torque CHRYSLER VOYAGER 2001 Service Manual

(12) Install rear carrier assembly to transaxle case
(Fig. 101).
(13) Install output gear bearing cone using Tool
5052 (Fig. 102).
(14)OUTPUT GEAR BEARING ADJUST-
MENT:
(a) With output gear removed, install a 4.50 mm
(0.177 in.) gauging shim (Fig. 104) on the rear car-
rier assembly hub, using grease to hold the shim in
place.
(b) Using Tool 6259, install output gear and
bearing assembly. Torque to 271 N´m (200 ft. lbs.).
(c) Measure bearing end play. Attach Tool L-4432
to the gear (Fig. 103).
(d) Push and pull the gear while rotating back
and forth to ensure seating of bearing rollers.(e) Using a dial indicator mounted to the trans-
axle case, measure output gear end play as shown
in (Fig. 103).
(f) Refer to the output gear bearing shim chart
for the required shim to obtain proper bearing set-
ting.
(g) Use Tool 6259 to remove the output gear
retaining bolt and washer. To remove the output
gear, use Tool L4407A.
(h) Remove the gauging shim and install the
proper shim determined by the chart. Use grease
to hold the shim in place.
Fig. 101 Install Rear Carrier Assembly
1 - REAR CARRIER ASSEMBLY
Fig. 102 Install Output Gear Bearing Cone
1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - TOOL 5052
4 - OUTPUT GEAR
Fig. 103 Checking Output Gear Bearings End Play
1 - TOOL L-4432
2 - DIAL INDICATOR
3 - SPECIAL SCREWS TOOL 6260
4 - OUTPUT GEAR
Fig. 104 Output Gear and (Select) Shim
1 - REAR CARRIER ASSEMBLY
2 - SHIM (SELECT)
3 - OUTPUT GEAR
21 - 190 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)

(15) Install the output gear and bearing assembly
using Tool 6261 (Fig. 105).
(16) Install NEW output gear retaining bolt and
washer (Fig. 106). Using Tool 6259, torque output
gear retaining bolt to 271 N´m (200 ft. lbs.) (Fig.
107).(17) Using an inch pound torque wrench (Fig.
108), check output shaft turning torque.Output
shaft turning torque should be within 3-8 in.
lbs.If the turning torque is too high, install a 0.04
mm (0.0016 in.) thicker shim. If the turning torque is
too low, install a 0.04 mm (0.0016 in.) thinner shim.
Repeat until the proper turning torque of 3-8 in. lbs.
is obtained.
Fig. 105 Install Output Gear
1 - WRENCHES
2 - TOOL 6261 WITH STUD
3 - OUTPUT GEAR
Fig. 106 Output Gear Bolt and Washer
1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
Fig. 107 Tighten Output Gear to 271 N²m (200 ft.
lbs.)
1 - OUTPUT GEAR
2 - TORQUE WRENCH
3 - 200 FT. LBS.
4 - TOOL 6259
Fig. 108 Check Output Gear Bearings Turning
Torque
1 - INCH-POUND TORQUE WRENCH
2 - OUTPUT GEAR
21 - 192 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)

(18) Install output gear stirrup with serrated side
out (Fig. 109).
(19) Install retaining strap.
(20) Install strap bolts but do not tighten at this
time (Fig. 110).(21) Rotate stirrup clockwise against flats of
retaining bolt (Fig. 111).
(22) Torque stirrup strap bolts to 23 N´m (200 in.
lbs.) (Fig. 112).
Fig. 109 Install Stirrup
1 - STIRRUP
2 - OUTPUT GEAR RETAINING BOLT
Fig. 110 Install Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
Fig. 111 Turn Stirrup Clockwise Against Bolt Flats
1 - RETAINING STRAP
2 - STIRRUP
Fig. 112 Tighten Stirrup Strap Bolts To 23 N´m
(200 in. lbs.)
1 - RETAINING STRAP
2 - STIRRUP
RSAUTOMATIC - 41TE21 - 193
AUTOMATIC - 41TE (Continued)

(32) Install the transfer shaft gear using Tool 6261
(Fig. 122).
CAUTION: Install a NEW retaining nut, as the origi-
nal nut MUST NOT be reused.
(33) Install the new retaining nut and washer.
(34) Using Tool 6259, torque transfer gear retain-
ing nut to 271 N´m (200 ft. lbs.) (Fig. 123).(35) Measure transfer shaft end play.Transfer
shaft end play should be within 0.05-0.10 mm
(0.002-0.004 in.).If the end play is too high, install a
0.04 mm (0.0016 in.) thicker shim. If the end play is
too low, install a 0.04 mm (0.0016 in.) thinner shim.
Repeat until 0.05-0.10 mm (0.002-0.004 in.) end play
is obtained.
(36) Install a bead of Moparž Silicone Rubber
Adhesive Sealant to transfer gear cover (Fig. 124).
(37) Install transfer gear cover-to-case bolts and
torque to 20 N´m (175 in. lbs.) torque (Fig. 125).
Fig. 122 Install Transfer Shaft Gear
1 - WRENCHES
2 - SPECIAL TOOL 6261
3 - OUTPUT GEAR
4 - TRANSFER SHAFT GEAR
Fig. 123 Tighten Transfer Gear Nut to 271 N²m (200
ft. lbs.)
1 - TRANSFER SHAFT GEAR
2 - 200 FT. LBS.
3 - TORQUE WRENCH
4 - SPECIAL TOOL 6259
Fig. 124 Install Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPAR SILICONE RUBBER ADHESIVE
SEALANT AS SHOWN
Fig. 125 Install Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
21 - 198 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)

(55) Install cooler bypass valve with o-ring end
towards rear of case (Fig. 148).
(56) Install oil pump gasket (Fig. 149).(57) Install oil pump assembly (Fig. 150).
(58) Install oil pump-to-case bolts and torque to 27
N´m (20 ft. lbs.) (Fig. 151).
Fig. 148 Install Cooler Bypass Valve
1 - COOLER BYPASS VALVE
Fig. 149 Install Oil Pump Gasket
1 - PUMP GASKET
Fig. 150 Install Oil Pump
1 - OIL PUMP
2 - GASKET
Fig. 151 Install Pump-to-Case Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
RSAUTOMATIC - 41TE21 - 205
AUTOMATIC - 41TE (Continued)

(63) Install valve body to transaxle (Fig. 158).
Rotate manual valve shaft fully clockwise to ease
installation. Make sure park rod rollers are posi-
tioned within park guide bracket.
(64) Install and torque valve body-to-case bolts to
12 N´m (105 in. lbs.) (Fig. 159).
Fig. 156 Accumulator (Overdrive)
1 - ACCUMULATOR PISTON (OVERDRIVE)
2 - RETURN SPRING
3 - SEAL RING
4 - SEAL RING
Fig. 157 Install Underdrive and Overdrive
Accumulators
1 - RETURN SPRING
2 - UNDERDRIVE CLUTCH ACCUMULATOR
3 - SEAL RING (2)
4 - OVERDRIVE CLUTCH ACCUMULATOR
Fig. 158 Install Valve Body
1 - VALVE BODY
Fig. 159 Install Valve Body-to-Case Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
RSAUTOMATIC - 41TE21 - 207
AUTOMATIC - 41TE (Continued)

(65) Install oil filter and new o-ring (Fig. 160).
(66) Apply an 1/8º bead of Moparž Silicone Rubber
Adhesive Sealant to oil pan and immediately install
to case (Fig. 161).
(67) Install oil pan-to-case bolts and torque to 19
N´m (165 in. lbs.).
(68) Install solenoid/pressure switch assembly and
gasket to case (Fig. 162).(69) Install and tighten solenoid/pressure switch
assembly-to-transaxle case bolts to 12 N´m (110 in.
lbs.) (Fig. 163).
(70) Install and torque input and output speed
sensors to case to 27 N´m (20 ft. lbs.).
Fig. 160 Install Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 161 Install Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 162 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 163 Attaching Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
21 - 208 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)

INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perfrom the TCM Quick Learn proce-
dure. (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
NOTE: If torque converter assembly has been
replaced, it is necessary to reset the TCC Break-In
Strategy. (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
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. 164).
(3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 164).
(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) Install rear mount and bracket assembly into
position (Fig. 165).
(12) Install and torque rear mount bolts to 54 N´m
(40 ft. lbs.) (Fig. 166).
(13) Lower vehicle.
(14) Install and torque rear mount bracket-to-tran-
saxle vertical bolts (Fig. 165) to 102 N´m (75 ft. lbs.).
(15) Raise vehicle.
(16) Install rear mount bracket-to-transaxle hori-
zontal bolt (Fig. 165) and torque to 102 N´m (75 ft.
lbs.).
(17) Install rear mount thru-bolt and torque to 54
N´m (40 ft. lbs.) (Fig. 166).
(18) Install rear mount heat shield (Fig. 167).
(19) AWD models: Install power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - INSTALLATION)
(20) Install cradle plate.
(21) Install exhaust pipe to manifold (Fig. 168).
(22) Install left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
(23) Install front wheel/tire assemblies.
(24) Lower vehicle.
(25) Install transaxle upper bellhousing-to-block
bolts and torque to 95 N´m (70 ft. lbs.).
(26) Install wiper module assembly. (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION)
(27) Connect crank position sensor (if equipped).
(28) Connect gearshift cable to upper mount
bracket and transaxle manual valve lever (Fig. 169).
(29) Connect solenoid/pressure switch assembly
(Fig. 170).
(30) Connect transmission range sensor connector
(Fig. 170).
(31) Connect input and output speed sensor con-
nectors (Fig. 170).
(32) Remove plugs and install transaxle oil cooler
line service splice kit. Refer to instructions included
with kit.
(33) Remove plug and Install fluid level indicator/
tube assembly.
(34) Install coolant recovery bottle (Fig. 171).
(35) Install battery shield.
(36) Connect battery cables.
(37) Fill transaxle with suitable amount of ATF+4
(Automatic Transmission FluidÐType 9602). (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE/FLUID - STANDARD PROCEDURE)
Fig. 164 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
RSAUTOMATIC - 41TE21 - 209
AUTOMATIC - 41TE (Continued)

SPECIFICATIONS
SPECIFICATIONS - 41TE TRANSAXLE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Transaxle TypeFully adaptive, electronically controlled, four speed
automatic with torque converter and integral differential
Cooling Method Air-to-oil heat exchanger
Lubrication Pump (internal-external gear-type
GEAR RATIOS
DESCRIPTION SPECIFICATION
First Gear 2.84
Second Gear 1.57
Direct Gear 1.00
Overdrive Gear 0.69
Reverse Gear 2.21
BEARING SETTINGS (END PLAY & TURNING TORQUE)
DESCRIPTION METRIC STANDARD
Differential Assembly 0.6-2 N´m 5-18 in. lbs.
Output Hub 0.3-2 N´m 3-8 in. lbs.
Transfer Shaft (End Play) 0.051-0.102 mm 0.002-0.004 in.
Overall Drag At Output Hub 0.3-1.9 N´m 3-16 in. lbs.
CLUTCH CLEARANCES
DESCRIPTION METRIC STANDARD
Low/Rev Clutch (Select Reaction
Plate)0.89-1.47 mm 0.035-0.058 in.
Two/Four Clutch (No Selection) 0.76-2.64 mm 0.030-0.104 in.
Reverse Clutch (Select Snap Ring) 0.89-1.37 mm 0.035-0.054 in.
Overdrive Clutch (No Selection) 1.07-3.25 mm 0.042-0.128 in.
Underdrive Clutch (Select Pressure
Plate)0.94-1.50 mm 0.037-0.059 in.
OIL PUMP CLEARANCES
DESCRIPTION METRIC STANDARD
Outer Gear To Pocket 0.045-0.141 mm 0.0018-0.0056 in.
Outer Gear Side Clearance 0.020-0.046 mm 0.0008-0.0018 in.
Inner Gear Side Clearance 0.020-0.046 mm 0.0008-0.0018 in.
RSAUTOMATIC - 41TE21 - 225
AUTOMATIC - 41TE (Continued)

INPUT SHAFT
DESCRIPTION METRIC SPECIFICATION
End Play 0.127-0.635mm 0.005-0.025 in.
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt, Differential
Cover-to-Case19 Ð 165
Bolt, Differential Ring
Gear-to-Case95 70 Ð
Bolt, Differential Bearing
Retainer-to-Case28 21 Ð
Bolt, Driveplate-to-
Crankshaft95 70 Ð
Bolt, Extension Housing/
Plate-to-Case28 21 Ð
Bolt, Oil Pan-to-Case 19 Ð 165
Bolt, Output Gear 271 200 Ð
Bolt, Output Gear
Stirrup/Strap23 17 Ð
Bolt, Oil Pump-to-Case 27 20 Ð
Bolt, Reaction Support-to-
Case27 20 Ð
Bolt, Solenoid/Pressure
Switch Assy.-to-Case12 Ð 110
Bolt, Torque Converter-to-
Driveplate75 55 Ð
Bolt, Transfer Gear Cover 20 Ð 175
Bolt, Valve Body-to-Case 12 Ð 105
Fitting, Oil Cooler Line 12 Ð 105
Nut, Tranfer Gear 271 200 Ð
Tap, Transaxle Pressure 5 Ð 45
Screw, L/R Clutch
Retainer5Ð45
Screw, Solenoid/Pressure
Switch Assy. Connector4Ð35
Screw, Valve Body-to-
Transfer Plate5Ð45
Sensor, Input Speed 27 20 Ð
Sensor, Output Speed 27 20 Ð
Sensor, Transmission
Range Sensor5Ð45
21 - 226 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)