CHRYSLER VOYAGER 2004 Service Manual

(62) Remove low/reverse clutch piston (Fig. 79).
(63) Remove low/reverse piston retainer-to-case
screws (Fig. 80). (64) Remove low/reverse piston retainer (Fig. 81).
(65) Remove low/reverse piston retainer-to-case
gasket (Fig. 82).
Fig. 79 Remove Low/Reverse Clutch Piston
1 - LOW/REVERSE CLUTCH PISTON
2 - BONDED SEAL
3 - BONDED SEAL
Fig. 80 Remove Piston Retainer-to-Case Screws
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - SCREWDRIVER
3 - TORX-LOC SCREWS
Fig. 81 Remove Piston Retainer
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - GASKET
Fig. 82 Remove Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
21s - 50 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(66) Using a hammer and suitable drift, drive out
inner output bearing cup (Fig. 83).
(67) Using tool 6062, remove outer output bearing
cup (Fig. 84).
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 proce-
dure must be performed. (Refer t o 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install both output bearing cups using Tool
5050 (Fig. 85).
(2) Install low/reverse piston retainer gasket (Fig.
86). Make sure gasket holes line up with case.
Fig. 83 Remove Output Bearing Inner Cup
1 - OUTPUT BEARING CUPS (REPLACE IN PAIRS)
2 - HAMMER
3 - BRASS DRIFT
Fig. 84 Remove Output Bearing Outer
1 - TOOL 6062
Fig. 85 Install Both Output Bearing Cups
1 - OUTPUT BEARING CUPS
2 - WRENCHES
3 - TOOL 5050
Fig. 86 Install Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
RS 40TE AUTOMATIC TRANSAXLE21s-51
40TE AUTOMATIC TRANSAXLE (Continued)

(3) Install low/reverse piston retainer (Fig. 87).
(4) Install low/reverse piston retainer-to-case bolts
(Fig. 88) and torque to 5 N´m (45 in. lbs.).
NOTE: The Low/Reverse Clutch Piston has bonded
seals which are not individually serviceable. Seal
replacement requires replacement of the piston
assembly. (5) Install low/reverse clutch piston (Fig. 89).
(6) Assemble park guide bracket assembly (Fig.
91) (Fig. 90).
Fig. 87 Install Piston Retainer
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - GASKET
Fig. 88 Install Piston Retainer-to-Case Screws
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - SCREWDRIVER
3 - TORX-LOC SCREWS
Fig. 89 Install Low/Reverse Clutch Piston
1 - LOW/REVERSE CLUTCH PISTON
2 - BONDED SEAL
3 - BONDED SEAL
Fig. 90 Guide Bracket Disassembled
1 - ANTIRATCHET SPRING
2 - GUIDE BRACKET
3 - SPLIT SLEEVE
4 - SPACER
5-PAWL
6 - STEPPED SPACER
21s - 52 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(7) Install guide bracket into position and insert
pivot shaft (Fig. 92). (8) Install anchor shaft and plug (Fig. 93). Make
sure guide bracket and split sleeve are in contact
with the rear of the transaxle case.
(9) Install low/reverse piston return spring (Fig.
94).
Fig. 91 Guide Bracket
1 - GUIDE BRACKET
2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN)
3-PAWL
Fig. 92 Pivot Shaft and Guide Bracket
1 - ANTIRACHET SPRING
2 - GUIDE BRACKET
3 - PIVOT SHAFT
4-PAWL
Fig. 93 Install Anchor Shaft and Plug
1 - GUIDE BRACKET ANCHOR SHAFT
2 - PIVOT SHAFT
3 - ANCHOR SHAFT PLUG
Fig. 94 Low/Reverse Piston Return Spring
1 - LOW/REVERSE PISTON RETURN SPRING
2 - PISTON
RS 40TE AUTOMATIC TRANSAXLE21s-53
40TE AUTOMATIC TRANSAXLE (Continued)

(10) Install low/reverse spring compressor into
position (Fig. 95). Compress low/reverse piston and
install snap ring as shown in (Fig. 96). (11) Install rear carrier bearing cone using Tool
6053 (Fig. 97).
(12) Install rear carrier assembly to transaxle case
(Fig. 98).
Fig. 95 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
Fig. 96 Install Snap Ring
1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS
(AS SHOWN)
2 - SNAP RING PLIERS
3 - TOOL 6057
Fig. 97 Install Rear Carrier Bearing Cone
1 - ARBOR PRESS RAM
2 - TOOL 6053
3 - NEW BEARING CONE
4 - REAR CARRIER ASSEMBLY
Fig. 98 Install Rear Carrier Assembly
1 - REAR CARRIER ASSEMBLY
21s - 54 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(13) Install output gear bearing cone using Tool
5052 (Fig. 99).
(14) OUTPUT GEAR BEARING ADJUST-
MENT: (a) With output gear Installd, install a 4.50 mm
(0.177 in.) gauging shim (Fig. 101) on the rear car-
rier assembly hub, using grease to hold the shim in
place. (b) Using Tool 6259, install output gear and
bearing assembly. Torque to 271 N´m (200 ft. lbs.). (c) Measure bearing end play. Attach Tool L-4432
to the gear (Fig. 100). (d) Push and pull the gear while rotating back
and forth to ensure seating of bearing rollers. (e) Using a dial indicator mounted to the trans-
axle case, measure output gear end play as shown
in (Fig. 100). (f) Refer to the output gear bearing shim chart
for the required shim to obtain proper bearing set-
ting. (g) Use Tool 6259 to remove the output gear
retaining bolt and washer. To remove the output
gear, use Tool L4407A. (h) Remove the gauging shim and install the
proper shim determined by the chart. Use grease
to hold the shim in place.
Fig. 99 Install Output Gear Bearing Cone
1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - TOOL 5052
4 - OUTPUT GEAR
Fig. 100 Checking Output Gear Bearings End Play
1 - TOOL L-4432
2 - DIAL INDICATOR
3 - SPECIAL SCREWS TOOL 6260
4 - OUTPUT GEAR
Fig. 101 Output Gear and (Select) Shim
1 - REAR CARRIER ASSEMBLY
2 - SHIM (SELECT)
3 - OUTPUT GEAR
RS 40TE AUTOMATIC TRANSAXLE21s-55
40TE AUTOMATIC TRANSAXLE (Continued)

OUTPUT GEAR BEARING SHIM CHART
End Play Shim Needed Part Number End Play Shim Needed Part Number
0.05mm (0.002 in.) 4.42mm (0.174
in.) 4412830AB 0.53mm
(0.021 in.) 3.94mm (0.155
in.) 4412818AB
0.08mm (0.003 in.) 4.38mm (0.172
in.) 4412829AB 0.56mm
(0.022 in.) 3.90mm (0.154
in.) 4412817AB
0.10mm (0.004 in.) 4.38mm (0.172
in.) 4412829AB 0.58mm
(0.023 in.) 3.90mm (0.154
in.) 4412817AB
0.13mm (0.005 in.) 4.34mm (0.171
in.) 4412828AB 0.61mm
(0.024 in.) 3.86mm (0.152
in.) 4412816AB
0.15mm (0.006 in.) 4.30mm (0.169
in.) 4412827AB 0.64mm
(0.025 in.) 3.82mm (0.150
in.) 4412815AB
0.18mm (0.007 in.) 4.30mm (0.169
in.) 4412827AB 0.66mm
(0.026 in.) 3.82mm (0.150
in.) 4412815AB
0.20mm (0.008 in.) 4.26mm (0.168
in.) 4412826AB 0.69mm
(0.027 in.) 3.78mm (0.149
in.) 4412814AB
0.23mm (0.009 in.) 4.22mm (0.166
in.) 4412825AB 0.71mm
(0.028 in.) 3.74mm (0.147
in.) 4412813AB
0.25mm (0.010 in.) 4.22mm (0.166
in.) 4412825AB 0.74mm
(0.029 in.) 3.74mm (0.147
in.) 4412813AB
0.28mm (0.011 in.) 4.18mm (0.165
in.) 4412824AB 0.76mm
(0.030 in.) 3.70mm (0.146
in.) 4412812AB
0.30mm (0.012 in.) 4.14mm (0.163
in.) 4412823AB 0.79mm
(0.031 in.) 3.66mm (0.144
in.) 4412811AB
0.33mm (0.013 in.) 4.14mm (0.163
in.) 4412823AB 0.81mm
(0.032 in.) 3.66mm (0.144
in.) 4412811AB
0.36mm (0.014 in.) 4.10mm (0.161
in.) 4412822AB 0.84mm
(0.033 in.) 3.62mm (0.143
in.) 4412810AB
0.38mm (0.015 in.) 4.10mm (0.161
in.) 4412822AB 0.86mm
(0.034 in.) 3.62mm (0.143
in.) 4412810AB
0.41mm (0.016 in.) 4.06mm (0.160
in.) 4412821AB 0.89mm
(0.035 in.) 3.58mm (0.141) 4412809AB
0.43mm (0.017 in.) 4.02mm (0.158
in.) 4412820AB 0.91mm
(0.036in.) 3.54mm (0.139
in.) 4412808AB
0.46mm (0.018 in.) 4.02mm (0.158
in.) 4412820AB 0.94mm
(0.037 in.) 3.54mm (0.139
in.) 4412808AB
0.48mm (0.019 in.) 3.98mm (0.157
in.) 4412819AB 0.97mm
(0.038 in.) 3.50mm (0.138
in.) 4412807AB
0.51mm (0.020 in.) 3.94mm (0.155
in.) 4412818AB
21s - 56 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(15) Install the output gear and bearing assembly
using Tool 6261 (Fig. 102).
(16) Install NEW output gear retaining bolt and
washer (Fig. 103). Using Tool 6259, torque output
gear retaining bolt to 271 N´m (200 ft. lbs.) (Fig.
104). (17) Using an inch pound torque wrench (Fig.
105), check output shaft turning torque. Output
shaft turning torque should be within 3-8 in.
lbs. If the turning torque is too high, install a 0.04
mm (0.0016 in.) thicker shim. If the turning torque is
too low, install a 0.04 mm (0.0016 in.) thinner shim.
Repeat until the proper turning torque of 3-8 in. lbs.
is obtained.
Fig. 102 Install Output Gear
1 - WRENCHES
2 - TOOL 6261 WITH STUD
3 - OUTPUT GEAR
Fig. 103 Output Gear Bolt and Washer
1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
Fig. 104 Tighten Output Gear to 271 N²m (200 ft.
lbs.)
1 - OUTPUT GEAR
2 - TORQUE WRENCH
3 - 200 FT. LBS.
4 - TOOL 6259
Fig. 105 Check Output Gear Bearings Turning Torque
1 - INCH-POUND TORQUE WRENCH
2 - OUTPUT GEAR
RS 40TE AUTOMATIC TRANSAXLE21s-57
40TE AUTOMATIC TRANSAXLE (Continued)

(18) Install output gear stirrup with serrated side
out (Fig. 106).
(19) Install retaining strap (Fig. 107).
(20) Install strap bolts but do not tighten at this
time (Fig. 107). (21) Rotate stirrup clockwise against flats of
retaining bolt (Fig. 108).
(22) Torque stirrup strap bolts to 23 N´m (200 in.
lbs.) (Fig. 109).
Fig. 106 Install Stirrup
1 - STIRRUP
2 - OUTPUT GEAR RETAINING BOLT
Fig. 107 Install Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
Fig. 108 Turn Stirrup Clockwise Against Flats Of Output Gear Retaining Bolt
1 - RETAINING STRAP
2 - STIRRUP
Fig. 109 Tighten Stirrup Strap Bolts to 23 N´m (200 in. lbs.)
1 - RETAINING STRAP
2 - STIRRUP
21s - 58 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(23) Bend tabs on strap up against flats of bolts
(Fig. 110).
(24) Install transfer shaft bearing cone using Tool
6052 (Fig. 111). (25) Install bearing cup and oil baffle to transfer
shaft (Fig. 112).
(26) Using Tool 5049A, install transfer shaft (Fig.
113).
Fig. 110 Bend Tabs On Strap Up Against Flats Of Bolts
1 - RETAINING STRAP TABS
2 - RETAINING STRAP
3 - STIRRUP
Fig. 111 Install Transfer Shaft Bearing Cone
1 - TOOL 6052
2 - NEW BEARING CONE
3 - TRANSFER SHAFT
4 - ARBOR PRESS RAM
Fig. 112 Install Bearing Cup to Shaft
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
Fig. 113 Install Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
RS 40TE AUTOMATIC TRANSAXLE21s-59
40TE AUTOMATIC TRANSAXLE (Continued)