clutch CHRYSLER CARAVAN 2005 Owners Manual

(10) Remove and inspect OD and UD Shafts, as
well as #3 thrust washer and plate, and #2 needle
bearing (Fig. 202).
Fig. 202 Overdrive/Underdrive Shafts
1 - OVERDRIVE SHAFT
2 - #3 THRUST PLATE (3 TABS)
3 - #3 THRUST WASHER (5 TABS)4 - UNDERDRIVE SHAFT
5 - #2 NEEDLE BEARING (3 TABS)
6 - INPUT CLUTCH ASSEMBLY
RS40TE AUTOMATIC TRANSAXLE21-89
INPUT CLUTCH ASSEMBLY (Continued)

(11) Remove the OD/UD reaction plate tapered
snap ring, reaction plate, and first friction disc (Fig.
203).
(12) Remove the UD clutch flat snap ring and rest
of UD clutch pack (Fig. 203).Tag clutch pack for
assembly identification.
Fig. 203 Underdrive Clutch Assembly
1 - SNAP RING (TAPERED)
2 - OD/UD REACTION PLATE
3 - CLUTCH DISC (3)4 - SNAP RING (FLAT)
5 - CLUTCH PLATE (3)
6 - INPUT CLUTCH ASSEMBLY
21 - 90 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

CAUTION: Compress return spring just enough to
remove or install snap ring.
(13) Using Tool 5059A and an arbor press, com-
press UD clutch piston/spring enough to remove snap
ring (Fig. 204) (Fig. 205).
(14) Remove spring retainer, spring, and piston
(Fig. 205).
Fig. 204 UD Spring Retainer Snap Ring
1 - SNAP RING PLIERS
2 - ARBOR PRESS RAM
3 - SNAP RING
4 - SPECIAL TOOL 5059A
Fig. 205 Underdrive Clutch Piston, Spring and Retainer
1 - SNAP RING
2 - SPRING RETAINER
3 - SPRING
4 - UD CLUTCH PISTON5 - SEAL, OUTER
6 - SEAL, INNER
7 - INPUT CLUTCH ASSEMBLY
RS40TE AUTOMATIC TRANSAXLE21-91
INPUT CLUTCH ASSEMBLY (Continued)

(15) Remove input hub tapered snap ring (Fig.
206) (Fig. 212).
(16) Tap on input hub with soft faced hammer and
separate input hub from OD/Reverse piston and
clutch retainer (Fig. 207).(17) Separate clutch retainer from OD/Reverse pis-
ton (Fig. 208).
(18) Using Tool 6057 and an arbor press, compress
return OD/Reverse piston return spring just enough
to remove snap ring (Fig. 209).
Fig. 206 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. 207 Tap on Input Hub
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - PLASTIC HAMMER
Fig. 208 Pull Retainer from Piston
1 - OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
Fig. 209 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
21 - 92 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(19) Remove input shaft to input clutch hub snap
ring (Fig. 210) (Fig. 212).(20) Using a suitably sized socket and an arbor
press, remove input shaft from input shaft hub (Fig.
211).
Fig. 210 Remove Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SHARP-POINTED TOOL
3 - SNAP RING
4 - O-RINGS
5 - SEALSFig. 211 Remove Input Shaft
1 - ARBOR PRESS RAM
2 - SOCKET
3 - SEAL
4 - O-RINGS
5 - INPUT SHAFT
6 - SEAL
7 - INPUT SHAFT HUB ASSEMBLY
RS40TE AUTOMATIC TRANSAXLE21-93
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 212 Input Clutch Hub, Retainer, and OD/Reverse Piston
1 - SNAP RING (INPUT SHAFT)
2 - SNAP RING
3 - CLUTCH RETAINER
4 - SEAL, OUTER
5 - SEAL, INNER
6 - OD/REVERSE PISTON7 - SEAL, INPUT SHAFT
8 - SHAFT, INPUT
9 - HUB
10 - SEAL
11 - SNAP RING
12 - BELLEVILLE SPRING
21 - 94 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

ASSEMBLY
Use petrolatum on all seals to ease assembly of
components.
(1) Using an arbor press, install input shaft to
input shaft hub (Fig. 213).
(2) Install input shaft snap ring (Fig. 214).(3) Using an arbor press and Tool 6057, Install
OD/Reverse piston return spring and snap ring (Fig.
215) (Fig. 216).
Fig. 213 Install Input Shaft
1 - INPUT SHAFT
2 - ARBOR PRESS RAM
3 - INPUT SHAFT HUB ASSEMBLY
Fig. 214 Install Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 215 Return Spring and Snap Ring
1 - OD/REVERSE PISTON
2 - RETURN SPRING
3 - SNAP RING
4 - O-RING
Fig. 216 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
RS40TE AUTOMATIC TRANSAXLE21-95
INPUT CLUTCH ASSEMBLY (Continued)

(4) Install the OD/Reverse piston assembly to the
input clutch retainer as shown in (Fig. 217).
(5) Install the input hub/shaft assy. to the OD/Re-
verse piston/clutch retainer assy. (Fig. 218).(6) Install input hub tapered snap ring (Fig. 219)
(Fig. 220).
Fig. 217 Install OD/Reverse Piston
1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
Fig. 218 Install Input Shaft Hub Assembly
1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY
(ROTATE TO ALIGN SPLINES)
2 - OD/REV. PISTON
Fig. 219 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
21 - 96 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 220 Input Clutch Hub, Retainer, and OD/Reverse Piston
1 - SNAP RING (INPUT SHAFT)
2 - SNAP RING
3 - CLUTCH RETAINER
4 - SEAL, OUTER
5 - SEAL, INNER
6 - OD/REVERSE PISTON7 - SEAL, INPUT SHAFT
8 - SHAFT, INPUT
9 - HUB
10 - SEAL
11 - SNAP RING
12 - BELLEVILLE SPRING
RS40TE AUTOMATIC TRANSAXLE21-97
INPUT CLUTCH ASSEMBLY (Continued)

(7) Install UD clutch piston (Fig. 221).
(8) Install UD piston return spring and Tool 5067
as shown in (Fig. 222).(9) Using Tool 5059A and an arbor press, Install
the UD spring retainer and snap ring (Fig. 223) (Fig.
224) (Fig. 225) Compress just enough to install snap
ring.
CAUTION: Compress return spring just enough to
install snap ring.
Fig. 221 Underdrive Clutch Piston
1 - PISTON
Fig. 222 Seal Compressor Special Tool 5067
1 - PISTON RETURN SPRING
2 - SPECIAL TOOL 5067
3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY
Fig. 223 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 224 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
21 - 98 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)