starter CHRYSLER CARAVAN 2005 Workshop Manual

(69) Install and tighten solenoid/pressure switch
assembly-to-transaxle case bolts to 12 N´m (110 in.
lbs.) (Fig. 158).
(70) Install and torque input and output speed
sensors to case to 27 N´m (20 ft. lbs.).
INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perfrom the ªQuick-Learnº procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
(1) Using a transmission jack and a helper, posi-
tion transaxle assembly to engine. Install and torque
bellhousing bolts to 95 N´m (70 ft. lbs.).
(2) Install upper mount assembly to transaxle and
torque bolts to 54 N´m (40 ft. lbs.) (Fig. 159).
(3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 159).
(4) Remove transmission jack and screw jack.
(5) Secure left wheelhouse splash shield.
(6) Install torque converter-to-drive plate bolts and
torque to 88 N´m (65 ft. lbs.)
(7) Install inspection cover.
(8) Install lateral bending brace.
(9) Install starter motor.(10) Install front mount/bracket assembly.
(11) Align and install rear mount bracket-to-case
bolts by hand (Fig. 160). Torque horizontal bolt to
102 N´m (75 ft. lbs.).
(12) AWD models: Install power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - INSTALLATION)
(13) Install left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
(14) Install front wheel/tire assemblies.
(15) Lower vehicle.
(16) Torque remaining rear mount bracket-to-tran-
saxle vertical bolts (Fig. 160) to 102 N´m (75 ft. lbs.).
(17) Install transaxle upper bellhousing-to-block
bolts and torque to 95 N´m (70 ft. lbs.).
(18) Install and connect crank position sensor (if
equipped).
(19) Connect gearshift cable to upper mount
bracket and transaxle manual valve lever (Fig. 161).
(20) Connect solenoid/pressure switch assembly
(Fig. 162).
(21) Connect transmission range sensor connector
(Fig. 162).
(22) Connect input and output speed sensor con-
nectors (Fig. 162).
Fig. 158 Attaching Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
Fig. 159 Left Mount to Bracket and Transaxle
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
RS40TE AUTOMATIC TRANSAXLE21-51
40TE AUTOMATIC TRANSAXLE (Continued)

DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE
When diagnosing converter housing fluid leaks,
three actions must be taken before repair:
(1) Verify proper transmission fluid level.
(2) Verify that the leak originates from the con-
verter housing area and is transmission fluid.
(3) Determine the true source of the leak.
Fluid leakage at or around the torque converter area
may originate from an engine oil leak (Fig. 7). The area
should be examined closely. Factory fill fluid is red and,
therefore, can be distinguished from engine oil.
Some suspected converter housing fluid leaks may not
be leaks at all. They may only be the result of residual
fluid in the converter housing, or excess fluid spilled
during factory fill, or fill after repair. Converter housing
leaks have several potential sources. Through careful
observation, a leak source can be identified before
removing the transmission for repair.
Pump seal leaks tend to move along the drive hub
and onto the rear of the converter (Fig. 7). Pump o-ring
or pump body leaks follow the same path as a seal leak.
Pump attaching bolt leaks are generally deposited on
the inside of the converter housing and not on the con-
verter itself. Pump seal or gasket leaks usually travel
down the inside of the converter housing (Fig. 7).
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
²Torque converter weld leaks at the outside diam-
eter weld (Fig. 8).
²Torque converter hub weld (Fig. 8).
REMOVAL
NOTE: If transaxle assembly is being replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perform the ªQuick-Learnº Procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
(1) Disconnect battery cables.
(2) Remove battery shield (Fig. 9).
Fig. 7 Converter Housing Leak Paths
1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK
Fig. 8 Converter Leak Points - Typical
1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG
Fig. 9 Battery Thermal Guard
1 - BATTERY THERMOWRAP (IF EQUIPPED)
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
21 - 154 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(11) Reposition leak detection pump harness and
hoses.
(12) Remove rear mount bracket-to-transaxle case
bolts (Fig. 13).
(13) Remove transaxle upper bellhousing-to-block
bolts.
(14) Raise vehicle on hoist.
(15) Remove transaxle oil pan and drain fluid into
suitable container.
(16) Remove front wheel/tire assemblies.
(17) Remove left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - REMOVAL)
(18) AWD models: Remove power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - REMOVAL)
(19) Remove rear mount bracket-to-transaxle case
lower (horizontal) bolt (Fig. 13).
(20) Remove front mount/bracket assembly.
(21) Remove starter motor.
(22) Remove lateral bending brace.
(23) Remove inspection cover.
(24) Remove torque converter-to-drive plate bolts.
(25) Support engine/transaxle assembly at engine
oil pan with screw jack and wood block.
(26) Partially remove left wheelhouse splash shield
to gain access to and remove upper mount thru-bolt
(Fig. 14).(27) Lower engine/transaxle assembly with screw
jack.
Fig. 13 Rear Mount Bracket - Typical
1 - BOLT - VERTICAL
2 - BRACKET - REAR MOUNT3 - BOLT - HORIZONTAL
Fig. 14 Left Mount-to-Bracket
1 - BOLT - BRACKET TO FRAME RAIL
2 - BOLT - MOUNT TO RAIL THROUGH
3 - BOLT - LEFT MOUNT TO TRANSAXLE
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
21 - 156 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(69) Install and tighten solenoid/pressure switch
assembly-to-transaxle case bolts to 12 N´m (110 in.
lbs.) (Fig. 158).
(70) Install and torque input and output speed
sensors to case to 27 N´m (20 ft. lbs.).
INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perfrom the ªQuick-Learnº procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
(1) Using a transmission jack and a helper, posi-
tion transaxle assembly to engine. Install and torque
bellhousing bolts to 95 N´m (70 ft. lbs.).
(2) Install upper mount assembly to transaxle and
torque bolts to 54 N´m (40 ft. lbs.) (Fig. 159).
(3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 159).
(4) Remove transmission jack and screw jack.
(5) Secure left wheelhouse splash shield.
(6) Install torque converter-to-drive plate bolts and
torque to 88 N´m (65 ft. lbs.)
(7) Install inspection cover.
(8) Install lateral bending brace.
(9) Install starter motor.
(10) Install front mount/bracket assembly.
(11) Align and install rear mount bracket-to-case
bolts by hand (Fig. 160). Torque horizontal bolt to
102 N´m (75 ft. lbs.).(12) AWD models: Install power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - INSTALLATION)
(13) Install left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
(14) Install front wheel/tire assemblies.
(15) Lower vehicle.
(16) Torque remaining rear mount bracket-to-tran-
saxle vertical bolts (Fig. 160) to 102 N´m (75 ft. lbs.).
(17) Install transaxle upper bellhousing-to-block
bolts and torque to 95 N´m (70 ft. lbs.).
(18) Install and connect crank position sensor (if
equipped).
(19) Connect gearshift cable to upper mount
bracket and transaxle manual valve lever (Fig. 161).
(20) Connect solenoid/pressure switch assembly
(Fig. 162).
(21) Connect transmission range sensor connector
(Fig. 162).
(22) Connect input and output speed sensor con-
nectors (Fig. 162).
(23) Remove plugs and connect transaxle oil cooler
lines. (Refer to 7 - COOLING/TRANSMISSION -
STANDARD PROCEDURE)
(24) Remove plug and Install fluid level indicator/
tube assembly.
Fig. 158 Solenoid Pack-to-Transaxle Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
Fig. 159 Left Mount to Bracket and Transaxle
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
21 - 196 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

SLEEVE - THIRD ROW - FOLD-IN-FLOOR- INSTALLATION, HEADREST ...........23-153
SLEEVE - THIRD ROW - FOLD-IN-FLOOR - REMOVAL, HEADREST ..............23-152
SLIDING DOOR - INSTALLATION .........23-29
SLIDING DOOR - REMOVAL ............23-29
SLIDING DOOR ADJUSTMENT, STANDARD PROCEDURE - POWER ......8N-49
SLIDING DOOR ADJUSTMENTS, ADJUSTMENTS ...................... 23-30
SLIDING DOOR CONTROL MODULE - DESCRIPTION ....................... 8E-18
SLIDING DOOR CONTROL MODULE - OPERATION ......................... 8E-18
SLIDING DOOR CONTROL MODULE, DIAGNOSIS AND TESTING .............8E-18
SLIDING DOOR GLASS - INSTALLATION . . 23-163
SLIDING DOOR GLASS - REMOVAL .....23-163
SLIDING DOOR LEARN CYCLE, STANDARD PROCEDURE - POWER ......8N-48
SLIDING DOOR LOCK MOTOR - INSTALLATION ...................... 8N-25
SLIDING DOOR LOCK MOTOR - REMOVAL .......................... 8N-25
SLIDING DOOR MOTOR - DESCRIPTION . . 8N-51
SLIDING DOOR MOTOR - INSTALLATION . . 8N-51
SLIDING DOOR MOTOR - OPERATION ....8N-51
SLIDING DOOR MOTOR - REMOVAL .....8N-51
SLIDING DOOR SILL PLATE - INSTALLATION ....................... 23-99
SLIDING DOOR SILL PLATE - REMOVAL ....23-98
SLIDING DOOR STOP BUMPER BEZEL - INSTALLATION ....................... 23-25
SLIDING DOOR STOP BUMPER BEZEL - REMOVAL .......................... 23-25
SLIDING DOOR SYSTEM - DESCRIPTION, POWER ............................ 8N-40
SLIDING DOOR SYSTEM - OPERATION, POWER ............................ 8N-41
SLIDING DOOR SYSTEM, DIAGNOSIS AND TESTING - POWER ...............8N-42
SLIDING DOOR WEATHERSTRIP - INSTALLATION ...................... 23-168
SLIDING DOOR WEATHERSTRIP - REMOVAL ......................... 23-168
SOCKET - INSTALLATION, STABILIZER ....23-33
SOCKET - REMOVAL, STABILIZER .......23-33
SOLENOID - DESCRIPTION, EVAP/PURGE . 25-13
SOLENOID - DESCRIPTION, SHIFT INTERLOCK .................. 21-113,21-264
SOLENOID - DIAGNOSIS AND TESTING, BRAKE/TRANSMISSION SHIFT
INTERLOCK .................. 21-115,21-266
SOLENOID - INSTALLATION, EVAP/ PURGE ............................. 25-13
SOLENOID - INSTALLATION, SHIFT INTERLOCK .................. 21-116,21-267
SOLENOID - OPERATION, EVAP/PURGE . . . 25-13
SOLENOID - OPERATION, SHIFT INTERLOCK .................. 21-114,21-265
SOLENOID - REMOVAL, EVAP/PURGE .....25-13
SOLENOID - REMOVAL, SHIFT INTERLOCK .................. 21-115,21-266
SOLENOID/PRESSURE SWITCH ASSY - DESCRIPTION ................ 21-117,21-268
SOLENOID/PRESSURE SWITCH ASSY - INSTALLATION ................ 21-119,21-270
SOLENOID/PRESSURE SWITCH ASSY - OPERATION .................. 21-118,21-268
SOLENOID/PRESSURE SWITCH ASSY - REMOVAL ................... 21-118,21-269
SPARE TIRE (TEMPORARY) - DESCRIPTION ....................... 22-14
SPARK PLUG CABLE - DESCRIPTION .....8I-10
SPARK PLUG CABLE RESISTANCE, SPECIFICATIONS ...................... 8I-2
SPARK PLUG, SPECIFICATIONS ...........8I-2
SPEAKER, DIAGNOSIS AND TESTING .....8A-18
SPEED CONTROL - DESCRIPTION ........8P-1
SPEED CONTROL (4 SPEED EATX ONLY) - OPERATION, INTERACTIVE .............8P-2
SPEED OPERATION - STANDARD PROCEDURE, TIRE PRESSURE FOR
HIGH .............................. 22-17
SPEED SENSOR - AWD - INSTALLATION, REAR WHEEL ........................ 5-92
SPEED SENSOR - AWD - REMOVAL, REAR WHEEL ........................ 5-92SPEED SENSOR - DESCRIPTION, ENGINE . 14-30
SPEED SENSOR - FWD - INSTALLATION,
REAR WHEEL ........................ 5-93
SPEED SENSOR - FWD - REMOVAL, REAR WHEEL ........................ 5-93
SPEED SENSOR - INPUT - DESCRIPTION ................ 21-120,21-271
SPEED SENSOR - INPUT - INSTALLATION ................ 21-121,21-272
SPEED SENSOR - INPUT - OPERATION . . 21-120, 21-271
SPEED SENSOR - INPUT - REMOVAL . . . 21-121, 21-272
SPEED SENSOR - INSTALLATION, FRONT WHEEL ............................. 5-92
SPEED SENSOR - OPERATION, ENGINE . . . 14-30
SPEED SENSOR - OUTPUT - DESCRIPTION ................ 21-122,21-273
SPEED SENSOR - OUTPUT - INSTALLATION ................ 21-123,21-274
SPEED SENSOR - OUTPUT - OPERATION .................. 21-122,21-273
SPEED SENSOR - OUTPUT - REMOVAL . . 21-123, 21-274
SPEED SENSOR - REMOVAL, FRONT WHEEL ............................. 5-91
SPEED SENSOR AIR GAP, SPECIFICATIONS - WHEEL ..............5-91
SPIRAL PLATE BATTERY CHARGING, STANDARD PROCEDURE ...............8F-10
SPLASH SHIELD - INSTALLATION, FRONT WHEELHOUSE .................23-57
SPLASH SHIELD - REMOVAL, FRONT WHEELHOUSE ....................... 23-57
SPLICE INFORMATION - DESCRIPTION, CONNECTOR, GROUND ..............8W-01-7
SPLICING - STANDARD PROCEDURE, WIRE ...........................8W -01-15
SPLIT - INSTALLATION, BENCH SEAT RISER - 50/50 ...................... 23-145
SPLIT - REMOVAL, BENCH SEAT RISER - 50/50 ............................. 23-145
SPLIT, BENCH - INSTALLATION, SEAT BACK HINGE COVERS - QUAD BUCKET,
50/50 ............................. 23-146
SPLIT, BENCH - INSTALLATION, SEAT CUSHION COVER - QUAD BUCKET,
50/50 ............................. 23-144
SPLIT, BENCH - REMOVAL, SEAT BACK HINGE COVERS - QUAD BUCKET, 50/50 . . 23-146
SPLIT, BENCH - REMOVAL, SEAT CUSHION COVER - QUAD BUCKET,
50/50 ............................. 23-144
SPRING - AWD - INSTALLATION ..........2-39
SPRING - AWD - REMOVAL .............2-38
SPRING - CARGO - INSTALLATION ........2-40
SPRING - CARGO - REMOVAL ...........2-40
SPRING - FWD - INSTALLATION ..........2-42
SPRING - FWD - REMOVAL .............2-40
SPRING ASSEMBLY - INSTALLATION, QUAD BUCKET SEAT SIDE SHIELD/CUP
HOLDER - FLAP ..................... 23-151
SPRING ASSEMBLY - REMOVAL, QUAD BUCKET SEAT SIDE SHIELD/CUP
HOLDER - FLAP ..................... 23-151
SPRING FRONT - INSTALLATION, BUSHING - LEAF ...................... 2-30
SPRING FRONT - REMOVAL, BUSHING - LEAF ............................... 2-29
SPRING MOUNTS - FRONT - INSTALLATION ........................ 2-43
SPRING MOUNTS - FRONT - REMOVAL ....2-42
SPRING MOUNTS - REAR - INSTALLATION ........................ 2-43
SPRING MOUNTS - REAR - REMOVAL .....2-43
SPRING SHACKLE - INSTALLATION .......2-44
SPRING SHACKLE - REMOVAL ...........2-44
SPRINGS - DESCRIPTION, VALVE ........9-109
SPRINGS - OPERATION, VALVE .........9-109
SPROCKET - INSTALLATION, CRANKSHAFT ................... 9-160,9-67
SPROCKET - INSTALLATION, TIMING CHAIN AND CAMSHAFT ...............9-160
SPROCKET - REMOVAL, CRANKSHAFT . . . 9-159,
9-66
SPROCKET - REMOVAL, TIMING CHAIN AND CAMSHAFT ..................... 9-159SPROCKETS - INSTALLATION,
CAMSHAFT .......................... 9-67
SPROCKETS - REMOVAL, CAMSHAFT ......9-66
STABILIZER - INSTALLATION ...........23-33
STABILIZER - REMOVAL ...............23-33
STABILIZER BAR - DESCRIPTION .....2-16,2-44
STABILIZER BAR - INSPECTION ..........2-17
STABILIZER BAR - INSTALLATION ........2-17
STABILIZER BAR - OPERATION .......2-16,2-44
STABILIZER BAR - REMOVAL ............2-17
STABILIZER BAR CUSHION - INSTALLATION .........................2-4
STABILIZER BAR CUSHION - REMOVAL .....2-4
STABILIZER SOCKET - INSTALLATION ....23-33
STABILIZER SOCKET - REMOVAL ........23-33
STAKING - STANDARD PROCEDURE, HEAT ............................... 23-9
STANDARD 4 CYLINDER - DESCRIPTION . . . 8I-9
STARTER, SPECIFICATIONS .............8F-37
STARTING - DESCRIPTION .............8F-31
STARTING - OPERATION ...............8F-31
STARTING - STANDARD PROCEDURE, JUMP ............................... 0-25
STARTING SYSTEM TEST - DIAGNOSIS AND TESTING ....................... 8F-31
STATE DISPLAY TEST MODE, OPERATION - DRB III T................ 25-10
STEERING - DIAGNOSIS AND TESTING, SUSPENSION .......................... 2-50
STEERING BELT TENSION - STANDARD PROCEDURE, CHECKING POWER ..........7-8
STEERING COLUMN - DESCRIPTION .....19-10
STEERING COLUMN - DIAGNOSIS AND TESTING ........................... 19-11
STEERING COLUMN COVER - INSTALLATION, LOWER ................23-74
STEERING COLUMN COVER - INSTALLATION, OVER .................23-76
STEERING COLUMN COVER - REMOVAL, LOWER ............................ 23-74
STEERING COLUMN COVER - REMOVAL, OVER .............................. 23-76
STEERING FASTENER TORQUE, SPECIFICATIONS - POWER ..............19-9
STEERING FLUID LEVEL CHECKING - STANDARD PROCEDURE, POWER .......19-44
STEERING GEAR, SPECIAL TOOLS - POWER ............................ 19-34
STEERING KNUCKLE - INSPECTION ........2-9
STEERING KNUCKLE - INSTALLATION ......2-9
STEERING KNUCKLE - REMOVAL ..........2-7
STEERING PUMP INITIAL OPERATION - STANDARD PROCEDURE, POWER .......19-37
STEERING PUMP, SPECIAL TOOLS - POWER ............................ 19-44
STEERING, SPECIAL TOOLS - POWER .....19-9
STEERING SYSTEM - DESCRIPTION, POWER ............................. 19-1
STEERING SYSTEM - OPERATION, POWER ............................. 19-1
STEERING SYSTEM DIAGNOSIS CHARTS - DIAGNOSIS AND TESTING .............19-3
STEERING SYSTEM FLOW AND PRESSURE TEST - DIAGNOSIS AND
TESTING, POWER ..................... 19-1
STEERING WHEEL - INSTALLATION ......19-24
STEERING WHEEL - REMOVAL ..........19-23
STEM SEALS - DESCRIPTION, VALVE .....9-114
STEM SEALS - INSTALLATION, VALVE ....9-115
STEM SEALS - REMOVAL, VALVE ........9-115
STOP BUMPER - INSTALLATION .........23-25
STOP BUMPER - REMOVAL ............23-25
STOP BUMPER BEZEL - INSTALLATION, SLIDING DOOR ...................... 23-25
STOP BUMPER BEZEL - REMOVAL, SLIDING DOOR ...................... 23-25
STOP LAMP - INSTALLATION, CENTER HIGH MOUNTED ...................... 8L-6
STOP LAMP - REMOVAL, CENTER HIGH MOUNTED ........................... 8L-6
STOP LAMP UNIT - INSTALLATION, CENTER HIGH MOUNTED ...............8L-6
STOP LAMP UNIT - REMOVAL, CENTER HIGH MOUNTED ...................... 8L-6
STORAGE BIN - INSTALLATION, UNDER SEAT ............................. 23-149
STORAGE BIN - REMOVAL, UNDER SEAT . 23-149
30 INDEXRS
Description Group-Page Description Group-Page Description Group-Page