
Fig. 253 Remove Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SHARP-POINTED TOOL
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 254 Remove Input Shaft
1 - ARBOR PRESS RAM
2 - SOCKET
3 - SEAL
4 - O-RINGS
5 - INPUT SHAFT
6 - SEAL
7 - INPUT SHAFT HUB ASSEMBLY
21 - 262 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)
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ASSEMBLY
Use petrolatum on all seals to ease assembly of
components.
(1) Using an arbor press, install input shaft to
input shaft hub (Fig. 255).
(2) Install input shaft snap ring (Fig. 256).(3) Using an arbor press and Tool 6057, Install
OD/Reverse piston return spring and snap ring (Fig.
257) (Fig. 258).
Fig. 255 Install Input Shaft
1 - INPUT SHAFT
2 - ARBOR PRESS RAM
3 - INPUT SHAFT HUB ASSEMBLY
Fig. 256 Install Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 257 Return Spring and Snap Ring
1 - OD/REVERSE PISTON
2 - RETURN SPRING
3 - SNAP RING
4 - O-RING
Fig. 258 Install Snap Ring
1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST
ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
3 - SNAP RING
4 - SPECIAL TOOL 6057
5 - OD/REVERSE PISTON
6 - RETURN SPRING
RS41TE AUTOMATIC TRANSAXLE21 - 263
INPUT CLUTCH ASSEMBLY (Continued)
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(4) Install the OD/Reverse piston assembly to the
input clutch retainer as shown in (Fig. 259).
(5) Install the input hub/shaft assy. to the OD/Re-
verse piston/clutch retainer assy. (Fig. 260).(6) Install input hub tapered snap ring (Fig. 261).
(7) Install UD clutch piston (Fig. 262).
Fig. 259 Install OD/Reverse Piston
1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
Fig. 260 Install Input Shaft Hub Assembly
1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY
(ROTATE TO ALIGN SPLINES)
2 - OD/REV. PISTON
Fig. 261 Install Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
Fig. 262 Underdrive Clutch Piston
1 - PISTON
21 - 264 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)
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(8) Install UD piston return spring and Tool 5067
as shown in (Fig. 263).
(9) Using Tool 5059A and an arbor press, Install
the UD spring retainer and snap ring. (Fig. 264) (Fig.
265) Compress just enough to install snap ring.
CAUTION: Compress return spring just enough to
install snap ring.(10) Install the UD clutch pack. Leave out upper
disc, until snap ring is installed (Fig. 266).
Fig. 263 Seal Compressor Special Tool 5067
1 - PISTON RETURN SPRING
2 - SPECIAL TOOL 5067
3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY
Fig. 264 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 265 Install UD Spring Retainer and Snap Ring
1 - ARBOR PRESS RAM
2 - SNAP RING PLIERS
3 - SNAP RING
4 - OD/REVERSE PISTON
5 - TOOL 5067
6 - TOOL 5059A
Fig. 266 Underdrive Clutch Pack
1 - CLUTCH PLATE
2 - ONE UD CLUTCH DISC
3 - CLUTCH DISC
RS41TE AUTOMATIC TRANSAXLE21 - 265
INPUT CLUTCH ASSEMBLY (Continued)
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