oil CHRYSLER VOYAGER 2002 Service Manual

(3) Remove coolant recovery bottle (Fig. 10).
(4) Remove fluid level indicator/tube assembly.
Plug opening to prevent debris from entering trans-
axle.
(5) Using a blade or suitable hose cutter, cut trans-
axle oil cooler lines off flush with fittings. Plug lines
and fittings to prevent debris from entering transaxle
or cooler circuit. A service splice kit will be installed
upon reassembly.
(6) Disconnect input and output shaft speed sensor
connectors (Fig. 11).
(7) Disconnect transmission range sensor (TRS)
connector (Fig. 11).
(8) Disconnect solenoid/pressure switch assembly
connector (Fig. 11).
(9) Disconnect gear shift cable from manual valve
lever and upper mount bracket (Fig. 12).
(10) Disconnect crankshaft position sensor (if
equipped). Remove sensor from bellhousing.
(11) Reposition leak detection pump harness and
hoses.
(12) Remove rear mount bracket-to-transaxle case
bolts (Fig. 13).
(13) Remove transaxle upper bellhousing-to-block
bolts.
(14) Raise vehicle on hoist.
(15) Remove transaxle oil pan and drain fluid into
suitable container.
(16) Remove front wheel/tire assemblies.
(17) Remove left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - REMOVAL)
Fig. 10 Coolant Recovery Bottle
1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL
Fig. 11 Component Connector LocationÐTypical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 12 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 170 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(18) AWD models: Remove power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - REMOVAL)
(19) Remove rear mount bracket-to-transaxle case
lower (horizontal) bolt (Fig. 13).
(20) Remove front mount/bracket assembly.
(21) Remove starter motor.
(22) Remove lateral bending brace.
(23) Remove inspection cover.
(24) Remove torque converter-to-drive plate bolts.
(25) Support engine/transaxle assembly at engine
oil pan with screw jack and wood block.
(26) Partially remove left wheelhouse splash shield
to gain access to and remove upper mount thru-bolt
(Fig. 14).
(27) Lower engine/transaxle assembly with screw
jack.
(28) Obtain helper and/or transmission jack.
Secure transmission jack to transaxle assembly.
(29) Remove upper mount bracket from transaxle
(Fig. 14).
(30) Remove remaining transaxle bellhousing-to-
engine bolts.
(31) Remove transaxle assembly from vehicle.DISASSEMBLY
CAUTION: If transaxle failure has occurred, it is
necessary to flush the transaxle oil cooler and lines
to remove debris and particles that could contami-
nate and/or fail a new or rebuilt unit. (Refer to 7 -
COOLING/TRANSMISSION - STANDARD PROCE-
DURE)
NOTE: If transaxle is being overhauled (clutch
and/or seal replacement) or replaced, it is neces-
sary to perform the TCM Quick Learn Procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
NOTE: This procedure does not include final drive
(differential) disassembly.
(1) Remove input and output speed sensors.
(2) Remove three (3) solenoid/pressure switch
assembly-to-case bolts.
Fig. 13 Rear Mount Bracket - Typical
1 - BOLT - VERTICAL
2 - BRACKET - REAR MOUNT3 - BOLT - HORIZONTAL
RS41TE AUTOMATIC TRANSAXLE21 - 171
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(3) Remove solenoid/pressure switch assembly and
gasket (Fig. 15).(4) Remove oil pan-to-case bolts (Fig. 16).
(5) Remove oil pan (Fig. 17).
Fig. 14 Left Mount-to-Bracket
1 - BOLT - BRACKET TO FRAME RAIL
2 - BOLT - MOUNT TO RAIL THROUGH
3 - BOLT - LEFT MOUNT TO TRANSAXLE
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
Fig. 15 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 16 Remove Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 17 Remove Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPARTATF RTV (MS-GF41)
3 - OIL FILTER
21 - 172 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(6) Remove oil filter (Fig. 18).
(7) Turn manual valve fully clock-wise to get park
rod into position for removal.
(8) Remove valve body-to-case bolts (Fig. 19).
CAUTION: Do not handle the valve body assembly
from the manual valve. Damage can result.(9) Using a screwdriver, push park rod rollers
away from guide bracket (Fig. 20) and remove valve
body assembly (Fig. 21).
NOTE: Depending on engine application, some
accumulators will have two springs and others will
have one spring. The springs are color-coded
according to application and year. When disassem-
bling, mark accumulator spring location to ease
assembly.
Fig. 18 Remove Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 19 Remove Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 20 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
Fig. 21 Remove Valve Body
1 - VALVE BODY
RS41TE AUTOMATIC TRANSAXLE21 - 173
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(16) Remove oil pump-to-case bolts (Fig. 30).
CAUTION: Be sure input speed sensor is removed
before removing oil pump.
(17) Install pullers Tool C-3752 as shown in (Fig.
31).(18) Remove oil pump assembly (Fig. 32) (Fig. 33).
Fig. 33 Oil Pump Removed
1 - OIL PUMP
2 - GASKET
Fig. 30 Remove Pump Attaching Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 31 Install Tool C-3752
1 - PULLERS TOOL C-3752
2 - PUMP
Fig. 32 Remove Oil Pump
1 - ªPUSH INº ON INPUT SHAFT WHILE REMOVING PUMP
21 - 176 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(19) Remove oil pump gasket (Fig. 34).
CAUTION: If transaxle failure has occurred, the
cooler bypass valve must be replaced. Do not
re-use or attempt to clean valve.
(20) Remove cooler bypass valve (Fig. 35).(21) Remove #1 needle bearing (Fig. 36).
(22) Remove input clutch assembly (Fig. 37).
Fig. 34 Remove Oil Pump Gasket
1 - PUMP GASKET
Fig. 35 Remove Bypass Valve
1 - COOLER BYPASS VALVE
Fig. 36 Remove Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 37 Remove Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
RS41TE AUTOMATIC TRANSAXLE21 - 177
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(30) Remove 2/4 clutch pack (Fig. 46).Tag 2/4
clutch pack for reassembly identification.
(31) Remove tapered snap ring (Fig. 47).(32) Remove low/reverse reaction plate (Fig. 48).
(33) Remove one low/reverse clutch disc (Fig. 49).
Fig. 46 Remove 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
Fig. 47 Remove Tapered Snap Ring
1 - LOW/REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)
4 - OIL PAN FACE
5 - LONG TAB
Fig. 48 Remove Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Fig. 49 Remove One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
21 - 180 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(45) Using tool 5049A, remove transfer shaft from
transaxle (Fig. 62).
(46) Slip bearing cup retainer and oil baffle off of
shaft (Fig. 63).(47) Using tool P-334, press transfer shaft bearing
cone off of shaft (Fig. 64).
(48) Bend output gear retaining strap ears flat to
allow bolt removal.
(49) Remove output shaft stirrup strap bolts (Fig.
65).
Fig. 62 Remove Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
Fig. 63 Bearing Cup Removed
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
Fig. 64 Remove Transfer Shaft Bearing Cone
1 - ARBOR PRESS RAM
2 - TRANSFER SHAFT
3 - TOOL P-334
4 - BEARING CONE
Fig. 65 Remove Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
21 - 184 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(68) Using tool 6062, remove outer output bearing
cup (Fig. 86).
ASSEMBLY
CAUTION: If transaxle failure has occurred, it is
necessary to flush the transaxle oil cooler and lines
to remove debris and particles that could contami-
nate and/or fail a new or rebuilt unit. (Refer to 7 -
COOLING/TRANSMISSION - STANDARD PROCE-
DURE)
CAUTION: The cooler bypass valve must be
replaced if transaxle failure has occurred. Do not
attempt to reuse or clean old valve.
NOTE: If transaxle is being overhauled (clutch
and/or seal replacement), the TCM Quick Learn pro-
cedure must be performed. (Refer to 8 - ELECTRI-
CAL/ELECTRONIC CONTROL MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
(1) Install both output bearing cups using Tool
5050 (Fig. 87).
(2) Install low/reverse piston retainer gasket (Fig.
88). Make sure gasket holes line up with case.
Fig. 86 Remove Output Bearing Outer Cup
1 - TOOL 6062
Fig. 87 Install Both Output Bearing Cups
1 - OUTPUT BEARING CUPS
2 - WRENCHES
3 - TOOL 5050
Fig. 88 Install Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
21 - 190 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(23) Bend tabs on strap up against flats of bolts
(Fig. 112).
(24) Install transfer shaft bearing cone using Tool
6052 (Fig. 113).(25) Install bearing cup and oil baffle to transfer
shaft (Fig. 114).
(26) Using Tool 5049A, install transfer shaft (Fig.
115).
Fig. 112 Bend Tabs On Strap Up Against Flats Of
Bolts
1 - RETAINING STRAP TABS
2 - RETAINING STRAP
3 - STIRRUP
Fig. 113 Install Transfer Shaft Bearing Cone
1 - TOOL 6052
2 - NEW BEARING CONE
3 - TRANSFER SHAFT
4 - ARBOR PRESS RAM
Fig. 114 Install Bearing Cup to Shaft
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
Fig. 115 Install Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
21 - 198 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com