transmission CHRYSLER VOYAGER 1996 Service Manual

(18) Rotate engine clockwise to gain access to
torque converter bolts (Fig. 41). Remove torque con-
verter mounting bolts.
(19) Remove front engine mount insulator and
bracket (Fig. 42).
(20) Remove rear engine mount shield.
(21) Remove rear engine mount bracket bolts and
bracket.
(22) Remove starter bolts and set starter aside. Do
not allow the starter to hang from battery cable (Fig.
43).
(23) Position transmission jack securely under
transaxle (Fig. 44).
(24) Remove left fender splash shield.
(25) With transmission jack in position, remove
the left transmission mount.
(26) Lower transaxle to access the crankshaft posi-
tion sensor, remove crankshaft position sensor from
bell housing. For installation procedure refer to sec-
tion 8D of this service manual.CAUTION: Remove the crankshaft position sensor
from the bell housing before transmission removal
or installation.
(27) Remove lower bellhousing bolts.
(28) Carefully lower the transaxle assembly from
vehicle.
INSTALLATION
(1) For installation of transaxle, reverse the above
procedure.
(2) Check and/or adjust gearshift cable.
(3) Refill transaxle with MOPARtATF PLUS 3
(Automatic Transmission Fluid) Type 7176.
Fig. 41 Rotate Engine
Fig. 42 Remove Front Engine Mount
Fig. 43 Starter Assembly
Fig. 44 Position Transmission Jack
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 91
REMOVAL AND INSTALLATION (Continued)

OIL PUMP SEAL
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
VALVE BODY RECONDITION
Fig. 45 Remove Oil Pump Seal
Fig. 46 Install Oil Pump Seal
Fig. 47 Transmission Range Sensor Screw
Fig. 48 Transmission Range Sensor Removed
Fig. 49 Manual Shaft and Rooster Comb
21 - 92 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS
41TE AUTOMATIC TRANSAXLE
Type..........................Fully adaptive,
electronically controlled,
four speed automatic with
torque converter
and integral differential
Torque Converter Diameter........241 millimeters
(9.48 in.)
Oil Capacity........................8.6 Liters
(18.25 pints)
OilType...........MopartATF PLUS 3Type 7176
Cooling Method...........Water Heat Exchanger
and/or air to oil
heat exchanger
Lubrication......Pump (internal-external gear-type
Gear Ratios
Transmission Portion
First Gear..............................2.84
Second Gear.............................1.57
Direct Gear.............................1.00
Overdrive Gear..........................0.69
Reverse Gear............................2.21
Overall Top Gear Ratio
3.8 Liter................................2.38
3.3 Liter................................2.49
2.4 Liter................................2.69
Pump Clearances
Outer Gear To Pocket.............0.045-0.141mm
(0.0018-0.0056 in.)
Outer Gear Side Clearance.........0.020-0.046mm
(0.0008-0.0018 in.)
Inner Gear Side Clearance.........0.020-0.046mm
(0.0008-0.0018 in.)
Tapered Roller Bearing Settings
Differential Assembly . . .5 to 18 in. lbs. Drag Torque
Output Hub............3to8in.lbs. Drag Torque
Transfer Shaft.........0.002 to 0.004 in. End Play
Overall Drag At Output Hub........3to16in.lbs.
Drag Torque
Clutch Pack Clearances
Low/Rev Clutch
(Select Reaction Plate)............0.89-1.04mm
(0.035-0.042 in.)
Two/Four Clutch
(No Selection)...................0.76-2.64mm
(0.030-0.104 in.)Reverse Clutch (Select Snap Ring).....0.76-1.24mm
(0.030-0.049 in.)
Overdrive Clutch
(No Selection)...................0.96-2.26mm
(0.038-0.089 in.)
Underdrive Clutch
Select Pressure Plate)............0.91-1.47mm
(0.036-0.058 in.)
Transmission End Play.............0.12-0.63mm
(0.005-0.025 in.)
41TE TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Cooler Line Fittings..........12N´m(105 in. lbs.)
Differential Cover............19N´m(165 in. lbs.)
Differential Ring Gear.........95N´m(70ft.lbs.)
Differential Bearing Ret........28N´m(21ft.lbs.)
Driveplate To Crank. Bolts......95N´m(70ft.lbs.)
Driveplate To Torque Conv.......75N´m(55ft.lbs.)
Eight Way Solenoid Conn........4N´m(35in.lbs.)
Extension Housing............28N´m(21ft.lbs.)
Input Speed Sensor............27N´m(20ft.lbs.)
L/R Clutch Retainer............5N´m(45in.lbs.)
Oil Pan To Trans. Case........19N´m(165 in. lbs.)
Output Gear Bolt...........271 N´m (200 ft. lbs.)
Output Gear Stirrup Ret........23N´m(17ft.lbs.)
Output Speed Sensor..........27N´m(20ft.lbs.)
Pressure Taps................5N´m(45in.lbs.)
Pump To Case Bolts...........27N´m(20ft.lbs.)
Reaction Shaft Bolts...........27N´m(20ft.lbs.)
Rear End Cover..............19N´m(14ft.lbs.)
Sixty-Way Connector...........4N´m(35in.lbs.)
Solenoid Assembly To Case.....12N´m(105 in. lbs.)
Transmission Range Sensor......5N´m(45in.lbs.)
Transfer Gear Nut..........271 N´m (200 ft. lbs.)
Transfer Plate To Case........12N´m(105 in. lbs.)
Valve Body To Case Bolts......12N´m(105 in. lbs.)
Valve Body Bolts..............5N´m(45in.lbs.)
Vent Assembly..............12N´m(105 in. lbs.)
21 - 158 TRANSAXLE AND POWER TRANSFER UNITNS

FLUID LEAK DIAGNOSIS
When diagnosing fluid leaks on the Power Transfer
Unit two weep holes are provided to diagnose certainseal leaks. These holes are located on the bottom side
of the assembly (Fig. 6).
If fluid leak is detected from either weep hole, seal
replacement is necessary.Do not attempt to repair
the leak by sealing weep holes,they must be kept
clear of sealants for proper seal operation.
If fluid is leaking from weep hole A (Fig. 6) the
type of fluid leaking will determine which seal needs
to be replaced. If the fluid leaking is red in color
(transmission fluid) this indicates that the Transmis-
sion differential carrier seal should be replaced. If
the fluid leaking is light brown (gear lube) this indi-
cates that the Power Transfer Unit input seal should
be replaced. For replacement of these seals refer to
Power Transfer Unit Service Procedures.
If fluid is leaking from weep hole B (Fig. 6) the
type of fluid leaking will determine which seal is
leaking. If the fluid leaking is red in color (transmis-
sion fluid) this indicates that the input shaft end seal
should be replaced. If the fluid leaking is light brown
(gear lube) this indicates that the half shaft inner
seal and P.T.U. input shaft cover seal should be
replaced. For replacement of these seals refer to
Power Transfer Unit Service Procedures.
Before condemning any seal or gasket be sure that
the rear rocker arm cover on the engine is not the
cause of the oil leak. Oil leaking from the rocker arm
cover is easily mistaken for a leaking Power Transfer
Unit.
REMOVAL AND INSTALLATION
POWER TRANSFER UNIT (P.T.U.)
REMOVAL
(1) Raise vehicle and remove front wheels.
Fig. 3 Seal Location
Fig. 4 Seal Location
Fig. 5 Seal Location
Fig. 6 Weep Hole Locations
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 167
DIAGNOSIS AND TESTING (Continued)

GENERAL INFORMATION
A-598 MANUAL TRANSAXLE
Safety goggles should be worn at all times
when working on these transaxles.The A-598
manual transaxle uses SAE 5W-30 engine oil, meet-
ing SG and/or SG-CD qualifications, as the factory
fill lubricant. SAE G5 10W-40 engine oil is a suitable
service fill alternative.
This transaxle combines gear reduction, ratio selec-
tion, and differential functions in one unit. It is
housed in a die-cast aluminum case.
A-558 MANUAL TRANSAXLEÐRHD VEHICLES
Safety goggles should be worn at all times
when working on these transaxles.The A-558
manual transaxle uses SAE 5W-30 engine oil, meet-
ing SG and/or SG-CD qualifications, as the factory
fill lubricant. SAE G5 10W-40 engine oil is a suitable
service fill alternative.
This transaxle combines gear reduction, ratio selec-
tion, and differential functions in one unit. It is
housed in a die-cast aluminum case.
TRANSAXLE IDENTIFICATION INFORMATION
The A-598 transaxle model, assembly number,
build date, and final-drive ratio are stamped on a tag
that is attached to the top of the transaxle (Fig. 1).
The last eight digits of the Vehicle Identification
Number (V.I.N.) are stamped on a raised boss on top
of the clutch housing area.
TRANSAXLE IDENTIFICATION INFORMATIONÐRHD
VEHICLES
The A-558 transaxle model, assembly number,
build date, and final-drive ratio are stamped on a tag
that is attached to the top of the transaxle (Fig. 2).NOTE: Certain transaxle assemblies utilize high-
strength steel in various gears. It is imperative that
the correct transaxle assembly number is utilized
when ordering service parts. Do not remove this
tag, so the information is available for future ser-
vice.
The last eight digits of the Vehicle Identification
Number (V.I.N.) are stamped on a raised boss on top
of the clutch housing area.
SELECTION OF LUBRICANT
The A-598 manual transaxle uses SAE 5W-30
engine oil, meeting SG and/or SG-CD qualifications,
as the factory fill lubricant. G5 SAE 10W-40 engine
oil is a suitable service fill alternative.Hypoid gear
lube, manual transmission fluid, and/or auto-
matic transmission fluid should not be used in
this transaxle.Hard shifting effort, bearing, gear,
and/or synchronizer failure may occur if incorrect
fluid is used.
SELECTION OF LUBRICANTÐRHD VEHICLES
The A-558 manual transaxle uses SAE 5W-30
engine oil, meeting SG and/or SG-CD qualifications,
as the factory fill lubricant. G5 SAE 10W-40 engine
oil is a suitable service fill alternative.Hypoid gear
lube, manual transmission fluid, and/or auto-
matic transmission fluid should not be used in
this transaxle.Hard shifting effort, bearing, gear,
and/or synchronizer failure may occur if incorrect
fluid is used.
SPECIAL ADDITIVES
The addition of any fluids to the transaxle, other
than the fluid listed above, is not recommended. An
exception to this policy is the use of special dyes to
aid in detecting fluid leaks. The use of transmission
Fig. 1 Transaxle Identification
Fig. 2 Transaxle Identification
21 - 2 A±598 MANUAL TRANSAXLENS/GS

sealers should be avoided, since they may adversely
affect seals.
SPECIAL ADDITIVESÐRHD VEHICLES
The addition of any fluids to the transaxle, other
than the fluid listed above, is not recommended. An
exception to this policy is the use of special dyes to
aid in detecting fluid leaks. The use of transmission
sealers should be avoided, since they may adversely
affect seals.
GEAR RATIOS
Gear ratios for the 2.4L gasoline engine and 2.5L
Turbo Diesel MTX are as follows:
²1stÐ3.36
²2ndÐ1.90
²3rdÐ1.28
²4thÐ0.92
²5thÐ0.71
²ReverseÐ3.17
Final drive ratio of 3.88 was selected for maximum
performance. All forward gears are synchronized.
Gear ratios for the 2.0L GAS MTX are as follows:
²1stÐ3.69
²2ndÐ2.24
²3rdÐ1.45
²4thÐ1.03
²5thÐ0.81
²ReverseÐ3.17
Final drive ratio of 4.08 was selected for maximum
performance. All forward gears are synchronized.
GEAR RATIOSÐRHD VEHICLES
Gear ratios for the 2.0L GAS MTX are as follows:
²1stÐ3.69
²2ndÐ2.24
²3rdÐ1.45
²4thÐ0.1.03
²5thÐ0.81
²ReverseÐ3.17
Final drive ratio of 4.08 was selected for maximum
performance. All forward gears are synchronized.
GEARSHIFT PATTERN
The A-598 transaxle shift pattern is a H±pattern
(Fig. 3). Overdrive fifth and reverse gears are in±line
and to the right of the first through fourth gear posi-
tions.
GEARSHIFT PATTERNÐRHD VEHICLES
The A-558 transaxle shift pattern is a H±pattern
(Fig. 4). Overdrive fifth and reverse gears are in±line
and to the right of the first through fourth gear posi-
tions.
DESCRIPTION AND OPERATION
GEARSHIFT LEVERS
The gear shift levers at the transaxle are service-
able in the vehicle. The shift levers are different from
each other and do not interchange. The select lever is
not interchangeable with model years earlier than 96
(length is different).
AXLE SEALS
The axle shaft seals are identical for both sides of
the differential and will interchange.
DIAGNOSIS AND TESTING
COMMON PROBLEM CAUSES
The majority of transaxle malfunctions are a result
of:
²Insufficient lubrication
²Incorrect lubricant
²Misassembled or damaged internal components
Fig. 3 A-598 Shift Pattern
Fig. 4 A-558 Shift Pattern
NS/GSA±598 MANUAL TRANSAXLE 21 - 3
GENERAL INFORMATION (Continued)

(25) Install transmission jack under transaxle
assembly.
(26) Remove left fender splash shield.
(27) Remove (4) left mount bolts (Fig. 42).(28) Remove lower bellhousing bolts.
(29) Lower transaxle and remove.
INSTALLATION
(1) For installation, reverse removal procedure.
NOTE: Lower control arm pinch bolts must be
installed with the bolt heads to the rear of the ball
joints.
(2) Fill transaxle to the proper level with the spec-
ified lubricant.
(3) While the vehicle is elevated slightly, run the
transaxle through all the forward gears. Apply
brakes and shift into reverse. Run the transaxle
through reverse gear.
Fig. 35 Lower Control Arm Pinch Bolt
Fig. 36 Unseat Control Arm
Fig. 37 Transaxle Drain Plug
Fig. 38 Vehicle Speed Sensor
Fig. 39 Clutch Cable Clip
21 - 14 A±598 MANUAL TRANSAXLENS/GS
REMOVAL AND INSTALLATION (Continued)

(22) Remove lower starter bolt.
(23) Remove engine wiring harness clip.
CAUTION: Always use a safety chain when remov-
ing or installing transaxle assembly.
(24) Place a transmission jack under the transmis-
sion
(25) Remove the transaxle lower dust cover.
(26) Remove the access cover in right splash shield
to access torsional damper bolt.
(27) Remove drive plate to modular clutch bolts
while holding torsional damper bolt with socket and
ratchet. To avoid distortion of the drive plate, remove
the modular clutch bolts a few turns at a time. Use a
crisscross pattern until all bolts are loosened.
(28) Unbolt rear engine mount through bolt and
two (2) mount bolts.
(29) Remove the left front fender splash shield.
(30) Unbolt left engine mount through bolt and
unbolt mount from the transaxle.(31) Remove front engine mount (Fig. 60) and (Fig.
61).
(32) Lower the transaxle and modular clutch.
To service the drive plate, refer to Group 9, Engine.
INSTALLATION
(1) Position the modular clutch assembly onto the
input shaft of the transaxle (Fig. 62).
(2) To reinstall transaxle, reverse removal proce-
dure making certain to align the elongated hole in
the drive plate with the modular clutch bolt hole that
has the white paint mark.
Fig. 57 Unseat Control Arm
Fig. 58 Transaxle Drain Plug
Fig. 59 Vehicle Speed Sensor
Fig. 60 Front Engine Mount (Left Side)
NS/GSA±598 MANUAL TRANSAXLE 21 - 19
REMOVAL AND INSTALLATION (Continued)

HEX
CODEGENERIC
SCAN
TOOL
CODEDRB SCAN TOOL
DISPLAYDESCRIPTION OF DIAGNOSTIC
TROUBLE CODE
52* SPD CTRL PWR RLY; or S/C 12v
Driver CKTMalfunction detected with power feed to speed
control servo solenoids.
5A A/C Pressure Sensor Volts Too
HighSensor input voltage is above 4.9 volts.
5B A/C Pressure Sensor Volts Too Low Sensor input voltage is below .098 volts.
60 P1698 No CCD Messages From TCM No messages received from Transmission Control
Module.
61 No CCD Message From Body
Control ModuleNo messages received from Body Control Module.
65* Fuel Pump Relay Control Circuit An open or shorted condition detected in the fuel
pump relay control circuit.
66 P0133 Right Bank Upstream O2S Slow
ResponseOxygen sensor response slower than minimum
required switching frequency.
67 P0135 Right Rear (or just) Upstream O2S
Heater FailureUpstream oxygen sensor heating element circuit
malfunction.
69 P0141 Right Rear (or just) Downstream
O2S Heater FailureOxygen sensor heating element circuit malfunction.
6A P0300 Multiple Cylinder Mis-fire Misfire detected in multiple cylinders.
6B P0301 Cylinder #1 Mis-fire Misfire detected in cylinder #1.
6C P0302 Cylinder #2 Mis-fire Misfire detected in cylinder #2.
6D P0303 Cylinder #3 Mis-fire Misfire detected in cylinder #3.
6E P0304 Cylinder #4 Mis-fire Misfire detected in cylinder #4.
70 P0420 Right Rear (or just) Catalyst
Efficency FailureCatalyst efficiency below required level.
71* P0441 Evap Purge Flow Monitor Failure Insufficient or excessive vapor flow detected during
evaporative emission system operation.
72 P1899 P/N Switch Stuck in Park or in Gear Incorrect input state detected for the Park/Neutral
switch, auto. trans. only.
76 P0172 Right Rear (or just) Fuel System
RichA rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
77 P0171 Right Rear (or just) Fuel System
LeanA lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
7E P0138 Right Rear (or just) Downstream
O2S Shorted to VoltageOxygen sensor input voltage maintained above the
normal operating range.
80 P0128 Closed Loop Temp Not Reached Engine does not reach 20ÉF within 5 minutes with
a vehicle speed signal.
81 P0140 Right Rear (or just) Downstream
O2S Stays at CenterNeither reich or lean condition detected from the
downstream oxygen sensor.
84 P0121 TPS Voltage Does Not Agree With
MAPTPS signal does not correlate to MAP sensor
89 P0700 EATX Controller DTC Present An automatic transmission input DTC has been set
in the transmission controller. Refer to Group 21.
8A P1294 Target Idle Not Reached Actual idle speed does not equal target idle speed.
25 - 6 EMISSION CONTROL SYSTEMSNS
DESCRIPTION AND OPERATION (Continued)