clutch CHRYSLER CARAVAN 2003 Service Manual

(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.(27) Setup tool 5058 as shown in (Fig. 43). Com-
press 2/4 clutch return spring (just enough to remove
snap ring) and remove snap ring.
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.
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
Fig. 42 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 43 Remove 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
RS41TE AUTOMATIC TRANSAXLE21 - 133
41TE AUTOMATIC TRANSAXLE (Continued)
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(28) Remove 2/4 clutch retainer (Fig. 44).
(29) Remove 2/4 clutch return spring (Fig. 45).(30) Remove 2/4 clutch pack (Fig. 46).Tag 2/4
clutch pack for reassembly identification.
(31) Remove tapered snap ring (Fig. 47).
Fig. 44 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 45 Remove 2/4 Clutch Return Spring
1 - 2/4 CLUTCH RETURN SPRING
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
21 - 134 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(32) Remove low/reverse reaction plate (Fig. 48).
(33) Remove one low/reverse clutch disc (Fig. 49).(34) Remove low/reverse reaction plate snap ring
(Fig. 50).
(35) Remove low/reverse clutch pack (Fig. 51).
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
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)
RS41TE AUTOMATIC TRANSAXLE21 - 135
41TE AUTOMATIC TRANSAXLE (Continued)
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(55) Remove rear carrier assembly from transaxle
(Fig. 72).
(56) Remove rear carrier assembly bearing cone
using setup shown in (Fig. 73).(57) Install low/reverse spring compressor tool as
shown in (Fig. 74) (Fig. 75).
Fig. 72 Remove Rear Carrier Assembly
1 - REAR CARRIER ASSEMBLY
Fig. 73 Remove Rear Carrier Bearing Cone
1 - TOOL 5048 WITH JAWS 5048±3 AND BUTTON 6055
2 - WRENCHES
3 - REAR CARRIER ASSEMBLY
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
RS41TE AUTOMATIC TRANSAXLE21 - 141
41TE AUTOMATIC TRANSAXLE (Continued)
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(62) Inspect guide bracket components for exces-
sive wear and replace if necessary (Fig. 80).
(63) Remove low/reverse clutch piston (Fig. 81).(64) Remove low/reverse piston retainer-to-case
screws (Fig. 82).
(65) Remove low/reverse piston retainer (Fig. 83).
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
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
RS41TE AUTOMATIC TRANSAXLE21 - 143
41TE AUTOMATIC TRANSAXLE (Continued)
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(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).(68) Using tool 6062, remove outer output bearing
cup (Fig. 86).
ASSEMBLY
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/PCM Quick Learn
procedure must be performed. (Refer to 8 - ELEC-
TRICAL/ELECTRONIC CONTROL MODULES/TRANS-
MISSION CONTROL MODULE - STANDARD
PROCEDURE)
(1) Install both output bearing cups using Tool
5050 (Fig. 87).
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
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
21 - 144 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(2) Install low/reverse piston retainer gasket (Fig.
88). Make sure gasket holes line up with case.
(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).
Fig. 88 Install Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
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
RS41TE AUTOMATIC TRANSAXLE21 - 145
41TE AUTOMATIC TRANSAXLE (Continued)
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(9) Install low/reverse piston return spring (Fig.
96).
(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).
Fig. 96 Low/Reverse Piston Return Spring
1 - LOW/REVERSE PISTON RETURN SPRING
2 - PISTON
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
RS41TE AUTOMATIC TRANSAXLE21 - 147
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 - 157
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).
(45) Orient 2/4 clutch return spring to retainer as
shown in (Fig. 133), and install to transaxle (Fig.
134).
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 - 158 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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