clutch CHRYSLER VOYAGER 2004 Service Manual

(10) Remove and inspect OD and UD Shafts, as
well as #3 thrust washer and plate, and #2 needle
bearing (Fig. 230).
(11) Remove the OD/UD reaction plate tapered
snap ring, reaction plate, and first friction disc (Fig.
231).(12) Remove the UD clutch flat snap ring and rest
of UD clutch pack (Fig. 231).Tag clutch pack for
assembly identification.
CAUTION: Compress return spring just enough to
remove or install snap ring.
Fig. 229 Overdrive Clutch Assembly
1 - SNAP RING
2 - OD/REVERSE PRESSURE PLATE
3 - SNAP RING (WAVE)4 - CLUTCH DISC (4)
5 - CLUTCH STEEL (3)
6 - INPUT CLUTCH ASSEMBLY
21 - 210 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 230 Overdrive/Underdrive Shafts
1 - OVERDRIVE SHAFT
2 - #3 THRUST PLATE (3 TABS)
3 - #3 THRUST WASHER (5 TABS)4 - UNDERDRIVE SHAFT
5 - #2 NEEDLE BEARING (3 TABS)
6 - INPUT CLUTCH ASSEMBLY
RS41TE AUTOMATIC TRANSAXLE21 - 211
INPUT CLUTCH ASSEMBLY (Continued)

(13) Using Tool 5059A and an arbor press, com-
press UD clutch piston/spring enough to remove snap
ring (Fig. 232) (Fig. 233).
(14) Remove spring retainer, spring, and piston
(Fig. 233).
(15) Remove input hub tapered snap ring (Fig.
234) (Fig. 240).
(16) Tap on input hub with soft faced hammer and
separate input hub from OD/Reverse piston and
clutch retainer (Fig. 235).
Fig. 231 Underdrive Clutch Assembly
1 - SNAP RING (TAPERED)
2 - OD/UD REACTION PLATE
3 - CLUTCH DISC4 - SNAP RING (FLAT)
5 - CLUTCH PLATE
6 - INPUT CLUTCH ASSEMBLY
Fig. 232 UD Spring Retainer Snap Ring
1 - SNAP RING PLIERS
2 - ARBOR PRESS RAM
3 - SNAP RING
4 - SPECIAL TOOL 5059A
21 - 212 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 233 Underdrive Clutch Piston, Spring and Retainer
1 - SNAP RING
2 - SPRING RETAINER
3 - SPRING
4 - UD CLUTCH PISTON5 - SEAL, OUTER
6 - SEAL, INNER
7 - INPUT CLUTCH ASSEMBLY
Fig. 234 Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERSFig. 235 Tap on Input Hub
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - PLASTIC HAMMER
RS41TE AUTOMATIC TRANSAXLE21 - 213
INPUT CLUTCH ASSEMBLY (Continued)

(17) Separate clutch retainer from OD/Reverse pis-
ton (Fig. 236).
(18) Using Tool 6057 and an arbor press, compress
return OD/Reverse piston return spring just enough
to remove snap ring (Fig. 237).(19) Remove input shaft to input clutch hub snap
ring (Fig. 238) (Fig. 240).
(20) Using a suitably sized socket and an arbor
press, remove input shaft from input shaft hub (Fig.
239).
Fig. 236 Pull Retainer from Piston
1 - OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
Fig. 237 Remove Snap Ring
1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST
ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
3 - SNAP RING
4 - SPECIAL TOOL 6057
5 - OD/REVERSE PISTON
6 - RETURN SPRING
Fig. 238 Remove Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SHARP-POINTED TOOL
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 239 Remove Input Shaft
1 - ARBOR PRESS RAM
2 - SOCKET
3 - SEAL
4 - O-RINGS
5 - INPUT SHAFT
6 - SEAL
7 - INPUT SHAFT HUB ASSEMBLY
21 - 214 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 240 Input Clutch Hub, Retainer, and OD/Reverse Piston
1 - SNAP RING (INPUT SHAFT)
2 - SNAP RING
3 - CLUTCH RETAINER
4 - SEAL, OUTER
5 - SEAL, INNER
6 - OD/REVERSE PISTON7 - SEAL, INPUT SHAFT
8 - SHAFT, INPUT
9 - HUB
10 - SEAL
11 - SNAP RING
12 - BELLEVILLE SPRING
RS41TE AUTOMATIC TRANSAXLE21 - 215
INPUT CLUTCH ASSEMBLY (Continued)

ASSEMBLY
Use petrolatum on all seals to ease assembly of
components.
(1) Using an arbor press, install input shaft to
input shaft hub (Fig. 241).
(2) Install input shaft snap ring (Fig. 242).(3) Using an arbor press and Tool 6057, Install
OD/Reverse piston return spring and snap ring (Fig.
243) (Fig. 244).
Fig. 241 Install Input Shaft
1 - INPUT SHAFT
2 - ARBOR PRESS RAM
3 - INPUT SHAFT HUB ASSEMBLY
Fig. 242 Install Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 243 Return Spring and Snap Ring
1 - OD/REVERSE PISTON
2 - RETURN SPRING
3 - SNAP RING
4 - O-RING
Fig. 244 Install Snap Ring
1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST
ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
3 - SNAP RING
4 - SPECIAL TOOL 6057
5 - OD/REVERSE PISTON
6 - RETURN SPRING
21 - 216 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(4) Install the OD/Reverse piston assembly to the
input clutch retainer as shown in (Fig. 245).
(5) Install the input hub/shaft assy. to the OD/Re-
verse piston/clutch retainer assy. (Fig. 246).(6) Install input hub tapered snap ring (Fig. 247)
(Fig. 248).
Fig. 245 Install OD/Reverse Piston
1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
Fig. 246 Install Input Shaft Hub Assembly
1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY
(ROTATE TO ALIGN SPLINES)
2 - OD/REV. PISTON
Fig. 247 Install Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
RS41TE AUTOMATIC TRANSAXLE21 - 217
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 248 Input Clutch Hub, Retainer, and OD/Reverse Piston
1 - SNAP RING (INPUT SHAFT)
2 - SNAP RING
3 - CLUTCH RETAINER
4 - SEAL, OUTER
5 - SEAL, INNER
6 - OD/REVERSE PISTON7 - SEAL, INPUT SHAFT
8 - SHAFT, INPUT
9 - HUB
10 - SEAL
11 - SNAP RING
12 - BELLEVILLE SPRING
21 - 218 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(7) Install UD clutch piston (Fig. 249).
(8) Install UD piston return spring and Tool 5067
as shown in (Fig. 250).
(9) Using Tool 5059A and an arbor press, Install
the UD spring retainer and snap ring (Fig. 251) (Fig.
252) (Fig. 253) Compress just enough to install snap
ring.
CAUTION: Compress return spring just enough to
install snap ring.(10) Install the UD clutch pack. Leave out upper
disc, until snap ring is installed (Fig. 254).
(11) Install the UD clutch flat snap ring (Fig. 255).
Fig. 249 Underdrive Clutch Piston
1 - PISTON
Fig. 250 Seal Compressor Special Tool 5067
1 - PISTON RETURN SPRING
2 - SPECIAL TOOL 5067
3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY
Fig. 251 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 252 Install UD Spring Retainer and Snap Ring
1 - ARBOR PRESS RAM
2 - SNAP RING PLIERS
3 - SNAP RING
4 - OD/REVERSE PISTON
5 - TOOL 5067
6 - TOOL 5059A
RS41TE AUTOMATIC TRANSAXLE21 - 219
INPUT CLUTCH ASSEMBLY (Continued)