CHRYSLER VOYAGER 2004 Service Manual

(2) Install regulator valve spring retainer (Fig.
329).
(3) Install dual retainer plate using Tool 6301 (Fig.
330). (4) Verify that all retainers are installed as shown
in (Fig. 331). Retainers should be flush or below
valve body surface.
(5) Install check balls into position as shown in
(Fig. 332). If necessary, secure them with petrolatum
or transmission assembly gel for assembly ease. (6) Install thermal valve into transfer plate (Fig.
333). (7) Install separator plate to valve body (Fig. 334).
Fig. 329 Install Regulator Valve Spring Retainer using Tool 6302
1 - TOOL 6302
2 - RETAINER
Fig. 330 Install Dual Retainer Plate using Tool 6301
1 - TOOL 6301
2 - RETAINER
Fig. 331 Valve Retainer Location
1 - RETAINER
2 - RETAINER
21s - 160 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

Fig. 332 Ball Check Location
1 - (#4) BALL CHECK LOCATION
2 - (#2) BALL CHECK LOCATION
3 - RETAINER4 - (#3) BALL CHECK LOCATION
5 - LOW/REVERSE SWITCH VALVE
6 - T/C LIMIT VALVE
Fig. 333 Install Thermal Valve
1 - THERMAL VALVE
Fig. 334 Install Separator Plate
1 - SEPARATOR PLATE
2 - VALVE BODY
RS
40TE AUTOMATIC TRANSAXLE21s - 161
VALVE BODY (Continued)

(8) Install the overdrive clutch (#5) check valve to
separator plate (Fig. 335)
(9) Install oil screen to separator plate (Fig. 336). (10) Install transfer plate to valve body and sepa-
rator plate. Make sure oil screen and #5 check valve
do not bind (Fig. 337).
(11) Install twenty-four transfer plate to valve
body screws (Fig. 338) and torque to 5 N´m (45 in.
lbs.).
Fig. 335 Install Overdrive Clutch (#5) Check Valve
1 - OVERDRIVE CLUTCH (#5) CHECK VALVE
Fig. 336 Install Oil Screen
1 - OIL SCREEN
Fig. 337 Install Transfer Plate
1 - TRANSFER PLATE
Fig. 338 Install Valve Body to Transfer Plate Screws
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
21s - 162 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(12) Install 2/4 Accumulator components as shown
in (Fig. 339).
(13) Torque 2/4 Accumulator retainer to 5 N´m (45
in. lbs.) (Fig. 340).
(14) Install Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 341). (15) Make sure Manual Valve control pin is con-
tained within the rooster comb slot (Fig. 342). Install
Transmission Range Sensor retaining screw (Fig.
342) and torque to 5 N´m (45 in. lbs.).
Fig. 339 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
Fig. 340 2/4 Accumulator Retaining Plate
1 - 2±4 ACCUMULATOR RETAINING PLATE
2 - DETENT SPRING
Fig. 341 Install Manual Shaft/Rooster Comb and Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
Fig. 342 Install Transmission Range Sensor Retaining Screw
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
RS 40TE AUTOMATIC TRANSAXLE21s - 163
VALVE BODY (Continued)

(16) Install manual shaft seal (Fig. 343).
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.
344). Install and torque valve body-to-transaxle case
bolts (Fig. 345) to 12 N´m (105 in. lbs.). (2) Install transaxle oil filter (Fig. 346). Inspect
the o-ring and replace if necessary.
Fig. 343 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 344 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 345 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 346 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
21s - 164 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(3) Ensure the transaxle oil pan and transaxle
case sealing surfaces are clean and dry. Install an
1/8º bead of Mopar tSilicone Rubber Adhesive Seal-
ant to the oil pan and install (Fig. 347). Torque oil
pan-to-transaxle case bolts (Fig. 348) to 19 N´m (165
in. lbs.).
(4) Lower vehicle.
(5) Connect transmission range sensor connector.
(6) Install manual valve lever to manual shaft.
(7) Install gearshift cable to manual valve lever.
(8) Connect battery negative cable.
(9) Fill transaxle with MopartATF +4 Transmis-
sion fluid. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
Fig. 348 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 347 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
RS 40TE AUTOMATIC TRANSAXLE21s - 165
VALVE BODY (Continued)

41TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
41TE AUTOMATIC TRANSAXLE DISASSEMBLY ........................166
ASSEMBLY ...........................184
ACCUMULATOR DESCRIPTION ........................206 VALVE BODY
REMOVAL ............................206
DISASSEMBLY ........................208
ASSEMBLY ...........................212
INSTALLATION ........................217
41TE AUTOMATIC
TRANSAXLE
DISASSEMBLY
NOTE: If transaxle is being overhauled (clutch and/or
seal replacement) or replaced, it is necessary to per-
form the PCM/TCM Quick Learn Procedure. (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES/POW-
ERTRAIN/TRANSMISSION CONTROL MODULE - STAN-
DARD PROCEDURE)
NOTE: This procedure does not include final drive
(differential) disassembly.
(1) Remove input and output speed sensors.
(2) Remove three (3) solenoid/pressure switch
assembly-to-case bolts. (3) Remove solenoid/pressure switch assembly and
gasket (Fig. 1).
Fig. 1 Solenoid/Pressure Switch Assembly and Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
21s - 166 41TE AUTOMATIC TRANSAXLERS

(4) Remove oil pan-to-case bolts (Fig. 2).
(5) Remove oil pan (Fig. 3).(6) Remove oil filter (Fig. 4).
(7) Turn manual valve fully clock-wise to get park
rod into position for removal. (8) Remove valve body-to-case bolts (Fig. 5).
Fig. 2 Remove Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 3 Remove Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPAR TATF RTV (MS-GF41)
3 - OIL FILTER
Fig. 4 Remove Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 5 Remove Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
RS 41TE AUTOMATIC TRANSAXLE21s - 167
41TE AUTOMATIC TRANSAXLE (Continued)

CAUTION: Do not handle the valve body assembly
from the manual valve. Damage can result.(9) Using a screwdriver, push park rod rollers
away from guide bracket (Fig. 6) and remove valve
body assembly (Fig. 7).
NOTE: Depending on engine application, some
accumulators will have two springs and others will
have one spring. The springs are color-coded
according to application and year. When disassem-
bling, mark accumulator spring location to ease
assembly. (10) Remove underdrive and overdrive accumula-
tors (Fig. 8).
(11) Remove low/reverse accumulator snap ring
(Fig. 9).
Fig. 6 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
Fig. 7 Remove Valve Body
1 - VALVE BODY
Fig. 8 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 9 Remove Low/Reverse Accumulator Snap Ring
1 - SNAP RING
2 - PLUG
21s - 168 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(12) Remove low/reverse accumulator plug (Fig.
10).
(13) Remove low/reverse accumulator piston using
suitable pliers (Fig. 11) (Fig. 12). (14) Measure input shaft end play. Place transaxle
so input shaft is vertical. Set up end play set and
dial indicator as shown in (Fig. 13). Input shaft end
play should be within 0.13-0.64 mm (0.005-0.025
in.) If outside of this range, a #4 thrust plate change
is required. Record indicator reading for reference
upon reassembly.
Fig. 10 Remove Low/Reverse Accumulator Plug (Cover)
1 - ADJUSTABLE PLIERS
2 - PLUG
Fig. 11 Low/Reverse Accumulator Piston
1 - ACCUMULATOR PISTON
Fig. 12 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
Fig. 13 Measure Input Shaft End Play Using EndPlay Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
RS 41TE AUTOMATIC TRANSAXLE21s - 169
41TE AUTOMATIC TRANSAXLE (Continued)