clock CHRYSLER VOYAGER 2004 Service Manual

FLUID DRAIN
(1) Raise vehicle on hoist.
(2) Remove transaxle drain plug (Fig. 127) and
drain fluid into suitable container.
(3) Install drain plug and torque to 23 N´m (17 ft.
lbs.).
FLUID FILL
(1) Remove transaxle fill plug (Fig. 128).
(2) Add 2.4-2.7L (2.5-2.9 qts.) of MopartATF+4
until fluid is within 3/16º below fill hole.
(3) Install fill plug, ensuring it is properly seated.
(4) Lower vehicle.
GEARSHIFT BOOT
REMOVAL
(1) Remove gearshift knob by pushing down and
rotating1¤4-turn clockwise (Fig. 129).
(2) Remove gearshift boot from center console by
disengaging three (3) retaining clips (Fig. 130).
Fig. 127 Transaxle Drain Plug
1 - TRANSAXLE DRAIN PLUG
2 - DIFFERENTIAL COVER
Fig. 128 Transaxle Fill Plug
1 - FILL PLUG
2 - END COVER
Fig. 129 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 130 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
21 - 72 T850 MANUAL TRANSAXLERS
FLUID (Continued)

INSTALLATION
(1) Install gearshift boot to console and secure
with three (3) retaining clips (Fig. 130).
(2) Install gearshift knob (Fig. 129). Orient shift
pattern
1¤4-turn clockwise, press down, and rotate1¤4-
turn counter-clockwise.
(3) Secure gearshift boot to base of knob.
GEARSHIFT CABLE -
CROSSOVER
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4-turn clock-wise (Fig. 131).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 132).
(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
133).
Fig. 131 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 132 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 133 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
RST850 MANUAL TRANSAXLE21-73
GEARSHIFT BOOT (Continued)

(15) Install gearshift boot to console (Fig. 153).
Secure with three (3) retainer clips.
(16) Install gearshift knob to gearshift lever (Fig.
154). Orient shift pattern
1¤4-turn clockwise, push
down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(17) Connect battery negative cable.
ADJUSTMENTS
ADJUSTMENT
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4-turn clock-wise (Fig. 155).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 156).
Fig. 153 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 154 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 155 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 156 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
RST850 MANUAL TRANSAXLE21-79
GEARSHIFT CABLE - CROSSOVER (Continued)

(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
157).
(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
158).(7) Loosen crossover cable adjustment screw (Fig.
159).
(8) Rock gearshift lever back and forth between
1±2 and 5±R planes. Release lever, allowing shifter
spring to return lever to the neutral position in the
3±4 plane. Place gearshift lever in the 3rd gear posi-
tion.
(9) Torque crossover lever adjustment screw to 8
N´m (70 in. lbs.).No load should be applied to
the shifter lever in any direction (hands off)
while tightening screw.
(10) Verify gearshift lever travel through all gear
ranges with engine off (not running).
(11) Install center console assembly (Fig. 158).
Install and torque center console-to-gearshift mecha-
nism screws to 5 N´m (45 in. lbs.).
(12) Install cupholder plugs (Fig. 157).
(13) Install gearshift boot to console (Fig. 156).
Secure boot to console with three (3) retainer clips.
(14) Install gearshift knob to gearshift lever (Fig.
155). Orient shift pattern on knob
1¤4-turn clockwise,
push down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(15) Connect battery negative cable.
Fig. 157 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 158 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 159 Crossover Cable Adjustment Screw
1 - CROSSOVER CABLE
2 - ADJUSTMENT SCREW
21 - 80 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - CROSSOVER (Continued)

GEARSHIFT CABLE -
SELECTOR
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4-turn clock-wise (Fig. 160).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 161).(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
162).
(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
163).
Fig. 160 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 161 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 162 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 163 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
RST850 MANUAL TRANSAXLE21-81

(15) Install gearshift knob to gearshift lever (Fig.
183). Orient shift pattern1¤4-turn clockwise, push
down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(16) Connect battery negative cable.
GEARSHIFT KNOB
REMOVAL
(1) Separate gearshift boot from base of knob.
(2) Remove gearshift knob by pushing down and
rotating
1¤4-turn clockwise (Fig. 184).
INSTALLATION
(1) Install gearshift knob pattern1¤4-turn clock-
wise, press down, and rotate1¤4-turn counter clock-
wise (Fig. 184).
(2) Secure gearshift boot to base of knob.
GEARSHIFT MECHANISM
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4turn clock-wise (Fig. 185).
Fig. 183 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 184 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 185 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
RST850 MANUAL TRANSAXLE21-87
GEARSHIFT CABLE - SELECTOR (Continued)

(7) Install cupholder plugs (Fig. 202).
(8) Install gearshift boot to console (Fig. 203).
Secure with three (3) retainer clips.(9) Install gearshift knob to gearshift lever (Fig.
204). Orient shift pattern1¤4-turn clockwise, push
down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(10) Connect battery negative cable.
Fig. 202 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 203 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 204 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
21 - 92 T850 MANUAL TRANSAXLERS
GEARSHIFT MECHANISM (Continued)

(4) Remove oil pan-to-case bolts (Fig. 16).
(5) Remove oil pan (Fig. 17).
(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.
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
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
RS41TE AUTOMATIC TRANSAXLE21 - 127
41TE AUTOMATIC TRANSAXLE (Continued)

(18) Install output gear stirrup with serrated side
out (Fig. 108).
(19) Install retaining strap.
(20) Install strap bolts but do not tighten at this
time (Fig. 109).(21) Rotate stirrup clockwise against flats of
retaining bolt (Fig. 110).
(22) Torque stirrup strap bolts to 23 N´m (200 in.
lbs.) (Fig. 111).
Fig. 108 Install Stirrup
1 - STIRRUP
2 - OUTPUT GEAR RETAINING BOLT
Fig. 109 Install Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
Fig. 110 Turn Stirrup Clockwise Against Bolt Flats
1 - RETAINING STRAP
2 - STIRRUP
Fig. 111 Tighten Stirrup Strap Bolts To 23 N´m (200
in.) lbs.)
1 - RETAINING STRAP
2 - STIRRUP
RS41TE AUTOMATIC TRANSAXLE21 - 151
41TE AUTOMATIC TRANSAXLE (Continued)

(63) Install valve body to transaxle (Fig. 157).
Rotate manual valve shaft fully clockwise to ease
installation. Make sure park rod rollers are posi-
tioned within park guide bracket.
(64) Install and torque valve body-to-case bolts to
12 N´m (105 in. lbs.) (Fig. 158).(65) Install oil filter and new o-ring (Fig. 159).
(66) Apply an 1/8º bead of MopartATF RTV (MS-
GF41) to oil pan and immediately install to case (Fig.
160).
Fig. 157 Install Valve Body
1 - VALVE BODY
Fig. 158 Install Valve Body-to-Case Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 159 Install Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 160 Install Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPARTATF RTV (MS-GF41)
3 - OIL FILTER
RS41TE AUTOMATIC TRANSAXLE21 - 165
41TE AUTOMATIC TRANSAXLE (Continued)