clutch CHRYSLER CARAVAN 2005 Service Manual

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. 228) (Fig. 229).
Fig. 228 UD Spring Retainer Snap Ring
1 - SNAP RING PLIERS
2 - ARBOR PRESS RAM
3 - SNAP RING
4 - SPECIAL TOOL 5059A
Fig. 229 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
21 - 242 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(14) Remove spring retainer, spring, and piston
(Fig. 229).
(15) Remove input hub tapered snap ring (Fig.
230) (Fig. 236).
(16) Tap on input hub with soft faced hammer and
separate input hub from OD/Reverse piston and
clutch retainer (Fig. 231).(17) Separate clutch retainer from OD/Reverse pis-
ton (Fig. 232).
(18) Using Tool 6057 and an arbor press, compress
return OD/Reverse piston return spring just enough
to remove snap ring (Fig. 233).
Fig. 230 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. 231 Tap on Input Hub
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - PLASTIC HAMMER
Fig. 232 Pull Retainer from Piston
1 - OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
Fig. 233 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
RS41TE AUTOMATIC TRANSAXLE21 - 243
INPUT CLUTCH ASSEMBLY (Continued)

(19) Remove input shaft to input clutch hub snap
ring (Fig. 234) (Fig. 236).(20) Using a suitably sized socket and an arbor
press, remove input shaft from input shaft hub (Fig.
235).
Fig. 234 Remove Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SHARP-POINTED TOOL
3 - SNAP RING
4 - O-RINGS
5 - SEALSFig. 235 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 - 244 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 236 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
RS41TE AUTOMATIC TRANSAXLE21 - 245
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. 237).
(2) Install input shaft snap ring (Fig. 238).(3) Using an arbor press and Tool 6057, Install
OD/Reverse piston return spring and snap ring (Fig.
239) (Fig. 240).
Fig. 237 Install Input Shaft
1 - INPUT SHAFT
2 - ARBOR PRESS RAM
3 - INPUT SHAFT HUB ASSEMBLY
Fig. 238 Install Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 239 Return Spring and Snap Ring
1 - OD/REVERSE PISTON
2 - RETURN SPRING
3 - SNAP RING
4 - O-RING
Fig. 240 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 - 246 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(4) Install the OD/Reverse piston assembly to the
input clutch retainer as shown in (Fig. 241).
(5) Install the input hub/shaft assy. to the OD/Re-
verse piston/clutch retainer assy. (Fig. 242).(6) Install input hub tapered snap ring (Fig. 243)
(Fig. 244).
Fig. 241 Install OD/Reverse Piston
1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
Fig. 242 Install Input Shaft Hub Assembly
1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY
(ROTATE TO ALIGN SPLINES)
2 - OD/REV. PISTON
Fig. 243 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
RS41TE AUTOMATIC TRANSAXLE21 - 247
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 244 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 - 248 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(7) Install UD clutch piston (Fig. 245).
(8) Install UD piston return spring and Tool 5067
as shown in (Fig. 246).(9) Using Tool 5059A and an arbor press, Install
the UD spring retainer and snap ring (Fig. 247) (Fig.
248) (Fig. 249) Compress just enough to install snap
ring.
CAUTION: Compress return spring just enough to
install snap ring.
Fig. 245 Underdrive Clutch Piston
1 - PISTON
Fig. 246 Seal Compressor Special Tool 5067
1 - PISTON RETURN SPRING
2 - SPECIAL TOOL 5067
3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY
Fig. 247 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 248 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
RS41TE AUTOMATIC TRANSAXLE21 - 249
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 249 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
21 - 250 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(10) Install the UD clutch pack. Leave out upper
disc, until snap ring is installed (Fig. 250).
(11) Install the UD clutch flat snap ring (Fig. 251).
(12) Install the last UD clutch disc (Fig. 252).
(13) Install the OD/UD clutch reaction plate and
snap ring (Fig. 253) (Fig. 254). The OD/UD clutches
reaction plate has a step on both sides. Install the
OD/UD clutches reaction plate tapered step side up.
NOTE: Snap ring ends must be located within one
finger of the input clutch hub. Be sure that snap
ring is fully seated, by pushing with screwdriver,
into snap ring groove all the way around.
Fig. 250 Underdrive Clutch Pack
1 - CLUTCH PLATE
2 - ONE UD CLUTCH DISC
3 - CLUTCH DISC
Fig. 251 UD Clutch Flat Snap Ring
1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
Fig. 252 Install Last UD Clutch Disc
1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 253 OD/UD Reaction Plate
1 - OD/UD CLUTCH REACTION PLATE (TAPERED STEP SIDE UP)
Fig. 254 Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
RS41TE AUTOMATIC TRANSAXLE21 - 251
INPUT CLUTCH ASSEMBLY (Continued)