shaft CHRYSLER CARAVAN 2002 Service Manual

(34) Apply 30 psi (206 kPa) air pressure to the
reverse clutch hose on Tool 8391. Measure and record
reverse clutch pack measurement in four (4) places,
90É apart.
(35) Take average of four measurements and com-
pare with reverse clutch pack clearance specification.
The reverse clutch pack clearance is 0.89-1.37
mm (0.035-0.054 in.).Select the proper reverse
clutch snap ring to achieve specifications:
REVERSE CLUTCH SNAP RING THICKNESS
4377195 1.53-1.58 mm (0.060-0.062 in.)
4412871 1.77-1.83 mm (0.070-0.072 in.)
4412872 2.02-2.07 mm (0.080-0.082 in.)
4412873 2.27-2.32 mm (0.090-0.091 in.)
(36) To complete the assembly, reverse clutch and
overdrive clutch must be removed.
(37) Install the #2 needle bearing (Fig. 286).
(38) Install the underdrive shaft assembly (Fig.
287).
(39) Install the #3 thrust washer to the underdrive
shaft assembly. Be sure five tabs are seated properly
(Fig. 288).
(40) Install the #3 thrust plate to the bottom of the
overdrive shaft assembly. Retain with petrolatum or
transmission assembly gel (Fig. 289).
Fig. 287 Install Underdrive Shaft Assembly
1 - UNDERDRIVE SHAFT ASSEMBLY
2 - #2 NEEDLE BEARING
Fig. 288 Install No. 3 Thrust Washer
1 - #3 THRUST WASHER (NOTE 5 TABS)
2 - UNDERDRIVE SHAFT ASSEMBLY
Fig. 289 Install No. 3 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - DABS OF PETROLATUM (FOR RETENTION)
3 - #3 THRUST PLATE (NOTE 3 TABS)
Fig. 286 Install No. 2 Needle Bearing
1 - #2 NEEDLE BEARING (NOTE 3 SMALL TABS)
2 - TABS UP
RS41TE AUTOMATIC TRANSAXLE21 - 271
INPUT CLUTCH ASSEMBLY (Continued)
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(41) Install the overdrive shaft assembly (Fig.
290).
(42) Reinstall overdrive and reverse clutch as
shown.Rechecking these clutch clearances is
not necessary.
OIL PUMP
DESCRIPTION
The oil pump is located in the pump housing inside
the bell housing of the transaxle case (Fig. 291). The
oil pump consists of an inner and outer gear, a hous-
ing, and a cover that also serves as the reaction shaft
support.
OPERATION
As the torque converter rotates, the converter hub
rotates the inner and outer gears. As the gears
rotate, the clearance between the gear teeth
increases in the crescent area, and creates a suction
at the inlet side of the pump. This suction draws
fluid through the pump inlet from the oil pan. As the
clearance between the gear teeth in the crescent area
decreases, it forces pressurized fluid into the pump
outlet and to the valve body.
STANDARD PROCEDURE - OIL PUMP VOLUME
CHECK
Measuring oil pump output volume will determine
if sufficient flow to the transmission oil cooler exists,
and whether or not an internal transmission failure
is present.
Verify that transmission fluid is at the proper
level. If adding fluid is necessary, fill to the properlevel with MopartATF+4 (Automatic Transmission
Fluid±Type 9602). The following procedure is to
check oil pump output volume:
(1) Using hose cutters or a suitable blade, cut the
ªto coolerº (Fig. 292) line off flush with the cooler
inlet fitting and place a collection container under
the open line.
Fig. 290 Install Overdrive Shaft Assembly
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #3 THRUST PLATE
3 - #3 THRUST WASHER
Fig. 291 Oil Pump Assembly
1 - PUMP HOUSING
2 - OUTER PUMP GEAR
3 - INNER PUMP GEAR
4 - REACTION SHAFT SUPPORT
5 - SEAL RINGS (4)
6 - REACTION SHAFT
7 - CRESCENT
Fig. 292 Transaxle Oil Cooler Fittings
1 - FROM COOLER
2 - TO COOLER
21 - 272 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)
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CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Start engine and runat curb idle speed, with
the shift selector in neutral.
(3) If one quart of ATF is collected in 20 seconds or
less, flow is within acceptable limits. If fluid flow is
intermittent or it takes more than 20 seconds to col-
lect one quart of ATF, (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - 41TE -
DIAGNOSIS AND TESTING).
(4) Inspect the cooler hose for damage. Replace if
necessary.
(5) Re-connect the to cooler line to the transmis-
sion using a service splice kit. Refer to instructions
inclued with the kit.
(6) Refill the transaxle to proper level with
MopartATF+4 (Automatic Transmission Fluid±Type
9602).
DISASSEMBLY
When disassembling the transaxle it is necessary
to inspect the oil pump for wear and damage.
(1) Remove the reaction shaft support bolts.
(2) Remove reaction shaft support from pump
housing (Fig. 293).
(3) Remove the pump gears (Fig. 294) and check
for wear and damage on pump housing and gears.
(4) Re-install the gears and check clearances.
(5) Measure the clearance between the outer gear
and the pump pocket (Fig. 295). Clearance should be
0.089±0.202 mm (0.0035-0.0079 in.).(6) Measure clearance between outer gear and
crescent. Clearance should be 0.060-0.298 mm
(0.0023-0.0117 in.).
(7) Measure clearance between inner gear and
crescent. Clearance should be 0.093-0.385 mm
(0.0036-0.0151 in.).
Fig. 293 Reaction Shaft Support
1 - PUMP HOUSING
2 - REACTION SHAFT SUPPORT
3 - PUMP GEARS
Fig. 294 Oil Pump Assembly
1 - PUMP HOUSING
2 - OUTER PUMP GEAR
3 - INNER PUMP GEAR
4 - REACTION SHAFT SUPPORT
5 - SEAL RINGS (4)
6 - REACTION SHAFT
7 - CRESCENT
Fig. 295 Measure Outer Gear to Pocket
1 - OUTER GEAR
2 - POCKET
RS41TE AUTOMATIC TRANSAXLE21 - 273
OIL PUMP (Continued)
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(8) Position an appropriate piece of Plastigage
across both pump gears.
(9) Align the Plastigage to a flat area on the reac-
tion shaft support housing.
(10) Install the reaction shaft to the pump hous-
ing. Tighten the bolts to 27 N´m (20 ft. lbs.).
(11) Remove bolts and carefully separate the hous-
ings. Measure the Plastigage following the instruc-
tions supplied.
(12) Clearance between outer gear side and the
reaction shaft support should be 0.020-0.046 mm
(0.0008-0.0018 in.). Clearance between inner gear
side and the reaction shaft support should be 0.020-
0.046 mm (0.0008-0.0018 in.).
ASSEMBLY
(1) Assemble oil pump as shown in (Fig. 296)
(2) Install and torque reaction shaft support-to-oil
pump housing bolts to 28 N´m (20 ft. lbs.) torque.
PLANETARY GEARTRAIN
DESCRIPTION
The planetary geartrain is located between the
input clutch assembly and the rear of the transaxle
case. The planetary geartrain consists of two sun
gears, two planetary carriers, two annulus (ring)
gears, and one output shaft (Fig. 297).
OPERATION
The planetary geartrain utilizes two planetary gear
sets that connect the transmission input shaft to the
output shaft. Input and holding clutches drive or lock
different planetary members to change output ratio
or direction.
Fig. 296 Oil Pump Assembly
1 - PUMP HOUSING
2 - OUTER PUMP GEAR
3 - INNER PUMP GEAR
4 - REACTION SHAFT SUPPORT
5 - SEAL RINGS (4)
6 - REACTION SHAFT
7 - CRESCENT
Fig. 297 Planetary Geartrain
1 - FRONT SUN GEAR ASSEMBLY
2 - #6 THRUST BEARING
3 - #7 THRUST BEARING
4 - REAR CARRIER/FRONT ANNULUS ASSEMBLY
5 - REAR SUN GEAR
6 - FRONT CARRIER/REAR ANNULUS ASSEMBLY
21 - 274 41TE AUTOMATIC TRANSAXLERS
OIL PUMP (Continued)
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OPERATION
The Input Speed Sensor provides information on
how fast the input shaft is rotating. As the teeth of
the input clutch hub pass by the sensor coil (Fig.
319), an AC voltage is generated and sent to the
TCM. The TCM interprets this information as input
shaft rpm.The TCM compares the input speed signal with
output speed signal to determine the following:
²Transmission gear ratio
²Speed ratio error detection
²CVI calculation
The TCM also compares the input speed signal and
the engine speed signal to determine the following:
²Torque converter clutch slippage
²Torque converter element speed ratio
REMOVAL
(1) Disconnect battery negative cable.
(2) If necessary, disconnect and cap off transmis-
sion oil cooler lines.
(3) Disconnect input speed sensor connector.
(4) Unscrew and remove input speed sensor (Fig.
320).
(5) Inspect speed sensor o-ring (Fig. 321) and
replace if necessary.
Fig. 318 O-Ring Location
1 - INPUT SPEED SENSOR
2 - O-RING
Fig. 319 Sensor Relation to Input Clutch Hub
1 - INPUT SPEED SENSOR
2 - TRANSAXLE CASE
3 - INPUT CLUTCH HUB
Fig. 320 Input (Turbine) Speed Sensor
1 - INPUT SPEED SENSOR
21 - 282 41TE AUTOMATIC TRANSAXLERS
SPEED SENSOR - INPUT (Continued)
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INSTALLATION
(1) Verify o-ring is installed into position.
(2) Install and tighten input speed sensor to 27
N´m (20 ft. lbs.).
(3) Connect speed sensor connector.
(4) Connect battery negative cable.
SPEED SENSOR - OUTPUT
DESCRIPTION
The Output Speed Sensor is a two-wire magnetic
pickup device that generates an AC signal as rotation
occurs. It is threaded into the transaxle case (Fig.
322) , sealed with an o-ring (Fig. 323), and is consid-
ered a primary input to the Transmission Control
Module (TCM).
OPERATION
The Output Speed Sensor provides information on
how fast the output shaft is rotating. As the rear
planetary carrier park pawl lugs pass by the sensor
coil (Fig. 324), an AC voltage is generated and sent to
the TCM. The TCM interprets this information as
output shaft rpm.
The TCM compares the input and output speed
signals to determine the following:
²Transmission gear ratio
²Speed ratio error detection
²CVI calculation
Fig. 321 O-ring Location
1 - INPUT SPEED SENSOR
2 - O-RING
Fig. 322 Output Speed Sensor
1 - OUTPUT SPEED SENSOR
Fig. 323 O-Ring Location
1 - OUTPUT SPEED SENSOR
2 - O-RING
RS41TE AUTOMATIC TRANSAXLE21 - 283
SPEED SENSOR - INPUT (Continued)
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VEHICLE SPEED SIGNAL
The vehicle speed signal is taken from the Output
Speed Sensor. The TCM converts this signal into a
pulse per mile signal and sends it to the PCM. The
PCM, in turn, sends the vehicle speed message
across the communication bus to the BCM. The BCM
sends this signal to the Instrument Cluster to dis-
play vehicle speed to the driver. The vehicle speed
signal pulse is roughly 8000 pulses per mile.
REMOVAL
(1) Disconnect battery negative cable.
(2) Raise vehicle on hoist.
(3) Disconnect output speed sensor connector.
(4) Unscrew and remove output speed sensor (Fig.
325).
(5) Inspect speed sensor o-ring (Fig. 326) and
replace if necessary.
INSTALLATION
(1) Verify o-ring is installed into position (Fig.
326).
(2) Install and tighten input speed sensor to 27
N´m (20 ft. lbs.).
(3) Connect speed sensor connector.
(4) Connect battery negative cable.
Fig. 324 Sensor Relation to Planet Carrier Park Pawl
1 - OUTPUT SPEED SENSOR
2 - REAR PLANET CARRIER/OUTPUT SHAFT ASSEMBLY
3 - TRANSAXLE CASE
Fig. 325 Output Speed Sensor
1 - OUTPUT SPEED SENSOR
Fig. 326 O-ring Location
1 - OUTPUT SPEED SENSOR
2 - O-RING
21 - 284 41TE AUTOMATIC TRANSAXLERS
SPEED SENSOR - OUTPUT (Continued)
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TORQUE CONVERTER
DESCRIPTION
The torque converter (Fig. 327) is a hydraulic
device that couples the engine crankshaft to the
transmission. The torque converter consists of an
outer shell with an internal turbine, a stator, an
overrunning clutch, an impeller and an electronically
applied converter clutch. The converter clutch pro-
vides reduced engine speed and greater fuel economy
when engaged. Clutch engagement also provides
reduced transmission fluid temperatures. The con-
verter clutch engages in third gear. The torque con-
verter hub drives the transmission oil (fluid) pump.
The torque converter is a sealed, welded unit that
is not repairable and is serviced as an assembly.
CAUTION: The torque converter must be replaced if
a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid. If the fluid
is contaminated, flush the fluid cooler and lines.
Fig. 327 Torque Converter Assembly
1 - TURBINE
2 - IMPELLER
3 - HUB
4-STATOR
5 - CONVERTER CLUTCH DISC
6 - DRIVE PLATE
RS41TE AUTOMATIC TRANSAXLE21 - 285
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TURBINE
The turbine (Fig. 329) is the output, or driven,
member of the converter. The turbine is mounted
within the housing opposite the impeller, but is not
attached to the housing. The input shaft is inserted
through the center of the impeller and splined into
the turbine. The design of the turbine is similar to
the impeller, except the blades of the turbine are
curved in the opposite direction.
Fig. 329 Turbine
1 - TURBINE VANE
2 - ENGINE ROTATION
3 - INPUT SHAFT
4 - PORTION OF TORQUE CONVERTER COVER5 - ENGINE ROTATION
6 - OIL FLOW WITHIN TURBINE SECTION
RS41TE AUTOMATIC TRANSAXLE21 - 287
TORQUE CONVERTER (Continued)
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STATOR
The stator assembly (Fig. 330) is mounted on a sta-
tionary shaft which is an integral part of the oil
pump. The stator is located between the impeller and
turbine within the torque converter case (Fig. 331).
The stator contains an over-running clutch, which
allows the stator to rotate only in a clockwise direc-
tion. When the stator is locked against the over-run-
ning clutch, the torque multiplication feature of the
torque converter is operational.
TORQUE CONVERTER CLUTCH (TCC)
The TCC (Fig. 332) was installed to improve the
efficiency of the torque converter that is lost to the
slippage of the fluid coupling. Although the fluid cou-
pling provides smooth, shock±free power transfer, it
is natural for all fluid couplings to slip. If the impel-
ler and turbine were mechanically locked together, a
zero slippage condition could be obtained. A hydraulic
piston was added to the turbine, and a friction mate-
rial was added to the inside of the front cover to pro-
vide this mechanical lock-up.
Fig. 330 Stator Components
1 - CAM (OUTER RACE)
2 - ROLLER
3 - SPRING
4 - INNER RACE
Fig. 331 Stator Location
1-STATOR
2 - IMPELLER
3 - FLUID FLOW
4 - TURBINE
Fig. 332 Torque Converter Clutch (TCC)
1 - IMPELLER FRONT COVER
2 - THRUST WASHER ASSEMBLY
3 - IMPELLER
4-STATOR
5 - TURBINE
6 - PISTON
7 - FRICTION DISC
21 - 288 41TE AUTOMATIC TRANSAXLERS
TORQUE CONVERTER (Continued)
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