electronic control modules CHRYSLER VOYAGER 2003 Workshop Manual

(66) Remove low/reverse piston retainer-to-case
gasket (Fig. 84).
(67) Using a hammer and suitable drift, drive out
inner output bearing cup (Fig. 85).(68) Using tool 6062, remove outer output bearing
cup (Fig. 86).
ASSEMBLY
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/PCM Quick Learn
procedure must be performed. (Refer to 8 - ELEC-
TRICAL/ELECTRONIC CONTROL MODULES/TRANS-
MISSION CONTROL MODULE - STANDARD
PROCEDURE)
(1) Install both output bearing cups using Tool
5050 (Fig. 87).
Fig. 84 Remove Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Fig. 85 Remove Output Bearing Inner Cup
1 - OUTPUT BEARING CUPS (REPLACE IN PAIRS)
2 - HAMMER
3 - BRASS DRIFT
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
21 - 144 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(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. 161).
(69) Install and tighten solenoid/pressure switch
assembly-to-transaxle case bolts to 12 N´m (110 in.
lbs.) (Fig. 162).(70) Install and torque input and output speed
sensors to case to 27 N´m (20 ft. lbs.).
INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perfrom the TCM Quick Learn proce-
dure. (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Using a transmission jack and a helper, posi-
tion transaxle assembly to engine. Install and torque
bellhousing bolts to 95 N´m (70 ft. lbs.).
(2) Install upper mount assembly to transaxle and
torque bolts to 54 N´m (40 ft. lbs.) (Fig. 163).
(3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 163).
(4) Remove transmission jack and screw jack.
(5) Secure left wheelhouse splash shield.
(6) Install torque converter-to-drive plate bolts and
torque to 88 N´m (65 ft. lbs.)
(7) Install inspection cover.
(8) Install lateral bending brace.
(9) Install starter motor.
(10) Install front mount/bracket assembly.
Fig. 161 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 162 Attaching Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
Fig. 163 Left Mount to Bracket and Transaxle
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
21 - 166 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

PRESSURE SWITCHES
The PCM/TCM relies on three pressure switches to
monitor fluid pressure in the L/R, 2/4, and OD
hydraulic circuits. The primary purpose of these
switches is to help the PCM/TCM detect when clutch
circuit hydraulic failures occur. The range for the
pressure switch closing and opening points is 11-23
psi. Typically the switch opening point will be
approximately one psi lower than the closing point.
For example, a switch may close at 18 psi and open
at 17 psi. The switches are continuously monitored
by the PCM/TCM for the correct states (open or
closed) in each gear as shown in the following chart:
PRESSURE SWITCH STATES
GEAR L/R 2/4 OD
ROPOPOP
P/N CL OP OP
1st CL OP OP
2nd OP CL OP
DOPOPCL
OD OP CL CL
OP = OPEN
CL = CLOSED
A Diagnostic Trouble Code (DTC) will set if the
PCM/TCM senses any switch open or closed at the
wrong time in a given gear.
The PCM/TCM also tests the 2/4 and OD pressure
switches when they are normally off (OD and 2/4 are
tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd
gear). The test simply verifies that they are opera-
tional, by looking for a closed state when the corre-
sponding element is applied. Immediately after a
shift into 1st, 2nd, or 3rd gear with the engine speed
above 1000 rpm, the PCM/TCM momentarily turns
on element pressure to the 2/4 and/or OD clutch cir-
cuits to identify that the appropriate switch has
closed. If it doesn't close, it is tested again. If the
switch fails to close the second time, the appropriate
Diagnostic Trouble Code (DTC) will set.
REMOVAL
NOTE: If solenoid/pressure switch assembly is
being replaced, it is necessary to perform the TCM
Quick Learn Procedure. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly.(3) Disconnect solenoid/pressure switch assembly
connector.
(4) Disconnect input speed sensor connector.
(5) Remove input speed sensor (Fig. 305).
(6) Remove three (3) solenoid/pressure switch
assembly-to-transaxle case bolts (Fig. 306).
(7) Remove solenoid/pressure switch assembly and
gasket (Fig. 307). Use care to prevent gasket mate-
rial and foreign objects from become lodged in the
transaxle case ports.
Fig. 305 Input Speed Sensor
1 - INPUT SPEED SENSOR
Fig. 306 Solenoid/Pressure Switch Assembly-to-
Case Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
21 - 238 41TE AUTOMATIC TRANSAXLERS
SOLENOID/PRESSURE SWITCH ASSY (Continued)
ProCarManuals.com

INSTALLATION
NOTE: If solenoid/pressure switch assembly is
being replaced, it is necessary to perform the TCM
Quick Learn Procedure. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install solenoid/pressure switch assembly and
new gasket to transaxle (Fig. 307).
(2) Install and torque three (3) bolts (Fig. 306) to
13 N´m (110 in. lbs.).
(3) Install input speed sensor (Fig. 305) and torque
to 27 N´m (20 ft. lbs.).
(4) Connect input speed sensor connector.
(5) Install solenoid/pressure switch 8-way connec-
tor and torque to 4 N´m (35 in. lbs.).
(6) Install air cleaner assembly.
(7) Connect battery negative cable.
(8) If solenoid/pressure switch assembly was
replaced, perform TCM Quick Learn procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
SPEED SENSOR - INPUT
DESCRIPTION
The Input Speed Sensor is a two-wire magnetic
pickup device that generates AC signals as rotation
occurs. It is threaded into the transaxle case (Fig.
308), sealed with an o-ring (Fig. 309), and is consid-
ered a primary input to the Powertrain/Transmission
Control Module.
Fig. 307 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 308 Input Speed Sensor Location
1 - INPUT SPEED SENSOR
Fig. 309 O-Ring Location
1 - INPUT SPEED SENSOR
2 - O-RING
RS41TE AUTOMATIC TRANSAXLE21 - 239
SOLENOID/PRESSURE SWITCH ASSY (Continued)
ProCarManuals.com

MANUAL VALVE
The manual valve is operated by the mechanical
shift linkage. Its primary responsibility is to send
line pressure to the appropriate hydraulic circuits
and solenoids. The valve has three operating ranges
or positions.
CONVERTER CLUTCH SWITCH VALVE
The main responsibility of the converter clutch
switch valve is to control hydraulic pressure applied
to the front (off) side of the converter clutch piston.
Line pressure from the regulator valve is fed to the
torque converter regulator valve, where it passes
through the valve, and is slightly regulated. The
pressure is then directed to the converter clutch
switch valve and to the front side of the converter
clutch piston. This pressure pushes the piston back
and disengages the converter clutch.
CONVERTER CLUTCH CONTROL VALVE
The converter clutch control valve controls the
back (on) side of the torque converter clutch. When
the PCM/TCM energizes or modulates the LR/CC
solenoid to apply the converter clutch piston, both
the converter clutch control valve and the converter
control valve move, allowing pressure to be applied to
the back side of the clutch.
T/C REGULATOR VALVE
The torque converter regulator valve slightly regu-
lates the flow of fluid to the torque converter.
LOW/REVERSE SWITCH VALVE
The low/reverse clutch is applied from different
sources, depending on whether low (1st) gear or
reverse is selected. The low/reverse switch valve
alternates positions depending on from which direc-
tion fluid pressure is applied. By design, when the
valve is shifted by fluid pressure from one channel,
the opposing channel is blocked. The switch valve
alienates the possibility of a sticking ball check, thus
providing consistent application of the low/reverse
clutch under all operating conditions.
REMOVAL
NOTE: If valve body is replaced or reconditioned,
the TCM Quick Learn Procedure must be per-
formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)(1) Disconnect battery negative cable.
(2) Disconnect gearshift cable from manual valve
lever.
(3) Remove manual valve lever from manual shaft.
(4) Raise vehicle on hoist.
(5) Remove oil pan bolts (Fig. 332).
(6) Remove oil pan (Fig. 333).
Fig. 332 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 333 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
RS41TE AUTOMATIC TRANSAXLE21 - 251
VALVE BODY (Continued)
ProCarManuals.com

(15) Remove remaining retainers as shown in (Fig.
352).(16) Remove valves and springs as shown in (Fig.
353).
NOTE: Refer to Valve Body Cleaning and Inspection
for cleaning procedures.
ASSEMBLY
NOTE: If valve body assembly is reconditioned, the
PCM/TCM Quick Learn Procedure must be per-
formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Install valves and springs as shown in (Fig.
353).
Fig. 353 Springs and Valves Location
1 - VALVE BODY 5 - MANUAL VALVE
2 - T/C REGULATOR VALVE 6 - CONVERTER CLUTCH SWITCH VALVE
3 - L/R SWITCH VALVE 7 - SOLENOID SWITCH VALVE
4 - CONVERTER CLUTCH CONTROL VALVE 8 - REGULATOR VALVE
Fig. 352 Valve Retainer Location
1 - RETAINER
2 - RETAINER
RS41TE AUTOMATIC TRANSAXLE21 - 257
VALVE BODY (Continued)
ProCarManuals.com

(16) Install manual shaft seal (Fig. 368).
INSTALLATION
NOTE: If valve body assembly is being replaced or
reconditioned, it is necessary to perform the TCM
Quick Learn Procedure. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install valve body assembly to transaxle (Fig.
369). Install and torque valve body-to-transaxle case
bolts (Fig. 370) to 12 N´m (105 in. lbs.).(2) Install transaxle oil filter (Fig. 371). Inspect
the o-ring and replace if necessary.
Fig. 368 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 369 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 370 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 371 Oil Filter
1 - OIL FILTER
2 - O-RING
21 - 262 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
ProCarManuals.com

EMISSIONS CONTROL
TABLE OF CONTENTS
page page
EMISSIONS CONTROL
DESCRIPTION
DESCRIPTION - VEHICLE EMISSION
CONTROL INFORMATION LABEL..........1
DESCRIPTION - TRIP DEFINITION.........1
DESCRIPTION - MONITORED COMPONENT . 1
OPERATION - NON-MONITORED CIRCUITS . . 5
DESCRIPTION - MONITORED SYSTEMS....6DESCRIPTION - HIGH AND LOW LIMITS....8
OPERATION
OPERATION - SYSTEM..................9
DRB IIITSTATE DISPLAY TEST MODE......9
EVAPORATIVE EMISSIONS................10
EXHAUST GAS RECIRCULATION...........21
ON-BOARD DIAGNOSTICS................24
EMISSIONS CONTROL
DESCRIPTION
DESCRIPTION - VEHICLE EMISSION CONTROL
INFORMATION LABEL
All models have a Vehicle Emission Control Infor-
mation (VECI) Label. Chrysler permanently attaches
the label in the engine compartment. It cannot be
removed without defacing information and destroying
the label.
The label contains the vehicle's emission specifica-
tions and vacuum hose routings. All hoses must be
connected and routed according to the label.
DESCRIPTION - TRIP DEFINITION
A ªTripº means vehicle operation (following an
engine-off period) of duration and driving mode such
that all components and systems are monitored at
least once by the diagnostic system. The monitors
must successfully pass before the PCM can verify
that a previously malfunctioning component is meet-
ing the normal operating conditions of that compo-
nent. For misfire or fuel system malfunction, the
MIL may be extinguished if the fault does not recur
when monitored during three subsequent sequential
driving cycles in which conditions are similar to
those under which the malfunction was first deter-
mined.
Anytime the MIL is illuminated, a DTC is stored.
The DTC can self erase only after the MIL has been
extinguished. Once the MIL is extinguished, the
PCM must pass the diagnostic test for the most
recent DTC for 40 warm-up cycles (80 warm-up
cycles for the Fuel System Monitor and the Misfire
Monitor). A warm-up cycle can best be described by
the following:
²The engine must be running²A rise of 40ÉF in engine temperature must occur
from the time when the engine was started
²Engine coolant temperature must crossover
160ÉF
²A ªdriving cycleº that consists of engine start up
and engine shut off.
Once the above conditions occur, the PCM is con-
sidered to have passed a warm-up cycle. Due to the
conditions required to extinguish the MIL and erase
the DTC, it is most important that after a repair has
been made, all DTC's be erased and the repair veri-
fied by running 1±good trip.
DESCRIPTION - MONITORED COMPONENT
There are several components that will affect vehi-
cle emissions if they malfunction. If one of these com-
ponents malfunctions the Malfunction Indicator
Lamp (Check Engine) will illuminate.
Some of the component monitors are checking for
proper operation of the part. Electrically operated
components now have input (rationality) and output
(functionality) checks. Previously, a component like
the Throttle Position sensor (TPS) was checked by
the PCM for an open or shorted circuit. If one of
these conditions occurred, a DTC was set. Now there
is a check to ensure that the component is working.
This is done by watching for a TPS indication of a
greater or lesser throttle opening than MAP and
engine rpm indicate. In the case of the TPS, if engine
vacuum is low and engine rpm is 1600 or greater and
the TPS indicates a small throttle opening, a DTC
will be set.
Any component that has an associated limp in will
set a fault after 1 trip with the malfunction present.
Refer to the Diagnostic Trouble Codes Description
Charts (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/POWERTRAIN CONTROL
MODULE - DESCRIPTION) and the appropriate
Powertrain Diagnostic Procedure Manual for diag-
nostic procedures.
RSEMISSIONS CONTROL25-1
ProCarManuals.com

OPERATION
OPERATION - SYSTEM
The Powertrain Control Module (PCM) monitors
many different circuits in the fuel injection, ignition,
emission and engine systems. If the PCM senses a
problem with a monitored circuit often enough to
indicate an actual problem, it stores a Diagnostic
Trouble Code (DTC) in the PCM's memory. If the
code applies to a non-emissions related component or
system, and the problem is repaired or ceases to
exist, the PCM cancels the code after 40 warmup
cycles. Diagnostic trouble codes that affect vehicle
emissions illuminate the Malfunction Indicator Lamp
(MIL). Refer to Malfunction Indicator Lamp in this
section.
Certain criteria must be met before the PCM
stores a DTC in memory. The criteria may be a spe-
cific range of engine RPM, engine temperature,
and/or input voltage to the PCM.
The PCM might not store a DTC for a monitored
circuit even though a malfunction has occurred. This
may happen because one of the DTC criteria for the
circuit has not been met.For example, assume the
diagnostic trouble code criteria requires the PCM to
monitor the circuit only when the engine operates
between 750 and 2000 RPM. Suppose the sensor's
output circuit shorts to ground when engine operates
above 2400 RPM (resulting in 0 volt input to the
PCM). Because the condition happens at an engine
speed above the maximum threshold (2000 rpm), the
PCM will not store a DTC.
There are several operating conditions for which
the PCM monitors and sets DTC's. Refer to Moni-
tored Systems, Components, and Non-Monitored Cir-
cuits in this section.
NOTE: Various diagnostic procedures may actually
cause a diagnostic monitor to set a DTC. For
instance, pulling a spark plug wire to perform a
spark test may set the misfire code. When a repair
is completed and verified, use the DRBIIITscan tool
to erase all DTC's and extinguish the MIL.Technicians can display stored DTC's. Refer to
Diagnostic Trouble Codes (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/POWER-
TRAIN CONTROL MODULE - DESCRIPTION). For
obtaining the DTC information, use the Data Link
Connector with the DRBIIItscan tool (Fig. 1).
DRB IIITSTATE DISPLAY TEST MODE
OPERATION
The switch inputs to the Powertrain Control Mod-
ule (PCM) have two recognized states; HIGH and
LOW. For this reason, the PCM cannot recognize the
difference between a selected switch position versus
an open circuit, a short circuit, or a defective switch.
If the State Display screen shows the change from
HIGH to LOW or LOW to HIGH, assume the entire
switch circuit to the PCM functions properly. From
the state display screen, access either State Display
Inputs and Outputs or State Display Sensors.
Fig. 1 Data Link Connector
RSEMISSIONS CONTROL25-9
EMISSIONS CONTROL (Continued)
ProCarManuals.com