CHRYSLER VOYAGER 2001 Service Manual

(18) Remove left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - REMOVAL)
(19) Disconnect exhaust pipe at manifold (Fig. 13).
(20) Remove cradle plate.
(21) AWD models: Remove power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - REMOVAL)
(22) Remove rear mount bracket-to-transaxle case
lower (horizontal) bolt (Fig. 12).
(23) Remove rear mount heat shield (Fig. 14).
(24) Remove rear mount-to-bracket thru-bolt and
nut (Fig. 15).
(25) Remove front mount/bracket assembly.
(26) Remove starter motor.
(27) Remove lateral bending brace.(28) Remove inspection cover.
(29) Remove torque converter-to-drive plate bolts.
(30) Support engine/transaxle assembly at engine
oil pan with screw jack and wood block.
(31) Partially remove left wheelhouse splash shield
to gain access to and remove upper mount thru-bolt
(Fig. 16).
(32) Lower engine/transaxle assembly with screw
jack.
(33) Obtain helper and transmission jack. Secure
transmission jack to transaxle assembly.
(34) Remove upper mount bracket from transaxle
(Fig. 16).
(35) Remove remaining transaxle bellhousing-to-
engine bolts.
(36) Remove transaxle assembly from vehicle.
Fig. 12 Rear Mount Bracket - Typical
1 - BOLT - VERTICAL
2 - BRACKET - REAR MOUNT3 - BOLT - HORIZONTAL
RSAUTOMATIC - 41TE21 - 167
AUTOMATIC - 41TE (Continued)

Fig. 13 Catalytic Converter to Exhaust Manifold
1 - FLAG NUT
2 - GASKET
3 - BOLT
4 - CATALYTIC CONVERTER
Fig. 14 Rear Mount Heat Shield
1 - BOLT - HEAT SHIELD
2 - HEAT SHIELD
3 - CLIP
4 - REAR MOUNT
Fig. 15 Rear Mount
1 - BOLT
2 - REAR MOUNT BRACKET
3 - THRU-BOLT
4 - REAR MOUNT
Fig. 16 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 - 168 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)

DISASSEMBLY
CAUTION: If transaxle failure has occurred, it is
necessary to flush the transaxle oil cooler and lines
to remove debris and particles that could contami-
nate and/or fail a new or rebuilt unit. (Refer to 7 -
COOLING/TRANSMISSION - STANDARD PROCE-
DURE)
NOTE: If transaxle is being overhauled (clutch
and/or seal replacement) or replaced, it is neces-
sary to perform the TCM Quick Learn Procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
NOTE: This procedure does not include final drive
(differential) disassembly.
(1) Remove input and output speed sensors.
(2) Remove three (3) solenoid/pressure switch
assembly-to-case bolts.
(3) Remove solenoid/pressure switch assembly and
gasket (Fig. 17).(4) Remove oil pan-to-case bolts (Fig. 18).
(5) Remove oil pan (Fig. 19).
(6) Remove oil filter (Fig. 20).
(7) Turn manual valve fully clock-wise to get park
rod into position for removal.
(8) Remove valve body-to-case bolts (Fig. 21).
CAUTION: Do not handle the valve body assembly
from the manual valve. Damage can result.
Fig. 17 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 18 Remove Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 19 Remove Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
RSAUTOMATIC - 41TE21 - 169
AUTOMATIC - 41TE (Continued)

(9) Using a screwdriver, push park rod rollers
away from guide bracket (Fig. 22) and remove valve
body assembly (Fig. 23).
NOTE: Depending on engine application, some
accumulators will have two springs and others will
have one spring. The springs are color-coded
according to application and year. When disassem-
bling, mark accumulator spring location to ease
assembly.
Fig. 20 Remove Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 21 Remove Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 22 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
Fig. 23 Remove Valve Body
1 - VALVE BODY
21 - 170 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)

(10) Remove underdrive and overdrive accumula-
tors (Fig. 24) (Fig. 25) (Fig. 26).
(11) Remove low/reverse accumulator snap ring
(Fig. 27).
Fig. 24 Remove Underdrive and Overdrive
Accumulators
1 - RETURN SPRING
2 - UNDERDRIVE CLUTCH ACCUMULATOR
3 - SEAL RING (2)
4 - OVERDRIVE CLUTCH ACCUMULATOR
Fig. 25 Accumulator (Underdrive)
1 - ACCUMULATOR PISTON (UNDERDRIVE)
2 - RETURN SPRINGS
3 - SEAL RING
4 - SEAL RING
Fig. 26 Accumulator (Overdrive)
1 - ACCUMULATOR PISTON (OVERDRIVE)
2 - RETURN SPRING
3 - SEAL RING
4 - SEAL RING
Fig. 27 Remove Low/Reverse Accumulator Snap
Ring
1 - SNAP RING
2 - PLUG
RSAUTOMATIC - 41TE21 - 171
AUTOMATIC - 41TE (Continued)

(12) Remove low/reverse accumulator plug (Fig.
28).
(13) Remove low/reverse accumulator piston using
petrolatum and a suitable tool (Fig. 29).(14) Remove low/reverse accumulator (Fig. 30).
(15) Measure input shaft end play. Place transaxle
so input shaft is vertical. Set up end play set and
dial indicator as shown in (Fig. 31).Input shaft end
play should be within 0.13-0.64 mm (0.005-0.025
in.)If outside of this range, a #4 thrust plate change
is required. Record indicator reading for reference
upon reassembly.
Fig. 28 Remove Low/Reverse Accumulator Plug
(Cover)
1 - ADJUSTABLE PLIERS
2 - PLUG
Fig. 29 Remove Low/Reverse Accumulator Piston
1 - SEAL RINGS
2 - PISTON
3 - PISTON
4 - PETROLATUM
5 - SUITABLE TOOL
Fig. 30 Remove Low/Reverse Accumulator
1 - ACCUMULATOR PISTON
2 - SEAL RINGS
3 - RETURN SPRINGS
4 - (NOTE NOTCH)
Fig. 31 Measure Input Shaft End Play Using End
Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
21 - 172 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)

(16) Remove oil pump-to-case bolts (Fig. 32).
CAUTION: Be sure input speed sensor is removed
before removing oil pump.
(17) Install pullers Tool C-3752 as shown in (Fig.
33).
(18) Remove oil pump assembly (Fig. 34) (Fig. 35).
(19) Remove oil pump gasket (Fig. 36).
CAUTION: If transaxle failure has occurred, the
cooler bypass valve must be replaced. Do not
re-use or attempt to clean valve.
Fig. 32 Remove Pump Attaching Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 33 Install Tool C-3752
1 - PULLERS TOOL C-3752
2 - PUMP
Fig. 34 Remove Oil Pump
1 - ªPUSH INº ON INPUT SHAFT WHILE REMOVING PUMP
Fig. 35 Oil Pump Removed
1 - OIL PUMP
2 - GASKET
Fig. 36 Remove Oil Pump Gasket
1 - PUMP GASKET
RSAUTOMATIC - 41TE21 - 173
AUTOMATIC - 41TE (Continued)

(20) Remove cooler bypass valve (Fig. 37).
(21) Remove #1 needle bearing (Fig. 38).(22) Remove input clutch assembly (Fig. 39).
(23) Remove #4 thrust plate (Fig. 40).
Fig. 37 Remove Bypass Valve
1 - COOLER BYPASS VALVE
Fig. 38 Remove Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 39 Remove Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 40 No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
21 - 174 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)

(24) Remove front sun gear assembly and #4
thrust washer (Fig. 41).
(25) Remove front carrier and rear annulus assem-
bly (Fig. 42).(26) Remove rear sun gear and #7 needle bearing
(Fig. 43).
NOTE: Verify that Tool 5058 is centered properly
over the 2/4 clutch retainer before compressing. If
necessary, fasten the 5058 bar to the bellhousing
flange with any combination of locking pliers and
bolts to center the tool properly.
(27) Setup tool 5058 as shown in (Fig. 44). Com-
press 2/4 clutch return spring (just enough to remove
snap ring) and remove snap ring.
Fig. 41 Remove Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
Fig. 42 Remove Front Carrier and Rear Annulus
Assembly
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 43 Remove Rear Sun Gear
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 44 Remove 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
RSAUTOMATIC - 41TE21 - 175
AUTOMATIC - 41TE (Continued)

(28) Remove 2/4 clutch retainer (Fig. 45).
(29) Remove 2/4 clutch return spring (Fig. 46).(30) Remove 2/4 clutch pack (Fig. 47).Tag 2/4
clutch pack for reassembly identification.
(31) Remove tapered snap ring (Fig. 48).
Fig. 45 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 46 Remove 2/4 Clutch Return Spring
1 - 2/4 CLUTCH RETURN SPRING
Fig. 47 Remove 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
Fig. 48 Remove Tapered Snap Ring
1 - LOW/REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)
4 - OIL PAN FACE
5 - LONG TAB
21 - 176 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)