CHRYSLER VOYAGER 2002 Service Manual

Disk 6057
Installer 6061
Remover 6062-A
Holder 6259
Bolt 6260
Installer 6261
Tip 6268
Remover/Installer 6301
21 - 234 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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Remover/Installer 6302
Installer 6536-A
Cooler Flusher 6906A
Puller 7794-A
End Play Socket Set 8266
Input Clutch Pressure Fixture 8391
RS41TE AUTOMATIC TRANSAXLE21 - 235
41TE AUTOMATIC TRANSAXLE (Continued)
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ACCUMULATOR
DESCRIPTION
The 41te underdrive, overdrive, low/reverse, and
2/4 clutch hydraulic circuits each contain an accumu-
lator. An accumulator typically consists of a piston,
seals, return spring(s), and a cover or plug. The over-
drive and underdrive accumulators are located
within the transaxle case, and are retained by the
valve body (Fig. 169) .
The low reverse accumulator (Fig. 170) is also
located within the transaxle case, but the assembly is
retained by a cover and a snap-ring.
The 2/4 accumulator is located in the valve body. It
is retained by a cover and retaining screws (Fig. 171)
.
OPERATION
The function of an accumulator is to cushion the
application of a frictional clutch element. When pres-
surized fluid is applied to a clutch circuit, the appli-
cation force is dampened by fluid collecting in the
respective accumulator chamber against the piston
and spring(s). The intended result is a smooth, firm
clutch application.
Fig. 169 Underdrive and Overdrive Accumulators
1 - RETURN SPRING
2 - UNDERDRIVE CLUTCH ACCUMULATOR
3 - SEAL RING (2)
4 - OVERDRIVE CLUTCH ACCUMULATOR
Fig. 170 Low/Reverse Accumulator Assembly
1 - ACCUMULATOR PISTON
2 - SEAL RINGS
3 - RETURN SPRINGS
4 - (NOTE NOTCH)
Fig. 171 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - SPRINGS
5 - SEALS
6 - PISTON
21 - 236 41TE AUTOMATIC TRANSAXLERS
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AUTOSTICK SWITCH
DESCRIPTION
Autostick is a driver-interactive transaxle feature
that offers manual gear shifting capability. The con-
trol switch is part of the transaxle gear shift lever as
shown in (Fig. 172). It can only be serviced by replac-
ing the gearshift lever assembly. (Refer to 19 -
STEERING/COLUMN/GEAR SHIFT LEVER -
REMOVAL)
OPERATION
When the shift lever is moved into the Autostick
position (as indicated by the Shift Lever Position
Indicator in the cluster), the transaxle remains in
whatever gear it was using before Autostick was acti-
vated. The TCM sends a 5 volt signal through the
switch and then monitors the signal for voltage drop.
Each switch state (driver command) results in a spe-
cific voltage reading sensed by the TCM. The TCM
then determines transaxle operation (upshift/down-
shift/OD Lockout) based on their corresponding volt-
age. Refer to the following chart for corresponding
switch states and voltage readings:
Switch State Voltage Reading
Autostick DOWN
depressed0.3V-1.6V
Autostick UP depressed 1.6V-2.8V
Overdrive OFF9Lockout9
depressed2.8V-3.8V
All switches open 3.8V-4.8V
-Voltage values <.3V and >4.8V are considered
INVALID and will result in a DTC
Moving the switch up causes an upshift and mov-
ing the switch down causes a downshift. The instru-
ment cluster will illuminate the selected gear. The
vehicle can be launched in 1st, 2nd, or 3rd gear while
in the Autostick mode. The speed control is operablein 3rd and 4th gear Autostick mode. Speed control
will be deactivated if the transaxle is shifted to 2nd
gear. Shifting into OD position cancels the Autostick
mode, and the transaxle resumes the OD shift sched-
ule.
DRIVING CLUTCHES
DESCRIPTION
Three hydraulically applied input clutches are used
to drive planetary components. The underdrive, over-
drive, and reverse clutches are considered input
clutches and are contained within the input clutch
assembly (Fig. 173). The input clutch assembly also
contains:
²Input shaft
²Input hub
²Clutch retainer
²Underdrive piston
²Overdrive/reverse piston
²Overdrive hub
²Underdrive hub
Fig. 172 Autostick Switch Location (if equipped)
Fig. 173 Input Clutch Assembly
1 - INPUT SHAFT
2 - UNDERDRIVE CLUTCH
3 - OVERDRIVE CLUTCH
4 - REVERSE CLUTCH
5 - OVERDRIVE SHAFT
6 - UNDERDRIVE SHAFT
RS41TE AUTOMATIC TRANSAXLE21 - 237
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OPERATION
The three input clutches are responsible for driving
different components of the planetary geartrain.
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.
UNDERDRIVE CLUTCH
The underdrive clutch is hydraulically applied in
first, second, and third (direct) gears by pressurized
fluid against the underdrive piston. When the under-
drive clutch is applied, the underdrive hub drives the
rear sun gear.
OVERDRIVE CLUTCH
The overdrive clutch is hydraulically applied in
third (direct) and overdrive gears by pressurized fluid
against the overdrive/reverse piston. When the over-
drive clutch is applied, the overdrive hub drives the
front planet carrier.
REVERSE CLUTCH
The reverse clutch is hydraulically applied in
reverse gear only by pressurized fluid against the
overdrive/reverse piston. When the reverse clutch is
applied, the front sun gear assembly is driven.
FINAL DRIVE
DISASSEMBLY
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.
The transfer shaft should be removed for differen-
tial repair and bearing turning torque checking.
(1) Remove the differential cover and bolts (Fig.
174) (Fig. 175).
(2) Remove the differential bearing retainer and
bolts (Fig. 176) (Fig. 177).
(3) Using a plastic hammer, remove extension
housing/adapter plate on the right side of the trans-
axle.
WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
(4) Use Miller Special Tool 5048, 5048-3 Collets,
and L-4539-2 Button to remove the differential bear-
ing cone on the extension housing side.
Fig. 174 Differential Cover Bolts
1 - DIFFERENTIAL COVER BOLTS
2 - DIFFERENTIAL COVER
Fig. 175 Remove Differential Cover
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL COVER
Fig. 176 Differential Retainer Bolts
1 - DIFFERENTIAL RETAINER BOLTS
21 - 238 41TE AUTOMATIC TRANSAXLERS
DRIVING CLUTCHES (Continued)
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(5) Use Miller Special Tool 5048, 5048-4 Collets,
and L-4539-2 Button to remove the differential bear-
ing cone on the bearing retainer side (Fig. 178) (Fig.
179) (Fig. 180).
Fig. 177 Remove Bearing Retainer
1 - DIFFERENTIAL BEARING RETAINER
2 - TOOL L-4435
Fig. 178 Position Button and Collets Onto
Differential and Bearing (Ring Gear Side)
1 - SPECIAL TOOL L-4539-2
2 - SPECIAL TOOL 5048
3 - SPECIAL TOOL 5048-4
Fig. 179 Position Tool 5048 Over Button and Collets
at Differential Bearing (Ring Gear Side)
1 - SPECIAL TO0L 5048
2 - DIFFERENTIAL
3 - SPECIAL TOOL 5048-4
Fig. 180 Remove Differential Bearing Cone (Ring
Gear Side)
1 - SPECIAL TOOL 5048
2 - RING GEAR
RS41TE AUTOMATIC TRANSAXLE21 - 239
FINAL DRIVE (Continued)
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(6) Using Miller Special Tool L-4518, remove the
differential bearing race from the extension housing.
(7) Using Miller Special Tool 6062A, remove the
differential bearing race from the bearing retainer
(Fig. 181) (Fig. 182).(8) Remove ring gear-to-differential case bolts and
floating pinion shaft retainers (Fig. 183).
(9) Separate ring gear from differential case (Fig.
184).
Fig. 181 Position Bearing Cup Remover Tool in
Retainer
1 - SPECIAL TOOL 6062A
2 - DIFFERENTIAL BEARING RETAINER
Fig. 182 Remove Bearing Cup
1 - SPECIAL TOOL 6062A
2 - DIFFERENTIAL BEARING RETAINER
Fig. 183 Ring Gear-to-Case Bolts
1 - DIFFERENTIAL CASE
2 - PINION SHAFT RETAINER
3 - RING GEAR
4 - RING GEAR-TO-CASE BOLT
Fig. 184 Ring Gear Removal
1 - DIFFERENTIAL CASE
2 - RING GEAR
21 - 240 41TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)
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(10) Separate differential cover from case using
suitable screwdrivers at position shown in (Fig. 185)
(11) Lift support from case (Fig. 186).(12) Remove side gear thrust washer (Fig. 187).
(13) Remove side gear (Fig. 188).
Fig. 185 Separating Differential Support with
Screwdrivers
1 - DIFFERENTIAL SUPPORT
2 - DIFFERENTIAL CASE
3 - SCREWDRIVER
4 - RELIEF (2 @ 180É APART)
Fig. 186 Differential Support Removal
1 - DIFFERENTIAL SUPPORT
2 - DIFFERENTIAL CASE
Fig. 187 Side Gear Thrust Washer Removal
1 - SIDE GEAR THRUST WASHER
Fig. 188 Side Gear Removal
1 - DIFFERENTIAL SIDE GEAR
RS41TE AUTOMATIC TRANSAXLE21 - 241
FINAL DRIVE (Continued)
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(14) Remove pinion shaft (Fig. 189).
(15) Remove pinion gears and tabbed washers
(Fig. 190).(16) Remove differential side gear (Fig. 191).
(17) Remove side gear thrust washer (Fig. 192).
(18) Inspect all components for excessive wear.
Fig. 189 Pinion Shaft Removal
1 - PINION SHAFT
Fig. 190 Pinion Gear and Washer Removal
1 - PINION GEAR
2 - TABBED WASHER
3 - LOCATING TAB
4 - NOTCH
Fig. 191 Side Gear Removal
1 - DIFFERENTIAL SIDE GEAR
Fig. 192 Side Gear Thrust Washer Removal
1 - THRUST WASHER
21 - 242 41TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)
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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. 193).
(2) Install side gear to differential case (Fig. 194).(3) Install both pinion gears and washers to case,
while orientating washer tabs to notch in case (Fig.
195).
(4) Install pinion shaft (Fig. 196).
Fig. 193 Thrust Washer Installation
1 - THRUST WASHER
Fig. 194 Side Gear Installation
1 - DIFFERENTIAL SIDE GEAR
Fig. 195 Pinion Gear and Washer Installation
1 - PINION GEAR
2 - TABBED WASHER
3 - LOCATING TAB
4 - NOTCH
Fig. 196 Pinion Shaft Installation
1 - PINION SHAFT
RS41TE AUTOMATIC TRANSAXLE21 - 243
FINAL DRIVE (Continued)
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