CHRYSLER VOYAGER 2002 Service Manual

(42) Install tapered snap ring (with tapered side
up) as shown in (Fig. 129) (Fig. 130).
(43) Set up dial indicator as shown in (Fig. 131) to
measure low/reverse clutch clearance. Press down on
clutch pack with finger and zero dial indicator.Low/
Reverse clutch pack clearance is 0.89-1.47 mm
(0.035-0.058 in.). Set up indicator and record mea-
surement in four (4) places. Take average of readings
and select the proper low/reverse reaction plate to
achieve specifications.
LOW/REVERSE REACTION PLATE CHART
PART NUMBER THICKNESS
4799846AA 5.88 mm (0.232 in.)
4799847AA 6.14 mm (0.242 in.)
4799848AA 6.40 mm (0.252 in.)
4799849AA 6.66 mm (0.262 in.)
4799855AA 6.92 mm (0.273 in.)
(44) Install 2/4 clutch pack (Fig. 132), staggering
clutch plate pads as shown in (Fig. 133).Fig. 129 Tapered Snap Ring Instructions
Fig. 130 Snap Ring Installed
1 - SCREWDRIVER
2 - TAPERED SNAP RING (INSTALL AS SHOWN)
Fig. 131 Check Low/Reverse Clutch Clearance
1 - DIAL INDICATOR
2 - DIAL INDICATOR TIP TOOL 6268
3 - HOOK TOOL
Fig. 132 Install 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
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(45) Orient 2/4 clutch return spring to retainer as
shown in (Fig. 134), and install to transaxle (Fig.
135).(46) Using tool 5058, compress 2/4 clutch return
spring just enough to install snap ring (Fig. 136).
Fig. 133 Stagger 2/4 Clutch Plate Pads
1 - PILOT PADS
2 - LUGS
Fig. 134 Proper Orientation of 2/4 Clutch Retainer
and Spring
1 - NOTE POSITION
2 - RETURN SPRING
3 - 2/4 CLUTCH RETAINER
Fig. 135 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 136 Install 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
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(47) Install snap ring.
(48) Set up dial indicator as shown in (Fig. 137)
and measure 2/4 clutch clearance. Press down on
clutch pack with finger and zero dial indicator.2/4
clutch pack clearance is 0.76-2.64 mm
(0.030-0.104 in.).Set up indicator and record mea-
surement in four (4) places. Take average of read-
ings. If clearance is outside this range, the clutch is
assembled improperly.There is no adjustment for
2/4 clutch clearance.
(49) Install rear sun gear and #7 needle bearing
(Fig. 139).
NOTE: The number seven needle bearing has three
anti-reversal tabs and is common with the number
five and number two position. The orientation
should allow the bearing to seat flat against the
rear sun gear (Fig. 138). A small amount of petrola-
tum can be used to hold the bearing to the rear sun
gear.
Fig. 137 Check 2/4 Clutch Clearance
1 - DIAL INDICATOR
2 - HOOK TOOL
3 - DIAL INDICATOR TIP TOOL 6268
Fig. 138 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 139 Install Rear Sun Gear and #7 Needle
Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
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(50) Install front carrier/rear annulus assembly
and #6 needle bearing (Fig. 140).
(51) Install front sun gear assembly and #4 thrust
washer (Fig. 141).(52)DETERMINING #4 THRUST PLATE
THICKNESS / INPUT SHAFT END PLAY:
(a) Select the thinnest #4 thrust plate thickness
and install to input clutch assembly (Fig. 142). Use
petrolatum to retain.
(b) Install input clutch assembly into position
and verify that it is completely seated by viewing
through input speed sensor hole. If view through
input speed sensor hole is not as shown in (Fig.
143), the input clutch assembly is not seated prop-
erly.
Fig. 142 Select Thinnest No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 143 View Through Input Speed Sensor Hole
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
Fig. 140 Install 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. 141 Install Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
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(c) Remove oil pump o-ring (Fig. 144).Be sure
to reinstall oil pump o-ring after selecting the
proper #4 thrust plate.
(d) Set up input shaft for measurement with
Indicator Set C3339 and End Play Set 8266 as
shown in (Fig. 145).
(e) Measure the input shaft end play with the
transaxle in the vertical position.Input shaft end
play must be within 0.005 to 0.025 inch.For
example, if end play reading is 0.055 inch, select
No. 4 Thrust Plate which is 0.071 to 0.074 thick.
This should provide an input shaft end play read-
ing of 0.020 inch which is within specifications.
(f) Refer to the No. 4 thrust plate chart to select
the proper No. 4 thrust plate:
NO. 4 THRUST PLATE CHART
PART NUMBER THICKNESS
4431665AB 1.60mm (0.063 in.)
3836237AB 1.73mm (0.068 in.)
4431666AB 1.80mm (0.071 in.)
3836238AB 1.96mm (0.077 in.)
4431667AB 2.03mm (0.080 in.)
3836239AB 2.16mm (0.085 in.)
4431668AB 2.24mm (0.088 in.)
3836240AB 2.39mm (0.094 in.)
4431669AB 2.46mm (0.097 in.)
3836241AB 2.62mm (0.103 in.)
4446670AB 2.67mm (0.105 in.)
4446671AB 2.90mm (0.114 in.)(53) Install input clutch assembly (Fig. 146).
Fig. 144 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 145 Measure Input Shaft End Play Using End
Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
Fig. 146 Install Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
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(54) Install #1 caged needle bearing (Fig. 147).
CAUTION: The cooler bypass valve must be
replaced if transaxle failure has occurred. Do not
attempt to reuse or clean old valve.
(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).
Fig. 147 Install Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
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
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(58) Install oil pump-to-case bolts and torque to 27
N´m (20 ft. lbs.) (Fig. 151).
(59) Install low/reverse accumulator (Fig. 152).(60) Install low/reverse accumulator plug (Fig.
153).
(61) Install low/reverse accumulator snap ring
(Fig. 154).
Fig. 151 Install Pump-to-Case Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 152 Install Low/Reverse Accumulator
1 - ACCUMULATOR PISTON
2 - SEAL RINGS
3 - RETURN SPRINGS
4 - (NOTE NOTCH)
Fig. 153 Install Low/Reverse Accumulator Plug
(Cover)
1 - ADJUSTABLE PLIERS
2 - PLUG
Fig. 154 Install Low/Reverse Accumulator Snap
Ring
1 - SNAP RING
2 - PLUG
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NOTE: Depending on engine application, some
accumulators will have two springs, and others will
have one spring. The springs are color-coded for
application and year.
(62) Install underdrive and overdrive accumulators
(Fig. 155) (Fig. 156) (Fig. 157).
(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.
Fig. 155 Accumulator (Underdrive)
1 - ACCUMULATOR PISTON (UNDERDRIVE)
2 - RETURN SPRINGS
3 - SEAL RING
4 - SEAL RING
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
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41TE AUTOMATIC TRANSAXLE (Continued)
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(64) Install and torque valve body-to-case bolts to
12 N´m (105 in. lbs.) (Fig. 159).
(65) Install oil filter and new o-ring (Fig. 160).(66) Apply an 1/8º bead of MopartATF RTV (MS-
GF41) 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).
Fig. 159 Install Valve Body-to-Case Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
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 MOPARTATF RTV (MS-GF41)
3 - OIL FILTER
Fig. 162 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
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(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.).
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)
(1) Using a transmission jack and a helper, posi-
tion transaxle assembly to engine. Install and torque
bellhousing 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.
Fig. 163 Attaching Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
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
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41TE AUTOMATIC TRANSAXLE (Continued)
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