ABS CHRYSLER VOYAGER 2001 Service Manual

ASSEMBLY
NOTE: The differential is serviced as an assembly.
Differential service is limited to bearing cups and
cones. Any other differential component failure
must be remedied by differential assembly and
transfer shaft replacement.
(1) Install side gear thrust washer to differential
case (Fig. 197).
(2) Install side gear to differential case (Fig. 198).(3) Install both pinion gears and washers to case,
while orientating washer tabs to notch in case (Fig.
199).
(4) Install pinion shaft (Fig. 200).
Fig. 197 Thrust Washer Installation
1 - THRUST WASHER
Fig. 198 Side Gear Installation
1 - DIFFERENTIAL SIDE GEAR
Fig. 199 Pinion Gear and Washer Installation
1 - PINION GEAR
2 - TABBED WASHER
3 - LOCATING TAB
4 - NOTCH
Fig. 200 Pinion Shaft Installation
1 - PINION SHAFT
21 - 240 AUTOMATIC - 41TERS
FINAL DRIVE (Continued)

(10) Remove and inspect #3 & #4 thrust washers
(Fig. 240) .
(11) Remove the underdrive shaft assembly (Fig.
241) .(12) Remove the #2 needle bearing (Fig. 242) .
(13) Remove the OD/UD reaction plate tapered
snap ring (Fig. 243) .
NOTE: The OD/UD clutch reaction plate has a step
on both sides. Install the OD/UD clutches reaction
plate tapered step side up.
Fig. 240 #3&4 Thrust Washers
1 - #3 THRUST PLATE (3 TABS)
2 - OD SHAFT ASSEMBLY
3 - #4 THRUST PLATE (3 SLOTS)
Fig. 241 Underdrive Shaft Assembly
1 - #3 THRUST WASHER (5 TABS)
2 - UNDERDRIVE SHAFT ASSEMBLY
Fig. 242 No. 2 Needle Bearing
1 - #2 NEEDLE BEARING (NOTE 3 TABS)
Fig. 243 OD/UD Reaction Plate Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
RSAUTOMATIC - 41TE21 - 255
INPUT CLUTCH ASSEMBLY (Continued)

(18) Using Tool 5059A and an arbor press, com-
press UD clutch piston enough to remove snap ring
(Fig. 248) (Fig. 249) .
(19) Remove spring retainer (Fig. 249) .(20) Remove UD clutch piston (Fig. 250) .
(21) Remove input hub tapered snap ring (Fig.
251) .
Fig. 248 UD Spring Retainer Snap Ring
1 - SNAP RING PLIERS
2 - ARBOR PRESS RAM
3 - SNAP RING
4 - SPECIAL TOOL 5059A
Fig. 249 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 250 Underdrive Clutch Piston
1 - PISTON
Fig. 251 Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
RSAUTOMATIC - 41TE21 - 257
INPUT CLUTCH ASSEMBLY (Continued)

(5) Install the input hub/shaft assy. to the OD/Re-
verse piston/clutch retainer assy. (Fig. 264).
(6) Install input hub tapered snap ring (Fig. 265).(7) Install UD clutch piston (Fig. 266).
(8) Install UD piston return spring and Tool 5067
as shown in (Fig. 267).
(9) Using Tool 5059A and an arbor press, Install
the UD spring retainer and snap ring. (Fig. 268) (Fig.
269)Compress just enough to install snap ring.
CAUTION: Compress return spring just enough to
install snap ring.
Fig. 264 Install Input Shaft Hub Assembly
1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY
(ROTATE TO ALIGN SPLINES)
2 - OD/REV. PISTON
Fig. 265 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
Fig. 266 Underdrive Clutch Piston
1 - PISTON
Fig. 267 Seal Compressor Special Tool 5067
1 - PISTON RETURN SPRING
2 - SPECIAL TOOL 5067
3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY
RSAUTOMATIC - 41TE21 - 261
INPUT CLUTCH ASSEMBLY (Continued)

(35) Take average of four measurements and com-
pare with reverse clutch pack clearance specification.
The reverse clutch pack clearance is 0.89-1.37
mm (0.035-0.054 in.).Select the proper reverse
clutch snap ring to achieve specifications:
REVERSE CLUTCH SNAP RING THICKNESS
4377195 1.53-1.58 mm (0.060-0.062 in.)
4412871 1.77-1.83 mm (0.070-0.072 in.)
4412872 2.02-2.07 mm (0.080-0.082 in.)
4412873 2.27-2.32 mm (0.090-0.091 in.)
(36) To complete the assembly, reverse clutch and
overdrive clutch must be removed .
(37) Install the #2 needle bearing (Fig. 290).
(38) Install the underdrive shaft assembly (Fig.
291).
(39) Install the #3 thrust washer to the underdrive
shaft assembly. Be sure five tabs are seated properly
(Fig. 292).
(40) Install the #3 thrust plate to the bottom of the
overdrive shaft assembly. Retain with petrolatum or
transmission assembly gel (Fig. 293).(41) Install the overdrive shaft assembly (Fig.
294).
(42) Reinstall overdrive and reverse clutch as
shown.Rechecking these clutch clearances is
not necessary.
Fig. 290 Install No. 2 Needle Bearing
1 - #2 NEEDLE BEARING (NOTE 3 SMALL TABS)
2 - TABS UP
Fig. 291 Install Underdrive Shaft Assembly
1 - UNDERDRIVE SHAFT ASSEMBLY
2 - #2 NEEDLE BEARING
Fig. 292 Install No. 3 Thrust Washer
1 - #3 THRUST WASHER (NOTE 5 TABS)
2 - UNDERDRIVE SHAFT ASSEMBLY
21 - 268 AUTOMATIC - 41TERS
INPUT CLUTCH ASSEMBLY (Continued)

OIL PUMP
DESCRIPTION
The oil pump is located in the pump housing inside
the bell housing of the transaxle case (Fig. 295). The
oil pump consists of an inner and outer gear, a hous-
ing, and a cover that also serves as the reaction shaft
support.
OPERATION
As the torque converter rotates, the converter hub
rotates the inner and outer gears. As the gears
rotate, the clearance between the gear teeth
increases in the crescent area, and creates a suctionat the inlet side of the pump. This suction draws
fluid through the pump inlet from the oil pan. As the
clearance between the gear teeth in the crescent area
decreases, it forces pressurized fluid into the pump
outlet and to the valve body.
STANDARD PROCEDURE - OIL PUMP VOLUME
CHECK
Measuring oil pump output volume will determine
if sufficient flow to the transmission oil cooler exists,
and whether or not an internal transmission failure
is present.
Verify that transmission fluid is at the proper
level. If adding fluid is necessary, fill to the proper
level with Moparž ATF+4 (Automatic Transmission
Fluid±Type 9602). The following procedure is to
check oil pump output volume:
(1) Using hose cutters or a suitable blade, cut the
ªto coolerº (Fig. 296) line off flush with the cooler
inlet fitting and place a collection container under
the open line .
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Start engine and runat curb idle speed, with
the shift selector in neutral.
Fig. 293 Install No. 3 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - DABS OF PETROLATUM (FOR RETENTION)
3 - #3 THRUST PLATE (NOTE 3 TABS)
Fig. 294 Install Overdrive Shaft Assembly
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #3 THRUST PLATE
3 - #3 THRUST WASHER
Fig. 295 Oil Pump Assembly
1 - PUMP HOUSING
2 - OUTER PUMP GEAR
3 - INNER PUMP GEAR
4 - REACTION SHAFT SUPPORT
5 - SEAL RINGS (4)
6 - REACTION SHAFT
7 - CRESCENT
RSAUTOMATIC - 41TE21 - 269
INPUT CLUTCH ASSEMBLY (Continued)

(1) Press intermediate shaft into NEW roller bear-
ing with arbor press (Fig. 262).
(2) Install intermediate shaft roller bearing snap
ring (Fig. 263).
(3) Install 1st gear roller bearing to intermediate
shaft (Fig. 264).(4) Install 1st gear to intermediate shaft (Fig.
265).
(5) Install 1/2 synchro to fixture 8483. Insert 1st
gear blocker ring, friction cone, and reactor ring as
shown in (Fig. 266).
(6) Install intermediate shaft to synchro assembly
on fixture (Fig. 267).When installing 1/2 synchro-
nizer, make sure to align oil slots on synchro-
nizer hub face with oil hole in the shaft splined
hub journal.Line up friction cone and reactor ring
tabs to gear slots. Remove shaft assembly from fix-
ture.
Fig. 262 Intermediate Shaft Bearing Installation
1 - ARBOR PRESS
2 - INTERMEDIATE SHAFT
3 - CAGED ROLLER BEARING
4 - BEARING SPLITTER
Fig. 263 Intermediate Shaft Roller Bearing Snap
Ring
1 - SNAP RING
Fig. 264 1st Gear Needle Bearing
1 - 1ST GEAR NEEDLE BEARING
Fig. 265 1st Gear Installation
1 - 1ST GEAR
RGT850 MANUAL TRANSAXLE21a-89
INTERMEDIATE SHAFT (Continued)

When wheels and tires are being installed, extra
care is needed to ensure that this direction of rota-
tion is maintained.
Refer to Owner's Manual for rotation schedule.
REMOVAL - TIRE AND WHEEL ASSEMBLY
(ALUMINUM WHEEL)
(1) Raise the vehicle so the tire and wheel assem-
bly clears ground level.
(2) Remove the 5 wheel mounting nuts from the
studs.
(3) Remove the tire and wheel from the hub.
REMOVAL - TIRE AND WHEEL ASSEMBLY
(STEEL WHEEL)
(1) Raise the vehicle so the tire and wheel assem-
bly clears ground level.
(2) Noting the location of the valve stem in rela-
tionship to the wheel mounting nuts, remove the
three wheel mounting nuts securing the wheel cover
to the wheel and hub (Fig. 12).
CAUTION: When removing the wheel cover, do not
pry the wheel cover from the wheel. This can result
in damage to the wheel cover. The wheel cover is
removed by pulling it off the wheel by hand.
(3) Grasp the wheel cover at the edges in line with
the remaining installed wheel mounting nuts and
pull straight outward from the wheel. This will pop
the wheel cover retaining tabs over the two remain-
ing wheel nuts, removing the wheel cover from the
vehicle.
(4) Remove the two remaining wheel mounting
nuts from the hub's studs.(5) Remove the wheel and tire from the hub.
INSTALLATION - TIRE AND WHEEL ASSEMBLY
(ALUMINUM WHEEL)
NOTE: Never use oil or grease on studs or wheel
mounting nuts.
(1) Position the tire and wheel assembly on the
wheel mounting studs using the hub pilot as a guide.
Place and hold the wheel flush up against the mount-
ing surface.
(2) Loosely install all 5 wheel mounting nuts.
Lightly snug the wheel nuts, then progressively
tighten them in the proper sequence (Fig. 13).
Tighten wheel mounting nuts to 135 N´m (100 ft.
lbs.).
(3) Lower the vehicle.
INSTALLATION - TIRE AND WHEEL ASSEMBLY
(STEEL WHEEL)
NOTE: Never use oil or grease on studs or wheel
mounting nuts.
(1) Position the tire and wheel assembly on the
wheel mounting studs using the hub pilot as a guide.
Place and hold the wheel flush up against the mount-
ing surface.
NOTE: Wheel mounting nuts must be installed on
the studs as shown (Fig. 14) to allow proper instal-
lation of the wheel cover.
(2) Using the valve stem as an index placed at the
12 O'clock position, install andlightly tightentwo
wheel mounting nuts on the studs located at the 4
O'clock and 8 O'clock positions as shown (Fig. 14).
Fig. 12 NUTS SECURING WHEEL COVER
1 - VALVE STEM
2 - BOLT-ON WHEEL COVER
3 - NUTS SECURING WHEEL COVER
Fig. 13 Tightening Sequence
RSTIRES/WHEELS22-7
TIRES/WHEELS (Continued)

(3) Place the wheel cover on the wheel in the fol-
lowing fashion:
(a) Align the valve notch in the wheel cover with
the valve stem on the wheel.
(b) At the same time, align the two holes in the
wheel cover having the retaining tabs with the two
installed wheel nuts (Fig. 15).
(c) Press in on center of wheel cover until wheel
cover retaining tabs push past and engage rear of
previously installed wheel mounting nuts (Fig. 15).
This will hold the wheel cover in place.(4) Install andlightly tightenthe three remain-
ing wheel mounting nuts, securing the wheel cover in
place (Fig. 12).
(5) Progressively tighten all five wheel mounting
nuts in the proper sequence (Fig. 16). Tighten wheel
nuts to a torque of 135 N´m (100 ft. lbs.).
(6) Lower the vehicle.
TIRES
DESCRIPTION - TIRE
Tires are designed and engineered for each specific
vehicle. They provide the best overall performance
for normal operation. The ride and handling charac-
teristics match the vehicle's requirements. With
proper care they will give excellent reliability, trac-
tion, skid resistance, and tread life.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain, in most
cases, much greater mileage than severe use or care-
less drivers. A few of the driving habits which will
shorten the life of any tire are:
²Rapid acceleration
²Severe application of brakes
²High-speed driving
²Taking turns at excessive speeds
²Striking curbs and other obstacles
²Operating vehicle with over or under inflated
tire pressures
Radial ply tires are more prone to irregular tread
wear. It is important to follow the tire rotation inter-
val shown in the section on Tire Rotation. This will
help to achieve a greater tread-life potential.
TIRE IDENTIFICATION
Tire type, size, aspect ratio and speed rating are
encoded in the letters and numbers imprinted on the
side wall of the tire. Refer to the chart to decipher
the tire identification code (Fig. 17).
Fig. 14 TWO WHEEL MOUNTING NUTS INSTALLED
1 - WHEEL
2 - VALVE STEM
3 - HUB PILOT
4 - NUTS
Fig. 15 WHEEL COVER INSTALLATION OVER TWO
NUTS
1 - RETAINING TABS
2 - VALVE STEM
3 - BOLT-ON WHEEL COVER
Fig. 16 NUT TIGHTENING SEQUENCE
22 - 8 TIRES/WHEELSRS
TIRES/WHEELS (Continued)

CLEANING - ALUMINUM WHEEL CARE
Chrome plated and painted aluminum wheels
should be cleaned regularly using mild soap and
water to maintain their luster and to prevent corro-
sion.
Care must be taken in the selection of tire and
wheel cleaning chemicals and equipment to prevent
damage to the wheels. Any of the ªDO NOT USEº
items listed below WILL damage chrome plated and
painted aluminum wheels.
DO NOT USE:
²any abrasive metal cleaner
²any abrasive cleaning pad or brush
²any cleaner that contains an acid (this will
immediately react with and discolor the chromium
surface)
²chrome polish (unless it is buffed off immedi-
ately after application)
²oven cleaner
²a car wash that uses carbide-tipped wheel clean-
ing brushes
SPECIFICATIONS
WHEEL
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Wheel Mounting (Lug)
Nut Hex Size19 mm
Wheel Mounting Stud
SizeM12 x 1.5 mm
TORQUE SPECIFICATIONS
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Wheel Mounting (Lug ) Nut 135 100 Ð
WHEEL COVER
DESCRIPTION
This vehicle uses a bolt-on type wheel cover (Fig.
25).
This bolt-on wheel cover cannot be removed from
the wheel until three of the five wheel mounting nuts
shown are removed (Fig. 25). The bolt-on wheel cover
can then be removed with the remaining two wheel
nuts tightened in place.
REMOVAL
(1) Noting the location of the valve stem in rela-
tionship to the wheel mounting nuts, remove the
three wheel mounting nuts securing the wheel cover
to the wheel and hub (Fig. 25).
CAUTION: When removing the wheel cover, do not
pry the wheel cover from the wheel. This can result
in damage to the wheel cover. The wheel cover is
removed by pulling it off the wheel by hand.
(2) Grasp the wheel cover at the edges in line with
the remaining installed wheel nuts and pull straight
outward from the wheel. This will pop the wheel
cover retaining tabs over the two remaining wheel
nuts, removing the wheel cover from the wheel.
INSTALLATION
NOTE: Wheel mounting nuts must be installed on
the studs as shown to allow installation of the
wheel cover (Fig. 26).
(1) Place the wheel cover on the wheel in the fol-
lowing fashion:
(a) Align the valve notch in the wheel cover with
the valve stem on the wheel.
(b) At the same time, align the two holes in the
wheel cover having the retaining tabs with the two
installed wheel nuts (Fig. 27).
(c) Press in on center of wheel cover until wheel
cover retaining tabs push past and engage rear of
previously installed wheel mounting nuts (Fig. 27).
This will hold the wheel cover in place.
Fig. 25 Nuts Securing Wheel Cover
1 - VALVE STEM
2 - BOLT-ON WHEEL COVER
3 - NUTS SECURING WHEEL COVER
22 - 14 TIRES/WHEELSRS
WHEELS (Continued)