CHRYSLER VOYAGER 2004 Service Manual

(28) Remove 2/4 clutch retainer (Fig. 44).
(29) Remove 2/4 clutch return spring (Fig. 45).(30) Remove 2/4 clutch pack (Fig. 46).Tag 2/4
clutch pack for reassembly identification.
(31) Remove tapered snap ring (Fig. 47).
Fig. 44 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 45 Remove 2/4 Clutch Return Spring
1 - 2/4 CLUTCH RETURN SPRING
Fig. 46 Remove 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
Fig. 47 Remove Tapered Snap Ring
1 - LOW/REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)
4 - OIL PAN FACE
5 - LONG TAB
21 - 134 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(32) Remove low/reverse reaction plate (Fig. 48).
(33) Remove one low/reverse clutch disc (Fig. 49).(34) Remove low/reverse reaction plate snap ring
(Fig. 50).
(35) Remove low/reverse clutch pack (Fig. 51).
Fig. 48 Remove Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Fig. 49 Remove One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
Fig. 50 Remove Low/Reverse Reaction Plate Snap
Ring
1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
Fig. 51 Remove Low/Reverse Clutch Pack
1 - CLUTCH PLATES (5)
2 - CLUTCH DISCS (5)
RS41TE AUTOMATIC TRANSAXLE21 - 135
41TE AUTOMATIC TRANSAXLE (Continued)

(36) Remove transfer gear cover-to-case bolts (Fig.
52).
(37) Remove transfer gear cover (Fig. 53).(38) Using Tool 6259, remove transfer shaft gear-
to-shaft nut and coned washer (Fig. 54) (Fig. 55).
Fig. 52 Remove Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
Fig. 53 Remove Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPARTATF RTV (MS-GF41) AS SHOWN
Fig. 54 Remove Transfer Shaft Gear Nut
1 - TRANSFER SHAFT GEAR
2 - OUTPUT GEAR
3 - SPECIAL TOOL 6259
Fig. 55 Transfer Shaft Gear Nut and Coned Washer
1 - TRANSFER SHAFT
2 - LOCK WASHER
3 - NUT
21 - 136 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(39) Using tool L-4407A, remove transfer shaft
gear (Fig. 56).
(40) Remove transfer gear shim (select) (Fig. 57).(41) Remove bearing cup retainer (Fig. 58).
(42) Remove transfer gear bearing cone using
setup shown in (Fig. 59).
Fig. 56 Remove Transfer Shaft Gear
1 - SPECIAL TOOL L4407-6
2 - TRANSFER SHAFT GEAR
3 - SPECIAL TOOL L4407A
Fig. 57 Remove Transfer Shaft Gear and (Select)
Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM (SELECT)
Fig. 58 Remove Bearing Cup Retainer
1 - ALIGN INDEXING TAB TO SLOT
2 - BEARING CUP RETAINER
Fig. 59 Remove Transfer Gear Bearing Cone
1 - WRENCHES
2 - TOOL 5048 WITH JAWS TOOL 5048±4 AND BUTTON TOOL
L-4539±2
3 - TRANSFER SHAFT GEAR
RS41TE AUTOMATIC TRANSAXLE21 - 137
41TE AUTOMATIC TRANSAXLE (Continued)

(43) Remove transfer shaft bearing cup from
retainer using Tool 6062 (Fig. 60).
(44) Using Tool 6051, remove transfer shaft bear-
ing snap ring (Fig. 61).(45) Using tool 5049A, remove transfer shaft from
transaxle (Fig. 62).
(46) Slip bearing cup retainer and oil baffle off of
shaft (Fig. 63).
Fig. 60 Remove Transfer Shaft Bearing Cup
1 - WRENCHES
2 - TOOL 6062
3 - TRANSFER SHAFT BEARING CUP RETAINER
Fig. 61 Remove Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS TOOL 6051
2 - TRANSFER SHAFT BEARING SNAP RING
3 - TRANSFER SHAFT
Fig. 62 Remove Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
Fig. 63 Bearing Cup Removed
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
21 - 138 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(47) Using tool P-334, press transfer shaft bearing
cone off of shaft (Fig. 64).
(48) Bend output gear retaining strap ears flat to
allow bolt removal.
(49) Remove output shaft stirrup strap bolts (Fig.
65).(50) Remove stirrup and strap (Fig. 66).
(51) Using Tool 6259 (Fig. 67), remove output shaft
gear-to-shaft bolt and washer (Fig. 68).
Fig. 64 Remove Transfer Shaft Bearing Cone
1 - ARBOR PRESS RAM
2 - TRANSFER SHAFT
3 - TOOL P-334
4 - BEARING CONE
Fig. 65 Remove Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
Fig. 66 Remove Stirrup Strap
1 - OUTPUT GEARBOLT
2 - RETAINING STRAP
3 - STIRRUP
Fig. 67 Remove Output Gear Bolt
1 - OUTPUT GEAR
2 - TOOL 6259
RS41TE AUTOMATIC TRANSAXLE21 - 139
41TE AUTOMATIC TRANSAXLE (Continued)

(52) Using Tool L4407A, and button 6055, remove
output gear from shaft (Fig. 69).(53) Remove output gear bearing shim (select)
(Fig. 70).
(54) Using setup as shown in (Fig. 71), remove
output gear bearing cone.
Fig. 68 Output Gear Bolt and Washer
1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
Fig. 69 Remove Output Gear
1 - OUTPUT GEAR
2 - BUTTON TOOL 6055
3 - WRENCHES
4 - TOOL L4407A
5 - BOLTS TOOL L4407±6
Fig. 70 Output Gear and (Select) Shim
1 - REAR CARRIER ASSEMBLY
2 - SHIM (SELECT)
3 - OUTPUT GEAR
Fig. 71 Remove Bearing Cone
1 - TOOL 5048 WITH JAWS 5048±5 AND BUTTON L-4539±2
2 - WRENCHES
3 - OUTPUT GEAR
21 - 140 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(55) Remove rear carrier assembly from transaxle
(Fig. 72).
(56) Remove rear carrier assembly bearing cone
using setup shown in (Fig. 73).(57) Install low/reverse spring compressor tool as
shown in (Fig. 74) (Fig. 75).
Fig. 72 Remove Rear Carrier Assembly
1 - REAR CARRIER ASSEMBLY
Fig. 73 Remove Rear Carrier Bearing Cone
1 - TOOL 5048 WITH JAWS 5048±3 AND BUTTON 6055
2 - WRENCHES
3 - REAR CARRIER ASSEMBLY
Fig. 74 Low/Reverse Spring Compressor Tool
1 - TOOL 6057
2 - TOOL 5059
3 - TOOL 5058±3
Fig. 75 Compressor Tool in Use
1 - LOW/REVERSE CLUTCH RETURN SPRING
2 - SNAP RING (INSTALL AS SHOWN)
3 - TOOL 6057
4 - TOOL 5059
5 - TOOL 5058±3
RS41TE AUTOMATIC TRANSAXLE21 - 141
41TE AUTOMATIC TRANSAXLE (Continued)

(58) Compress low/reverse piston return spring
and remove snap ring (Fig. 76).
(59) Remove low/reverse spring compressor tool
and low reverse piston return spring (Fig. 77).(60) Using a suitable punch , drive out park guide
bracket pivot shaft plug (Fig. 78).
(61) Using ordinary pliers, remove pivot shaft and
guide bracket assembly (Fig. 79).
Fig. 76 Remove Snap Ring
1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS
(AS SHOWN)
2 - SNAP RING PLIERS
3 - TOOL 6057
Fig. 77 Low/Reverse Piston Return Spring
1 - LOW/REVERSE PISTON RETURN SPRING
2 - PISTON
Fig. 78 Remove Anchor Shaft and Plug
1 - GUIDE BRACKET ANCHOR SHAFT
2 - PIVOT SHAFT
3 - ANCHOR SHAFT PLUG
Fig. 79 Pivot Shaft and Guide Bracket
1 - ANTIRACHET SPRING
2 - GUIDE BRACKET
3 - PIVOT SHAFT
4-PAWL
21 - 142 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(62) Inspect guide bracket components for exces-
sive wear and replace if necessary (Fig. 80).
(63) Remove low/reverse clutch piston (Fig. 81).(64) Remove low/reverse piston retainer-to-case
screws (Fig. 82).
(65) Remove low/reverse piston retainer (Fig. 83).
Fig. 80 Guide Bracket Disassembled
1 - ANTIRATCHET SPRING
2 - GUIDE BRACKET
3 - SPLIT SLEEVE
4 - SPACER
5-PAWL
6 - STEPPED SPACER
Fig. 81 Remove Low/Reverse Clutch Piston
1 - LOW/REVERSE CLUTCH PISTON
2 - D-RING SEAL
3 - D-RING SEAL
Fig. 82 Remove Piston Retainer Attaching Screws
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - SCREWDRIVER
3 - TORX-LOC SCREWS
Fig. 83 Remove Piston Retainer
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - GASKET
RS41TE AUTOMATIC TRANSAXLE21 - 143
41TE AUTOMATIC TRANSAXLE (Continued)