oil CHRYSLER VOYAGER 2002 Service Manual

(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)
RS41TE AUTOMATIC TRANSAXLE21 - 207
41TE AUTOMATIC TRANSAXLE (Continued)
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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
21 - 208 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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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
RS41TE AUTOMATIC TRANSAXLE21 - 209
41TE AUTOMATIC TRANSAXLE (Continued)
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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
21 - 210 41TE AUTOMATIC TRANSAXLERS
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
21 - 212 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(20) Connect solenoid/pressure switch assembly
(Fig. 167).
(21) Connect transmission range sensor connector
(Fig. 167).
(22) Connect input and output speed sensor con-
nectors (Fig. 167).(23) Remove plugs and install transaxle oil cooler
line service splice kit. Refer to instructions included
with kit.
(24) Remove plug and Install fluid level indicator/
tube assembly.
(25) Install coolant recovery bottle (Fig. 168).
(26) Install battery shield.
(27) Connect battery cables.
(28) Fill transaxle with suitable amount of ATF+4
(Automatic Transmission FluidÐType 9602). (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE/FLUID - STANDARD PROCEDURE)
Fig. 167 Component Connector Location - Typical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 168 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
RS41TE AUTOMATIC TRANSAXLE21 - 215
41TE AUTOMATIC TRANSAXLE (Continued)
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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-Crescent 0.060-0.298 mm 0.0023-0.0117 in.
Inner Gear-to-Crescent 0.093-0.385 mm 0.0036-0.0151 in.
Outer Gear-to-Pocket 0.089-0.202 mm 0.0035-0.0079 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.
21 - 228 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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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
RS41TE AUTOMATIC TRANSAXLE21 - 229
41TE AUTOMATIC TRANSAXLE (Continued)
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SPECIAL TOOLS
41TE AUTOMATIC TRANSAXLE
Puller C-637
Pressure Gauge (High) C-3293SP
Dial Indicator C-3339
Oil Pump Puller C-3752
Seal Puller C-3981B
Universal Handle C-4171
Seal Installer C-4193A
Adapter C-4996
21 - 230 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(3) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.
(4) Using Tool L-4436A and an inch-pound torque
wrench, check the turning torque of the differential
(Fig. 209).The turning torque should be
between 5 and 18 inch-pounds.
(5) If the turning torque is within specifications,
remove tools. Setup is complete.
(6) If turning torque is not within specifications
proceed with the following steps.(a) Remove differential bearing retainer from
the transaxle case.
(b) Remove the bearing cup from the differential
bearing retainer using Tool 6062A.
(c) Remove the existing shim from under the
cup.
(d) Measure the existing shim.
(e) If the turning torque was too high when mea-
sured, install a 0.05 mm (0.002 inch) thinner shim.
If the turning torque is was too low, install a 0.05
mm (0.002 inch) thicker shim. Repeat until 5-18
inch-pounds turning torque is obtained. Oil Baffle
is not required to be installed when making shim
selection.
(f) Install the proper shim under the bearing
cup. Make sure the oil baffle is installed properly
in the bearing retainer, below the bearing shim
and cup.
(g) Install the differential bearing retainer using
Tool 5052 and C-4171. Seal the retainer to the
housing with MOPARtSilicone Rubber Adhesive
Sealant and torque bolts to 28 N´m (250 in. lbs.).
(7) Using Tool L-4436A and an inch-pound torque
wrench, recheck the turning torque of the differential
(Fig. 209).The turning torque should be within
5-18 inch-pounds.
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Differential carrier
²Differential bearing retainer
²Extension housing
²Differential bearing cups and cones
Fig. 209 Checking Differential Bearings Turning
Torque
1 - SPECIAL TOOL L-4436±A
2 - TORQUE WRENCH
RS41TE AUTOMATIC TRANSAXLE21 - 247
FINAL DRIVE (Continued)
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