cluster CHRYSLER VOYAGER 2003 Workshop Manual

4TH GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft fourth speed gear is in constant mesh
with the intermediate shaft 3-4 cluster gear, which is
fixed to the intermediate shaft. Because of this con-
stant mesh, the input shaft fourth speed gear free-
wheels until fourth gear is selected. As the gearshiftlever is moved to the fourth gear position, the 3-4
fork moves the 3-4 synchronizer sleeve towards
fourth gear on the input shaft. The synchronizer
sleeve engages the fourth gear clutch teeth, fixing
the gear to the input shaft, and allowing power to
transmit through the intermediate shaft to the differ-
ential (Fig. 7).
Fig. 7 4th Gear Operation
21 - 28 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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INTERMEDIATE SHAFT
DESCRIPTION
The intermediate shaft assembly (Fig. 227) is part
of the transaxle geartrain, meshes with and is driven
by the input shaft, drives the differential via an inte-
grated pinion gear, and consists of the following com-
ponents:
²Intermediate Mainshaft
²1st Speed Gear
²2nd Speed Gear
²3/4 Cluster Gear
²5th Speed Gear
²Reverse Gear
²1/2 Synchronizer
²5/R Synchronizer
The intermediate shaft is supported by a caged
roller bearing at the front of the transaxle, and a
sealed roller bearing at the rear of the transaxle.DISASSEMBLY
CAUTION: Do not re-use snap rings when servicing
the intermediate shaft assembly. Discard upon dis-
assembly and install new ones provided with avail-
able snap ring service kit.
NOTE: Depending on date of transaxle manufacture,
some intermediate shafts will utilize a needle bear-
ing under the 2nd and 5th Speed Gears.
(1) Install intermediate shaft assembly to arbor
press table with bearing splitter P-334 under the
reverse gear.
Fig. 227 Intermediate Shaft Assembly
1 - INTERMEDIATE SHAFT 10 - SNAP RING
2 - ROLLER BEARING 11 - SEALED ROLLER BEARING
3 - SNAP RING 12 - THRUST WASHER
4 - NEEDLE BEARING 13 - NEEDLE BEARING
5 - 1ST SPEED GEAR 14 - REVERSE GEAR
6 - SNAP RING 15 - SNAP RING
7 - 2ND SPEED GEAR 16 - 5/R SYNCHRO
8 - 3/4 CLUSTER GEAR 17 - 5TH SPEED GEAR
9 - SNAP RING 18 - 1/2 SYNCHRO
21 - 100 T850 MANUAL TRANSAXLERS
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(7) Remove 5th gear blocker ring (Fig. 232).
(8) Remove 5th gear and needle bearing (if
equipped) (Fig. 233).(9) Remove 3/4 cluster gear snap ring (Fig. 234).
(10) Install shaft assembly into fixture 8483, with
split collar 8483-3 oriented chamfer side up (Fig.
235). Place 8483-2 into position with chamfer side up
(Fig. 236).
Fig. 232 5th Gear Blocker Ring
1 - 5th GEAR BLOCKER RING
Fig. 233 5th Gear
1 - 5th GEAR
Fig. 234 3/4 Cluster Gear Snap Ring
1 - SNAP RING
Fig. 235 Fixture 8483
1 - FIXTURE 8483
2 - COLLAR 8483-3
21 - 102 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)
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(11) Using an arbor press, press intermediate shaft
out of 3/4 cluster gear (Fig. 237).
(12) Remove intermediate shaft from fixture and
remove 3/4 cluster gear from shaft (Fig. 238).
(13) Remove 2nd gear and needle bearing (if
equipped) (Fig. 239).
Fig. 236 Loading Intermediate Shaft
1 - FIXTURE 8483
2 - 3/4 CLUSTER GEAR
3 - COLLAR 8483-2
Fig. 237 Press Intermediate Shaft Out of 3/4 Cluster
Gear
1 - ARBOR PRESS RAM
2 - INTERMEDIATE SHAFT
3 - 3/4 CLUSTER GEAR
4 - FIXTURE 8483
Fig. 238 3/4 Cluster Gear
1 - 3/4 CLUSTER GEAR
2 - INTERMEDIATE SHAFT
Fig. 239 2nd Gear Removal
1 - 2ND GEAR
2 - INTERMEDIATE SHAFT
RST850 MANUAL TRANSAXLE21 - 103
INTERMEDIATE SHAFT (Continued)
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ASSEMBLY
NOTE: Depending on date of transaxle manufacture,
some intermediate shafts will utilize a needle bear-
ing under 2nd and 5th Speed Gears.
NOTE: Do not re-use snap rings when servicing the
intermediate shaft assembly. Discard snap rings
and install new ones provided with available snap
ring service kit.NOTE: When installing 1/2 & 5/R synchronizers,
make sure to align oil slots on synchronizer hub
face with oil hold in the shaft splined hub journal.
NOTE: Refer to (Fig. 252) for intermediate shaft
assembly reference.
Fig. 252 Intermediate Shaft Assembly
1 - INTERMEDIATE SHAFT 10 - SNAP RING
2 - ROLLER BEARING 11 - SEALED ROLLER BEARING
3 - SNAP RING 12 - THRUST WASHER
4 - NEEDLE BEARING 13 - NEEDLE BEARING
5 - 1ST SPEED GEAR 14 - REVERSE GEAR
6 - SNAP RING 15 - SNAP RING
7 - 2ND SPEED GEAR 16 - 5/R SYNCHRO
8 - 3/4 CLUSTER GEAR 17 - 5TH SPEED GEAR
9 - SNAP RING 18 - 1/2 SYNCHRO
RST850 MANUAL TRANSAXLE21 - 107
INTERMEDIATE SHAFT (Continued)
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(9) Install 2nd gear friction cone (Fig. 261).
(10) Install 2nd gear reactor ring (Fig. 262).
(11) Install 2nd gear and needle bearing (if
equipped) to intermediate shaft (Fig. 263).
(12) Press 3/4 cluster gear onto intermediate shaft
using cup 8481 (Fig. 264).
Fig. 261 2nd Gear Friction Cone
1 - 2ND GEAR FRICTION CONE
Fig. 262 2nd Gear Reactor Ring
1 - 2ND GEAR REACTOR RING
Fig. 263 2nd Gear
1 - 2ND GEAR
2 - INTERMEDIATE SHAFT
Fig. 264 Install 3/4 Cluster Gear using Tool 8481
1 - ARBOR PRESS
2 - INSTALLER 8481
3 - 3/4 CLUSTER GEAR
21 - 110 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)
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(13) InstallNEW3/4 cluster gear snap ring (Fig.
265).
(14) Install 5th gear and needle bearing (if
equipped) to intermediate shaft (Fig. 266).(15) Install 5th gear blocker ring to synchronizer
(Fig. 267).
(16) Install 5th gear synchronizer assembly to
intermediate shaft (Fig. 268).When installing 5/R
synchronizer, make sure to align oil slots on
synchronizer hub face with oil hole in the shaft
splined hub journal.
Fig. 265 3/4 Cluster Gear Snap Ring
1 - SNAP RING
Fig. 266 5th Gear Installation
1 - 5th GEAR
Fig. 267 5th Gear Blocker Ring to Synchro
1 - 5th GEAR BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 268 Install 5/R Synchro and 5th Blocker Ring to
5th Gear
1 - 5/R SYNCHRONIZER
2 - 5TH GEAR BLOCKER RING
3 - 5TH GEAR
RST850 MANUAL TRANSAXLE21 - 111
INTERMEDIATE SHAFT (Continued)
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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.
AUTOSTICK SWITCH
DESCRIPTION
Autostick is a driver-interactive transaxle feature
that offers manual gear shifting capability. The control
switch is part of the transaxle gear shift lever as
shown in (Fig. 171). It can only be serviced by replac-
ing the gearshift lever assembly. (Refer to 19 - STEER-
ING/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
Fig. 169 Low/Reverse Accumulator Assembly
1 - ACCUMULATOR PISTON
2 - SEAL RINGS
3 - RETURN SPRINGS
4 - (NOTE NOTCH)
Fig. 170 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - SPRINGS
5 - SEALS
6 - PISTON
Fig. 171 Autostick Switch Location (if equipped)
RS41TE AUTOMATIC TRANSAXLE21 - 189
ACCUMULATOR (Continued)
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Moving the switch up causes an upshift and moving
the switch down causes a downshift. The instrument
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 operable in 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 schedule.
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. 172). The input clutch assembly also
contains:
²Input shaft
²Input hub
²Clutch retainer
²Underdrive piston
²Overdrive/reverse piston
²Overdrive hub
²Underdrive hub
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.
Fig. 172 Input Clutch Assembly
1 - INPUT SHAFT
2 - UNDERDRIVE CLUTCH
3 - OVERDRIVE CLUTCH
4 - REVERSE CLUTCH
5 - OVERDRIVE SHAFT
6 - UNDERDRIVE SHAFT
21 - 190 41TE AUTOMATIC TRANSAXLERS
AUTOSTICK SWITCH (Continued)
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SPEED SENSOR - OUTPUT
DESCRIPTION
The Output Speed Sensor is a two-wire magnetic
pickup device that generates an AC signal as rotation
occurs. It is threaded into the transaxle case (Fig.
313), sealed with an o-ring (Fig. 314), and is consid-
ered a primary input to the Powetrain/Transmission
Control Module.
OPERATION
The Output Speed Sensor provides information on
how fast the output shaft is rotating. As the rear
planetary carrier park pawl lugs pass by the sensor
coil (Fig. 315), an AC voltage is generated and sent to
the PCM/TCM. The PCM/TCM interprets this infor-
mation as output shaft rpm.
The PCM/TCM compares the input and output
speed signals to determine the following:
²Transmission gear ratio
²Speed ratio error detection
²CVI calculation
VEHICLE SPEED SIGNAL
The vehicle speed signal is taken from the Output
Speed Sensor. The PCM converts this signal into a
pulse per mile signal and sends the vehicle speed
message across the communication bus to the BCM.
The BCM sends this signal to the Instrument Cluster
to display vehicle speed to the driver. The vehicle
speed signal pulse is roughly 8000 pulses per mile.
REMOVAL
(1) Disconnect battery negative cable.
(2) Raise vehicle on hoist.
(3) Disconnect output speed sensor connector.
(4) Unscrew and remove output speed sensor (Fig.
316).
(5) Inspect speed sensor o-ring (Fig. 317) and
replace if necessary.
Fig. 313 Output Speed Sensor
1 - OUTPUT SPEED SENSOR
Fig. 314 O-Ring Location
1 - OUTPUT SPEED SENSOR
2 - O-RING
Fig. 315 Sensor Relation to Planet Carrier Park Pawl
1 - OUTPUT SPEED SENSOR
2 - REAR PLANET CARRIER/OUTPUT SHAFT ASSEMBLY
3 - TRANSAXLE CASE
RS41TE AUTOMATIC TRANSAXLE21 - 241
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