CHRYSLER VOYAGER 2002 Service Manual

(6) Install gear shift cable to transaxle upper
mount bracket (Fig. 223). An audible ªclickº should
be heard.
(7) Connect gear shift cable end to transaxle man-
ual valve lever (Fig. 223).
(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.
ADJUSTMENTS
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. 224).
(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.
Fig. 223 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 224 Gearshift Cable Adjustment
1 - GEARSHIFT CABLE ADJUSTMENT SCREW
2 - GEARSHIFT CABLE
21 - 254 41TE AUTOMATIC TRANSAXLERS
GEAR SHIFT CABLE (Continued)
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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. 225) .
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.
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. 226).
Fig. 225 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. 226 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
RS41TE AUTOMATIC TRANSAXLE21 - 255
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(3) Remove reverse clutch snap ring (Fig. 227).
(4) Pry up and remove reverse clutch reaction
plate (Fig. 228) (Fig. 229).(5) Remove the reverse clutch pack (two frictions/
one steel) (Fig. 230).
NOTE: Tag reverse clutch pack for reassembly iden-
tification.
Fig. 227 Reverse Clutch Snap Ring
1 - REACTION PLATE
2 - SCREWDRIVER
3 - REVERSE CLUTCH SNAP RING (SELECT)
Fig. 228 Pry Reverse Clutch Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
3 - SCREWDRIVER
Fig. 229 Reverse Clutch Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE (INSTALL FLAT SIDE
DOWN)
Fig. 230 Reverse Clutch Pack
1 - REVERSE CLUTCH PLATE
2 - REVERSE CLUTCH DISC
21 - 256 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)
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(6) Remove the OD/Reverse pressure plate snap
ring (Fig. 231).
(7) Remove OD/Reverse pressure plate (Fig. 232).(8) Remove OD/Reverse pressure plate wave snap
ring (Fig. 233).
(9) Remove OD shaft/hub and OD clutch pack (Fig.
234) (Fig. 235).
NOTE: Tag overdrive clutch pack for reassembly
identification.
Fig. 231 OD/Reverse Pressure Plate Snap Ring
1 - OD/REVERSE PRESSURE PLATE
2 - SCREWDRIVER
3 - OD/REVERSE PRESSURE PLATE SNAP RING
Fig. 232 OD/Reverse Pressure Plate
1 - OD/REVERSE PRESSURE PLATE (STEP SIDE DOWN)
2 - (STEP SIDE DOWN)
Fig. 233 Waved Snap Ring
1 - OVERDRIVE SHAFT ASSEMBLY
2 - OD/REVERSE CLUTCH WAVED SNAP RING
3 - SCREWDRIVER
Fig. 234 Remove OD Clutch Pack
1 - OVERDRIVE SHAFT ASSEMBLY AND OD CLUTCH PACK
2 - #3 THRUST PLATE
3 - #3 THRUST WASHER
4 - UNDERDRIVE SHAFT ASSEMBLY
RS41TE AUTOMATIC TRANSAXLE21 - 257
INPUT CLUTCH ASSEMBLY (Continued)
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(10) Remove and inspect #3 & #4 thrust washers
(Fig. 236).(11) Remove the underdrive shaft assembly (Fig.
237).
(12) Remove the #2 needle bearing (Fig. 238).
Fig. 235 Overdrive Clutch Pack
1 - OVERDRIVE CLUTCH PLATE
2 - OVERDRIVE SHAFT ASSEMBLY
3 - OVERDRIVE CLUTCH DISC
Fig. 236 #3&4 Thrust Washers
1 - #3 THRUST PLATE (3 TABS)
2 - OD SHAFT ASSEMBLY
3 - #4 THRUST PLATE (3 SLOTS)
Fig. 237 Underdrive Shaft Assembly
1 - #3 THRUST WASHER (5 TABS)
2 - UNDERDRIVE SHAFT ASSEMBLY
Fig. 238 No. 2 Needle Bearing
1 - #2 NEEDLE BEARING (NOTE 3 TABS)
21 - 258 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)
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(13) Remove the OD/UD reaction plate tapered
snap ring (Fig. 239).
NOTE: The OD/UD clutch reaction plate has a step
on both sides. Install the OD/UD clutches reaction
plate tapered step side up.
(14) Remove the OD/UD reaction plate (Fig. 240).(15) Remove the first UD clutch disc (Fig. 241).
(16) Remove the UD clutch flat snap ring (Fig.
242).
Fig. 239 OD/UD Reaction Plate Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
Fig. 240 OD/UD Reaction Plate
1 - OD/UD CLUTCH REACTION PLATE (TAPERED STEP SIDE
UP)
Fig. 241 Remove One UD Clutch Disc
1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 242 UD Clutch Flat Snap Ring
1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
RS41TE AUTOMATIC TRANSAXLE21 - 259
INPUT CLUTCH ASSEMBLY (Continued)
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NOTE: Tag underdrive clutch pack for reassembly
identification.
(17) Remove the UD clutch pack (Fig. 243).
CAUTION: Compress return spring just enough to
remove or install snap ring.
(18) Using Tool 5059A and an arbor press, com-
press UD clutch piston enough to remove snap ring
(Fig. 244) (Fig. 245).(19) Remove spring retainer (Fig. 245).
(20) Remove UD clutch piston (Fig. 246).
Fig. 243 Underdrive Clutch Pack
1 - CLUTCH PLATE
2 - ONE UD CLUTCH DISC
3 - CLUTCH DISC
Fig. 244 UD Spring Retainer Snap Ring
1 - SNAP RING PLIERS
2 - ARBOR PRESS RAM
3 - SNAP RING
4 - SPECIAL TOOL 5059A
Fig. 245 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 246 Underdrive Clutch Piston
1 - PISTON
21 - 260 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)
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(21) Remove input hub tapered snap ring (Fig.
247).
(22) Tap on input hub with soft faced hammer and
separate input hub from OD/Reverse piston and
clutch retainer (Fig. 248) (Fig. 249).(23) Separate clutch retainer from OD/Reverse pis-
ton (Fig. 250).
Fig. 247 Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
Fig. 248 Tap on Input Hub
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - PLASTIC HAMMER
Fig. 249 Input Hub Removed
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - INPUT CLUTCHES RETAINER
3 - O-RING
4 - SEAL
5 - OVERDRIVE/REVERSE PISTON
Fig. 250 Pull Retainer from Piston
1 - OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
RS41TE AUTOMATIC TRANSAXLE21 - 261
INPUT CLUTCH ASSEMBLY (Continued)
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(24) Using Tool 6057 and an arbor press, compress
return OD/Reverse piston return spring just enough
to remove snap ring (Fig. 251) (Fig. 252).(25) Remove input shaft to input clutch hub snap
ring (Fig. 253).
(26) Using a suitably sized socket and an arbor
press, remove input shaft from input shaft hub (Fig.
254).
Fig. 251 Remove Snap Ring
1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST
ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
3 - SNAP RING
4 - SPECIAL TOOL 6057
5 - OD/REVERSE PISTON
6 - RETURN SPRING
Fig. 252 Snap Ring and Return Spring
1 - OD/REVERSE PISTON
2 - RETURN SPRING
3 - SNAP RING
4 - O-RING
Fig. 253 Remove Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SHARP-POINTED TOOL
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 254 Remove Input Shaft
1 - ARBOR PRESS RAM
2 - SOCKET
3 - SEAL
4 - O-RINGS
5 - INPUT SHAFT
6 - SEAL
7 - INPUT SHAFT HUB ASSEMBLY
21 - 262 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)
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ASSEMBLY
Use petrolatum on all seals to ease assembly of
components.
(1) Using an arbor press, install input shaft to
input shaft hub (Fig. 255).
(2) Install input shaft snap ring (Fig. 256).(3) Using an arbor press and Tool 6057, Install
OD/Reverse piston return spring and snap ring (Fig.
257) (Fig. 258).
Fig. 255 Install Input Shaft
1 - INPUT SHAFT
2 - ARBOR PRESS RAM
3 - INPUT SHAFT HUB ASSEMBLY
Fig. 256 Install Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 257 Return Spring and Snap Ring
1 - OD/REVERSE PISTON
2 - RETURN SPRING
3 - SNAP RING
4 - O-RING
Fig. 258 Install Snap Ring
1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST
ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
3 - SNAP RING
4 - SPECIAL TOOL 6057
5 - OD/REVERSE PISTON
6 - RETURN SPRING
RS41TE AUTOMATIC TRANSAXLE21 - 263
INPUT CLUTCH ASSEMBLY (Continued)
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