clutch CHRYSLER VOYAGER 2004 Service Manual

SOLENOID SWITCH VALVE
The solenoid switch valve controls line pressure
from the LR/CC solenoid. In one position, it allows
the low/reverse clutch to be pressurized. In the other,
it directs line pressure to the converter control and
converter clutch valves.
MANUAL VALVE
The manual valve is operated by the mechanical
shift linkage. Its primary responsibility is to send
line pressure to the appropriate hydraulic circuits
and solenoids. The valve has three operating ranges
or positions.
CONVERTER CLUTCH SWITCH VALVE
The main responsibility of the converter clutch
switch valve is to control hydraulic pressure applied
to the front (off) side of the converter clutch piston.
Line pressure from the regulator valve is fed to the
torque converter regulator valve, where it passes
through the valve, and is slightly regulated. The
pressure is then directed to the converter clutch
switch valve and to the front side of the converter
clutch piston. This pressure pushes the piston back
and disengages the converter clutch.
CONVERTER CLUTCH CONTROL VALVE
The converter clutch control valve controls the
back (on) side of the torque converter clutch. When
the PCM/TCM energizes or modulates the LR/CC
solenoid to apply the converter clutch piston, both
the converter clutch control valve and the converter
control valve move, allowing pressure to be applied to
the back side of the clutch.
T/C REGULATOR VALVE
The torque converter regulator valve slightly regu-
lates the flow of fluid to the torque converter.
LOW/REVERSE SWITCH VALVE
The low/reverse clutch is applied from different
sources, depending on whether low (1st) gear or
reverse is selected. The low/reverse switch valve
alternates positions depending on from which direc-
tion fluid pressure is applied. By design, when the
valve is shifted by fluid pressure from one channel,
the opposing channel is blocked. The switch valve
alienates the possibility of a sticking ball check, thus
providing consistent application of the low/reverse
clutch under all operating conditions.
REMOVAL
NOTE: If valve body is replaced or reconditioned,
the TCM Quick Learn Procedure must be per-
formed. (Refer t o 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Disconnect battery negative cable.
(2) Disconnect gearshift cable from manual valve
lever. (3) Remove manual valve lever from manual shaft.
(4) Raise vehicle on hoist.
(5) Remove oil pan bolts (Fig. 307).
(6) Remove oil pan (Fig. 308).
Fig. 307 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 308 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
RS 40TE AUTOMATIC TRANSAXLE21s - 153
VALVE BODY (Continued)

(9) Remove the overdrive clutch (#5) check valve
(Fig. 321)
(10) Remove separator plate (Fig. 322). (11) Remove thermal valve (Fig. 323).
Fig. 321 Remove Overdrive Clutch (#5) Check Valve
1 - OVERDRIVE CLUTCH (#5) CHECK VALVE
Fig. 322 Remove Separator Plate
1 - SEPARATOR PLATE
2 - VALVE BODY
Fig. 323 Remove Thermal Valve
1 - THERMAL VALVE
RS
40TE AUTOMATIC TRANSAXLE21s - 157
VALVE BODY (Continued)

(15) Remove remaining retainers as shown in (Fig.
327). (16) Remove valves and springs as shown in (Fig.
328).
NOTE: Refer to Valve Body Cleaning and Inspection
for cleaning procedures.
ASSEMBLY
NOTE: If valve body assembly is reconditioned, the
PCM/TCM Quick Learn Procedure must be per-
formed. (Refer t o 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Install valves and springs as shown in (Fig.
328).
Fig. 328 Springs and Valves Location
1 - VALVE BODY 5 - MANUAL VALVE
2 - T/C REGULATOR VALVE 6 - CONVERTER CLUTCH SWITCH VALVE
3 - L/R SWITCH VALVE 7 - SOLENOID SWITCH VALVE
4 - CONVERTER CLUTCH CONTROL VALVE 8 - REGULATOR VALVE
Fig. 327 Valve Retainer Location
1 - RETAINER
2 - RETAINER
RS 40TE AUTOMATIC TRANSAXLE21s - 159
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)

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

(18) Remove oil pump gasket (Fig. 18).
CAUTION: If transaxle failure has occurred, the
cooler bypass valve must be replaced. Do not
re-use or attempt to clean valve. (19) Remove cooler bypass valve (Fig. 19). (20) Remove #1 needle bearing (Fig. 20).
(21) Remove input clutch assembly (Fig. 21).
Fig. 18 Remove Oil Pump Gasket
1 - PUMP GASKET
Fig. 19 Remove Bypass Valve
1 - COOLER BYPASS VALVE
Fig. 20 Remove Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 21 Remove Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
RS
41TE AUTOMATIC TRANSAXLE21s - 171
41TE AUTOMATIC TRANSAXLE (Continued)

(26) Setup tool 5058 as shown in (Fig. 27). Com-
press 2/4 clutch return spring (just enough to remove
snap ring) and remove snap ring.
NOTE: Verify that Tool 5058 is centered properly
over the 2/4 clutch retainer before compressing. If
necessary, fasten the 5058 bar to the bellhousing
flange with any combination of locking pliers and
bolts to center the tool properly.
NOTE: The 2/4 Clutch Piston has bonded seals
which are not individually serviceable. Seal replace-
ment requires replacement of the piston assembly. (27) Remove 2/4 clutch retainer (Fig. 28).
(28) Remove 2/4 clutch return spring (Fig. 29).
Fig. 26 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 27 Remove 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
Fig. 28 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 29 Remove 2/4 Clutch Return Spring
1 - 2/4 CLUTCH RETURN SPRING
RS
41TE AUTOMATIC TRANSAXLE21s - 173
41TE AUTOMATIC TRANSAXLE (Continued)

(29) Remove 2/4 clutch pack (Fig. 30).Tag 2/4
clutch pack for reassembly identification.
(30) Remove tapered snap ring (Fig. 31). (31) Remove low/reverse reaction plate (Fig. 32).
(32) Remove one low/reverse clutch disc (Fig. 33).
Fig. 30 Remove 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
Fig. 31 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
Fig. 32 Remove Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Fig. 33 Remove One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
21s - 174 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(33) Remove low/reverse reaction plate snap ring
(Fig. 34).
(34) Remove low/reverse clutch pack (Fig. 35). (35) Remove transfer gear cover-to-case bolts (Fig.
36).
(36) Remove transfer gear cover (Fig. 37).
Fig. 34 Remove Low/Reverse Reaction Plate Snap Ring
1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
Fig. 35 Remove Low/Reverse Clutch Pack
1 - CLUTCH PLATES (5)
2 - CLUTCH DISCS (5)
Fig. 36 Remove Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
Fig. 37 Remove Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPAR TATF RTV (MS-GF41) AS SHOWN
RS 41TE AUTOMATIC TRANSAXLE21s - 175
41TE AUTOMATIC TRANSAXLE (Continued)

(56) Install low/reverse spring compressor tool as
shown in (Fig. 58) (Fig. 59). (57) Compress low/reverse piston return spring
and remove snap ring (Fig. 60).
(58) Remove low/reverse spring compressor tool
and low reverse piston return spring (Fig. 61).
Fig. 58 Low/Reverse Spring Compressor Tool
1 - TOOL 6057
2 - TOOL 5059
3 - TOOL 5058±3
Fig. 59 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. 60 Remove Snap Ring
1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS
(AS SHOWN)
2 - SNAP RING PLIERS
3 - TOOL 6057
Fig. 61 Low/Reverse Piston Return Spring
1 - LOW/REVERSE PISTON RETURN SPRING
2 - PISTON
RS 41TE AUTOMATIC TRANSAXLE21s - 181
41TE AUTOMATIC TRANSAXLE (Continued)