CHRYSLER VOYAGER 2001 Service Manual

NOTE: Only fluids of the type labeled Moparž
ATF+4 (Automatic Transmission Fluid) Type 9602
should be used. A filter change should be made at
the time of the transmission oil change. The magnet
(on the inside of the oil pan) should also be cleaned
with a clean, dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Refer to LUBRICA-
TION and MAINTENANCE for proper procedures.
Place a drain container with a large opening, under
transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and o-ring on bottom of the
valve body (Fig. 216).
(4) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.).
Fig. 215 Transmission Fluid Temperature Chart
Fig. 216 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
RSAUTOMATIC - 41TE21 - 247
FLUID (Continued)

(5) Pour four quarts of Moparž ATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick
opening.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 217).
(8) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.). Refer
to Fluid Level and Condition Check for the proper
fluid fill procedure.
(9) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
DIPSTICK TUBE FLUID SUCTION METHOD
(ALTERNATIVE)
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (VaculaŸ
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Pour four quarts of Moparž ATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick
opening.(7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 217).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/FLUID - STANDARD PROCEDURE)
(10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
GEAR SHIFT CABLE
REMOVAL
(1) Disconnect battery cables.
(2) Remove battery shield.
(3) Remove battery.
(4) Remove speed control servo and position out of
way.
(5) Disconnect gear shift cable at manual valve
lever (Fig. 218).
(6) Disconnect gear shift cable from upper mount
bracket (Fig. 218).
Fig. 217 Transaxle Fluid Level Indicator
1 - TRANSAXLE DIPSTICK
Fig. 218 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 248 AUTOMATIC - 41TERS
FLUID (Continued)

(7) Remove instrument panel lower silencer (Fig.
219).
(8) Remove knee bolster (Fig. 220).
(9) Disconnect gear shift cable from gear shift
lever (Fig. 221).
(10) Remove gear shift cable from column bracket
(Fig. 221).
(11) Disengage grommet from dash panel (Fig.
222) and remove gear shift cable from inside vehicle.
Fig. 219 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 220 Knee Bolster
1 - KNEE BOLSTER
Fig. 221 Gearshift Cable at Column
1 - GEAR SHIFT CABLE
Fig. 222 Gearshift Cable/Grommet at Dash Panel
1 - CABLE GROMMET
2 - DASH PANEL
RSAUTOMATIC - 41TE21 - 249
GEAR SHIFT CABLE (Continued)

INSTALLATION
(1) Fish gear shift cable dash panel opening into
engine compartment and secure grommet (Fig. 223).
(2) Install gear shift cable through column bracket
(Fig. 224) until audible ªclickº is heard.
(3) Connect gear shift cable to gear shift lever (Fig.
224).(4) Install knee bolster (Fig. 225).
(5) Install instrument panel lower silencer (Fig.
226).
(6) Install gear shift cable to transaxle upper
mount bracket (Fig. 227). An audible ªclickº should
be heard.
(7) Connect gear shift cable end to transaxle man-
ual valve lever (Fig. 227).
(8) Adjust gearshift cable. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 41TE/GEAR
SHIFT CABLE - ADJUSTMENTS)
(9) Install speed control servo into position.
(10) Install battery.
(11) Install battery shield.
(12) Connect battery cables.
Fig. 223 Gearshift Cable/Grommet at Dash Panel
1 - CABLE GROMMET
2 - DASH PANEL
Fig. 224 Gearshift Cable at Column
1 - GEAR SHIFT CABLE
Fig. 225 Knee Bolster
1 - KNEE BOLSTER
Fig. 226 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
21 - 250 AUTOMATIC - 41TERS
GEAR SHIFT CABLE (Continued)

GEARSHIFT CABLE ADJUSTMENT
VERIFICATION
(1) Place gearshift lever in gated park (P).
(2) Attempt to move vehicle by rocking back and
forth on level ground. If vehicle does not move,
attempt to start engine. If engine starts, the park
position is correct.
(3) Set parking brake.
(4) Turn key to on/run and depress brake pedal.
Place gearshift lever in neutral (N).
(5) Attempt to start engine. If engine starts in
both neutral (N) or park (P), gearshift cable is
adjusted properly. No adjustment is required.
(6) If engine does not start in either park (P) or
neutral (N), perform adjustment procedure.
ADJUSTMENT
(1) Park the vehicle on level ground and set the
parking brake.
(2) Place the gearshift lever in gated park (P) and
remove ignition key.
(3) Loosen the cable adjustment screw at the
transaxle manual valve lever (Fig. 228).(4) Pull the gearshift lever fully forward to the
park detent position.
(5) Release the park brake, then rock the vehicle
to assure it is in park. Reset the park brake.
(6) Tighten the cable adjustment screw to 8 N´m
(70 in. lbs.). Gearshift cable should now be properly
adjusted.
(7) Verify adjustment by using the verification pro-
cedure.
HOLDING CLUTCHES
DESCRIPTION
Two hydraulically applied multi-disc clutches are
used to hold planetary geartrain components station-
ary while the input clutches drive others. The 2/4
and Low/Reverse clutches are considered holding
clutches and are contained at the rear of the trans-
axle case. (Fig. 229) .
OPERATION
NOTE: Refer to the ªElements In Useº chart in Diag-
nosis and Testing for a collective view of which
clutch elements are applied at each position of the
selector lever.
2/4 CLUTCH
The 2/4 clutch is hydraulically applied in second
and fourth gears by pressurized fluid against the 2/4
clutch piston. When the 2/4 clutch is applied, the
front sun gear assembly is held or grounded to the
transaxle case.
Fig. 227 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 228 Gearshift Cable Adjustment
1 - GEARSHIFT CABLE ADJUSTMENT SCREW
2 - GEARSHIFT CABLE
RSAUTOMATIC - 41TE21 - 251
GEAR SHIFT CABLE (Continued)

LOW/REVERSE CLUTCH
The Low/Reverse clutch is hydraulically applied in
park, reverse, neutral, and first gears by pressurized
fluid against the Low/Reverse clutch piston. When
the Low/Reverse clutch is applied, the front planet
carrier/rear annulus assembly is held or grounded to
the transaxle case.
INPUT CLUTCH ASSEMBLY
DISASSEMBLY
(1) Mount input clutch assembly to Input Clutch
Pressure Fixture (Tool 8391).
(2) Tap down reverse clutch reaction plate to
release pressure from snap ring (Fig. 230) .
(3) Remove reverse clutch snap ring (Fig. 231) .
Fig. 229 2/4 and Low/Reverse Clutches
1 - FRONT PLANET CARRIER/REAR ANNULUS
2 - 2/4 CLUTCH
3 - L/R CLUTCH
4 - REAR PLANET CARRIER/FRONT ANNULUS
5 - REAR SUN GEAR
6 - FRONT SUN GEAR ASSEMBLY
Fig. 230 Tapping Reaction Plate
1 - #4 THRUST PLATE (SELECT)
2 - TAP DOWN REVERSE CLUTCH REACTION PLATE TO
REMOVE OR INSTALL SNAP RING
3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY
4 - REVERSE CLUTCH REACTION PLATE
Fig. 231 Reverse Clutch Snap Ring
1 - REACTION PLATE
2 - SCREWDRIVER
3 - REVERSE CLUTCH SNAP RING (SELECT)
21 - 252 AUTOMATIC - 41TERS
HOLDING CLUTCHES (Continued)

(4) Pry up and remove reverse clutch reaction
plate (Fig. 232) (Fig. 233) .
(5) Remove the reverse clutch pack (two fibers/one
steel) (Fig. 234) .NOTE: Tag reverse clutch pack for reassembly iden-
tification.
(6) Remove the OD/Reverse reaction plate snap
ring (Fig. 235) .
Fig. 232 Pry Reverse Clutch Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
3 - SCREWDRIVER
Fig. 233 Reverse Clutch Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE (INSTALL FLAT SIDE
DOWN)
Fig. 234 Reverse Clutch Pack
1 - REVERSE CLUTCH PLATE
2 - REVERSE CLUTCH DISC
Fig. 235 OD/Reverse Reaction Plate Snap Ring
1 - OD/REVERSE PRESSURE PLATE
2 - SCREWDRIVER
3 - OD/REVERSE PRESSURE PLATE SNAP RING
RSAUTOMATIC - 41TE21 - 253
INPUT CLUTCH ASSEMBLY (Continued)

(7) Remove OD/Reverse reaction plate (Fig. 236) .
(8) Remove OD/Reverse reaction plate wave snap
ring (Fig. 237) .(9) Remove OD shaft/hub and OD clutch pack (Fig.
238) (Fig. 239) .
NOTE: Tag overdrive clutch pack for reassembly
identification.
Fig. 236 OD/Reverse Reaction Plate
1 - OD/REVERSE PRESSURE PLATE (STEP SIDE DOWN)
2 - (STEP SIDE DOWN)
Fig. 237 Waved Snap Ring
1 - OVERDRIVE SHAFT ASSEMBLY
2 - OD/REVERSE CLUTCH WAVED SNAP RING
3 - SCREWDRIVER
Fig. 238 Remove OD Clutch Pack
1 - OVERDRIVE SHAFT ASSEMBLY AND OD CLUTCH PACK
2 - #3 THRUST PLATE
3 - #3 THRUST WASHER
4 - UNDERDRIVE SHAFT ASSEMBLY
Fig. 239 Overdrive Clutch Pack
1 - OVERDRIVE CLUTCH PLATE
2 - OVERDRIVE SHAFT ASSEMBLY
3 - OVERDRIVE CLUTCH DISC
21 - 254 AUTOMATIC - 41TERS
INPUT CLUTCH ASSEMBLY (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)

(14) Remove the OD/UD reaction plate (Fig. 244) .
(15) Remove the first UD clutch disc (Fig. 245) .(16) Remove the UD clutch flat snap ring (Fig.
246) .
NOTE: Tag underdrive clutch pack for reassembly
identification.
(17) Remove the UD clutch pack (Fig. 247) .
CAUTION: Compress return spring just enough to
remove or install snap ring.
Fig. 244 OD/UD Reaction Plate
1 - OD/UD CLUTCH REACTION PLATE (STEP SIDE DOWN)
Fig. 245 Remove One UD Clutch Disc
1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 246 UD Clutch Flat Snap Ring
1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
Fig. 247 Underdrive Clutch Pack
1 - CLUTCH PLATE
2 - ONE UD CLUTCH DISC
3 - CLUTCH DISC
21 - 256 AUTOMATIC - 41TERS
INPUT CLUTCH ASSEMBLY (Continued)