body CHRYSLER CARAVAN 2005 Service Manual

VALVE BODY
DESCRIPTION
The valve body assembly consists of a cast alumi-
num valve body, a separator plate, and transfer
plate. The valve body contains valves and check balls
that control fluid delivery to the torque converter
clutch, solenoid/pressure switch assembly, and fric-
tional clutches. The valve body contains the following
components (Fig. 310):
²Regulator valve
²Solenoid switch valve
²Manual valve
²Converter clutch switch valve
²Converter clutch control valve
²Torque converter regulator valve
²Low/Reverse switch valve
In addition, the valve body also contains the ther-
mal valve, #2,3&4 check balls, the #5 (overdrive)
check valve and the 2/4 accumulator assembly. (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE/VALVE BODY - DISASSEMBLY)
OPERATION
NOTE: Refer to the Hydraulic Schematics for a
visual aid in determining valve location, operation
and design.
REGULATOR VALVE
The regulator valve controls hydraulic pressure in
the transaxle. It receives unregulated pressure from
the pump, which works against spring tension to
maintain oil at specific pressures. A system of sleeves
and ports allows the regulator valve to work at one of
three predetermined pressure levels. Regulated oil
pressure is also referred to as ªline pressure.º
SOLENOID SWITCH VALVE
The solenoid switch valve controls line pressure
from the LR/CC solenoid. In one position, it allows
the low/reverse clutch to be pressurized. In the other,
it directs line pressure to the converter control and
converter clutch valves.
Fig. 310 Valve Body Assembly
1 - VALVE BODY 5 - MANUAL VALVE
2 - T/C REGULATOR VALVE 6 - CONVERTER CLUTCH SWITCH VALVE
3 - L/R SWITCH VALVE 7 - SOLENOID SWITCH VALVE
4 - CONVERTER CLUTCH CONTROL VALVE 8 - REGULATOR VALVE
21 - 132 40TE AUTOMATIC TRANSAXLERS

MANUAL VALVE
The manual valve is operated by the mechanical
shift linkage. Its primary responsibility is to send
line pressure to the appropriate hydraulic circuits
and solenoids. The valve has three operating ranges
or positions.
CONVERTER CLUTCH SWITCH VALVE
The main responsibility of the converter clutch
switch valve is to control hydraulic pressure applied
to the front (off) side of the converter clutch piston.
Line pressure from the regulator valve is fed to the
torque converter regulator valve, where it passes
through the valve, and is slightly regulated. The
pressure is then directed to the converter clutch
switch valve and to the front side of the converter
clutch piston. This pressure pushes the piston back
and disengages the converter clutch.
CONVERTER CLUTCH CONTROL VALVE
The converter clutch control valve controls the
back (on) side of the torque converter clutch. When
the PCM/TCM energizes or modulates the LR/CC
solenoid to apply the converter clutch piston, both
the converter clutch control valve and the converter
control valve move, allowing pressure to be applied to
the back side of the clutch.
T/C REGULATOR VALVE
The torque converter regulator valve slightly regu-
lates the flow of fluid to the torque converter.
LOW/REVERSE SWITCH VALVE
The low/reverse clutch is applied from different
sources, depending on whether low (1st) gear or
reverse is selected. The low/reverse switch valve
alternates positions depending on from which direc-
tion fluid pressure is applied. By design, when the
valve is shifted by fluid pressure from one channel,
the opposing channel is blocked. The switch valve
alienates the possibility of a sticking ball check, thus
providing consistent application of the low/reverse
clutch under all operating conditions.
REMOVAL
NOTE: If valve body is replaced or reconditioned,
the ªQuick-Learnº Procedure must be performed.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
(1) Disconnect battery negative cable.
(2) Disconnect gearshift cable from manual valve
lever.
(3) Remove manual valve lever from manual shaft.
(4) Raise vehicle on hoist.
(5) Remove oil pan bolts (Fig. 311).
(6) Remove oil pan (Fig. 312).
Fig. 311 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 312 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
RS40TE AUTOMATIC TRANSAXLE21 - 133
VALVE BODY (Continued)

(7) Remove oil filter (Fig. 313).
(8) Remove the valve body-to-transaxle case bolts
(Fig. 314).
NOTE: To ease removal of the valve body, turn the
manual valve lever fully clockwise to low or first
gear.(9) Remove park rod rollers from guide bracket
and remove valve body from transaxle (Fig. 315) (Fig.
316).
CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
Fig. 313 Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 314 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 315 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
Fig. 316 Valve Body Removal/Installation
1 - VALVE BODY
21 - 134 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

DISASSEMBLY
NOTE: If valve body assembly is being recondi-
tioned, the PCM/TCM Quick Learn Procedure must
be performed. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Remove manual shaft seal (Fig. 317).
(2) Remove Transmission Range Sensor retaining
screw (Fig. 318).(3) Remove Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 319).
(4) Remove 2/4 Accumulator Retaining Plate (Fig.
320).
Fig. 317 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 318 Remove Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
Fig. 319 Manual Shaft/Rooster Comb and
Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
Fig. 320 2/4 Accumulator Retaining Plate
1 - 2±4 ACCUMULATOR RETAINING PLATE
2 - DETENT SPRING
RS40TE AUTOMATIC TRANSAXLE21 - 135
VALVE BODY (Continued)

(5) Remove 2/4 Accumulator components as shown
in (Fig. 321).
(6) Remove Valve Body to Transfer Plate screws
(Fig. 322).(7) Invert assembly and remove Transfer Plate
(Fig. 323). Beware of loose check balls.
(8) Remove oil screen (Fig. 324).
Fig. 321 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
Fig. 322 Remove Valve Body to Transfer Plate
Screws
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
Fig. 323 Remove Transfer Plate
1 - TRANSFER PLATE
Fig. 324 Remove Oil Screen
1 - OIL SCREEN
21 - 136 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(9) Remove the overdrive clutch (#5) check valve
(Fig. 325)
(10) Remove separator plate (Fig. 326).(11) Remove thermal valve (Fig. 327).
(12) Remove check balls (Fig. 328).
NOTE: Tag all valve/spring assemblies for reassem-
bly identification.
(13) Remove dual retainer plate using Tool 6301
(Fig. 329).
(14) Remove regulator valve spring retainer (Fig.
330).
Fig. 325 Remove Overdrive Clutch (#5) Check Valve
1 - OVERDRIVE CLUTCH (#5) CHECK VALVE
Fig. 326 Remove Separator Plate
1 - SEPARATOR PLATE
2 - VALVE BODY
Fig. 327 Remove Thermal Valve
1 - THERMAL VALVE
RS40TE AUTOMATIC TRANSAXLE21 - 137
VALVE BODY (Continued)

Fig. 328 Ball Check Location
1 - (#4) BALL CHECK LOCATION
2 - (#2) BALL CHECK LOCATION
3 - RETAINER4 - (#3) BALL CHECK LOCATION
5 - LOW/REVERSE SWITCH VALVE
6 - T/C LIMIT VALVE
Fig. 329 Remove Dual Retainer Plate using Tool
6301
1 - TOOL 6301
2 - RETAINER
Fig. 330 Remove Regulator Valve Spring Retainer
using Tool 6302
1 - TOOL 6302
2 - RETAINER
21 - 138 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(15) Remove remaining retainers as shown in (Fig.
331).
(16) Remove valves and springs as shown in (Fig.
332).
NOTE: Refer to Valve Body Cleaning and Inspection
for cleaning procedures.
ASSEMBLY
NOTE: If valve body assembly is reconditioned, the
PCM/TCM Quick Learn Procedure must be per-
formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Install valves and springs as shown in (Fig.
332).
Fig. 331 Valve Retainer Location
1 - RETAINER
2 - RETAINER
Fig. 332 Springs and Valves Location
1 - VALVE BODY 5 - MANUAL VALVE
2 - T/C REGULATOR VALVE 6 - CONVERTER CLUTCH SWITCH VALVE
3 - L/R SWITCH VALVE 7 - SOLENOID SWITCH VALVE
4 - CONVERTER CLUTCH CONTROL VALVE 8 - REGULATOR VALVE
RS40TE AUTOMATIC TRANSAXLE21 - 139
VALVE BODY (Continued)

(2) Install regulator valve spring retainer (Fig.
333).
(3) Install dual retainer plate using Tool 6301 (Fig.
334).(4) Verify that all retainers are installed as shown
in (Fig. 335). Retainers should be flush or below
valve body surface.
(5) Install check balls into position as shown in
(Fig. 336). If necessary, secure them with petrolatum
or transmission assembly gel for assembly ease.
(6) Install thermal valve into transfer plate (Fig.
337).
(7) Install separator plate to valve body (Fig. 338).
Fig. 333 Install Regulator Valve Spring Retainer
using Tool 6302
1 - TOOL 6302
2 - RETAINER
Fig. 334 Install Dual Retainer Plate using Tool 6301
1 - TOOL 6301
2 - RETAINER
Fig. 335 Valve Retainer Location
1 - RETAINER
2 - RETAINER
21 - 140 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

Fig. 336 Ball Check Location
1 - (#4) BALL CHECK LOCATION
2 - (#2) BALL CHECK LOCATION
3 - RETAINER4 - (#3) BALL CHECK LOCATION
5 - LOW/REVERSE SWITCH VALVE
6 - T/C LIMIT VALVE
Fig. 337 Install Thermal Valve
1 - THERMAL VALVE
Fig. 338 Install Separator Plate
1 - SEPARATOR PLATE
2 - VALVE BODY
RS40TE AUTOMATIC TRANSAXLE21 - 141
VALVE BODY (Continued)