8e electrical CHRYSLER VOYAGER 2004 Service Manual

(16) Install manual shaft seal (Fig. 368).
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.
369). Install and torque valve body-to-transaxle case
bolts (Fig. 370) to 12 N´m (105 in. lbs.).(2) Install transaxle oil filter (Fig. 371). Inspect
the o-ring and replace if necessary.
Fig. 368 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 369 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 370 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 371 Oil Filter
1 - OIL FILTER
2 - O-RING
21 - 262 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE
When diagnosing converter housing fluid leaks,
three actions must be taken before repair: (1) Verify proper transmission fluid level.
(2) Verify that the leak originates from the con-
verter housing area and is transmission fluid. (3) Determine the true source of the leak.
Fluid leakage at or around the torque converter
area may originate from an engine oil leak (Fig. 7).
The area should be examined closely. Factory fill
fluid is red and, therefore, can be distinguished from
engine oil.
Some suspected converter housing fluid leaks may not
be leaks at all. They may only be the result of residual
fluid in the converter housing, or excess fluid spilled
during factory fill, or fill after repair. Converter housing
leaks have several potential sources. Through careful
observation, a leak source can be identified before
removing the transmission for repair. Pump seal leaks tend to move along the drive hub
and onto the rear of the converter (Fig. 7). Pump o-ring
or pump body leaks follow the same path as a seal leak.
Pump attaching bolt leaks are generally deposited on
the inside of the converter housing and not on the con-
verter itself. Pump seal or gasket leaks usually travel
down the inside of the converter housing (Fig. 7).
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
² Torque converter weld leaks at the outside diam-
eter weld (Fig. 8). ²
Torque converter hub weld (Fig. 8).
REMOVAL
NOTE: If transaxle assembly is being replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perform the TCM Quick Learn Proce-
dure. (Refer t o 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Disconnect battery cables.
(2) Remove battery shield (Fig. 9).
Fig. 7 Converter Housing Leak Paths
1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK
Fig. 8 Converter Leak Points - Typical
1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG
Fig. 9 Battery Thermal Guard
1 - BATTERY THERMOWRAP (IF EQUIPPED)
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
RS 40TE AUTOMATIC TRANSAXLE21s-31
40TE AUTOMATIC TRANSAXLE (Continued)

(27) Lower engine/transaxle assembly with screw
jack. (28) Obtain helper and/or transmission jack.
Secure transmission jack to transaxle assembly. (29) Remove upper mount bracket from transaxle
(Fig. 14). (30) Remove remaining transaxle bellhousing-to-
engine bolts. (31) Remove transaxle assembly from vehicle.
DISASSEMBLY
NOTE: If transaxle is being overhauled (clutch
and/or seal replacement) or replaced, it is neces-
sary to perform the PCM/TCM Quick Learn Proce-
dure. (Refer t o 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/POWERTRAIN/TRANSMIS-
SION CONTROL MODULE - STANDARD PROCE-
DURE)
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. 15). (4) Remove oil pan-to-case bolts (Fig. 16).
(5) Remove oil pan (Fig. 17).
Fig. 15 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 16 Remove Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 17 Remove Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPAR TATF RTV (MS-GF41)
3 - OIL FILTER
21s - 34 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)

INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is nec-
essary to perfrom the TCM Quick Learn procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
(1) Using a transmission jack and a helper, posi-
tion transaxle assembly to engine. Install and torque
bellhousing bolts to 95 N´m (70 ft. lbs.). (2) Install upper mount assembly to transaxle and
torque bolts to 54 N´m (40 ft. lbs.) (Fig. 159). (3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 159). (4) Remove transmission jack and screw jack.
(5) Secure left wheelhouse splash shield.
(6) Install torque converter-to-drive plate bolts and
torque to 88 N´m (65 ft. lbs.) (7) Install inspection cover.
(8) Install lateral bending brace.
(9) Install starter motor.
(10) Install front mount/bracket assembly.
(11) Align and install rear mount bracket-to-case
bolts by hand (Fig. 160). Torque horizontal bolt to
102 N´m (75 ft. lbs.). (12) AWD models: Install power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - INSTALLATION)
Fig. 160 Rear Mount Bracket - Typical
1 - BOLT - VERTICAL 102 N´m (75 ft. lbs.)
2 - BRACKET - REAR MOUNT 3 - BOLT - HORIZONTAL 102 N´m (75 ft. lbs.)
Fig. 159 Left Mount to Bracket and Transaxle
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
RS
40TE AUTOMATIC TRANSAXLE21s-73
40TE AUTOMATIC TRANSAXLE (Continued)

(3) Install steering column lower shroud.
(4) Install knee bolster (Fig. 274).
(5) Install instrument panel lower silencer (Fig.
275).
(6) Connect battery negative cable.
(7) Verify proper shift interlock system operation.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/SHIFT INTERLOCK SOLENOID -
OPERATION)
SOLENOID/PRESSURE
SWITCH ASSY
DESCRIPTION
The Solenoid/Pressure Switch Assembly (Fig. 276)
is external to the transaxle and mounted to the transaxle case. The assembly consists of four sole-
noids that control hydraulic pressure to the LR/CC,
2/4, OD, and UD friction elements. The reverse
clutch is controlled by line pressure from the manual
valve in the valve body. The solenoids are contained
within the Solenoid/Pressure Switch Assembly, and
can only be serviced by replacing the assembly.
The solenoid assembly also contains pressure
switches that monitor and send hydraulic circuit
information to the PCM/TCM. Likewise, the pressure
switches can only be service by replacing the assem-
bly.
OPERATION
SOLENOIDS
The solenoids receive electrical power from the
Transmission Control Relay through a single wire.
The PCM/TCM energizes or operates the solenoids
individually by grounding the return wire of the sole-
noid needed. When a solenoid is energized, the sole-
noid valve shifts, and a fluid passage is opened or
closed (vented or applied), depending on its default
operating state. The result is an apply or release of a
frictional element. The 2/4 and UD solenoids are normally applied,
which by design allow fluid to pass through in their
relaxed or ªoffº state. This allows transaxle limp-in
(P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are
periodically tested. Each solenoid is turned on or off
depending on its current state. An inductive spike
Fig. 274 Knee Bolster
1 - KNEE BOLSTER
Fig. 275 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 276 Solenoid/Pressure Switch Assembly
1 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
RS 40TE AUTOMATIC TRANSAXLE21s - 137
SHIFT INTERLOCK SOLENOID (Continued)

should be detected by the PCM/TCM during this test.
It no spike is detected, the circuit is tested again to
verify the failure. In addition to the periodic testing,
the solenoid circuits are tested if a speed ratio or
pressure switch error occurs.
PRESSURE SWITCHES
The PCM/TCM relies on three pressure switches to
monitor fluid pressure in the L/R, 2/4, and OD
hydraulic circuits. The primary purpose of these
switches is to help the PCM/TCM detect when clutch
circuit hydraulic failures occur. The range for the
pressure switch closing and opening points is 11-23
psi. Typically the switch opening point will be
approximately one psi lower than the closing point.
For example, a switch may close at 18 psi and open
at 17 psi. The switches are continuously monitored
by the PCM/TCM for the correct states (open or
closed) in each gear as shown in the following chart:
PRESSURE SWITCH STATES
GEAR L/R 2/4 OD
ROPOPOP
P/N CL OP OP 1st CL OP OP
2nd OP CL OP DOPOPCL
OD OP CL CL OP = OPEN
CL = CLOSED
A Diagnostic Trouble Code (DTC) will set if the
PCM/TCM senses any switch open or closed at the
wrong time in a given gear. The PCM/TCM also tests the 2/4 and OD pressure
switches when they are normally off (OD and 2/4 are
tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd
gear). The test simply verifies that they are opera-
tional, by looking for a closed state when the corre-
sponding element is applied. Immediately after a
shift into 1st, 2nd, or 3rd gear with the engine speed
above 1000 rpm, the PCM/TCM momentarily turns
on element pressure to the 2/4 and/or OD clutch cir-
cuits to identify that the appropriate switch has
closed. If it doesn't close, it is tested again. If the
switch fails to close the second time, the appropriate
Diagnostic Trouble Code (DTC) will set.
REMOVAL
NOTE: If solenoid/pressure switch assembly is
being replaced, it is necessary to perform the TCM
Quick Learn Procedure. (Refer t o 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly.
(3) Disconnect solenoid/pressure switch assembly
connector (Fig. 277). (4) Disconnect input speed sensor connector (Fig.
277).
Fig. 277 Transmission Connectors
1 - SOLENOID PACK CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
21s - 138 40TE AUTOMATIC TRANSAXLERS
SOLENOID/PRESSURE SWITCH ASSY (Continued)

(5) Remove input speed sensor (Fig. 278).
(6) Remove three (3) solenoid/pressure switch
assembly-to-transaxle case bolts (Fig. 279).
(7) Remove solenoid/pressure switch assembly and
gasket (Fig. 280). Use care to prevent gasket mate-
rial and foreign objects from become lodged in the
transaxle case ports.
INSTALLATION
NOTE: If solenoid/pressure switch assembly is
being replaced, it is necessary to perform the TCM
Quick Learn Procedure. (Refer t o 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install solenoid/pressure switch assembly and
new gasket to transaxle (Fig. 280). (2) Install and torque three (3) bolts (Fig. 279) to
13 N´m (110 in. lbs.). (3) Install input speed sensor (Fig. 278) and torque
to 27 N´m (20 ft. lbs.). (4) Connect input speed sensor connector (Fig.
277). (5) Install solenoid/pressure switch 8-way connec-
tor and torque to 4 N´m (35 in. lbs.) (Fig. 277). (6) Install air cleaner assembly.
(7) Connect battery negative cable.
(8) If solenoid/pressure switch assembly was
replaced, perform TCM Quick Learn procedure.
(Refer t o 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
Fig. 278 Input Speed Sensor
1 - INPUT SPEED SENSOR
Fig. 279 Solenoid/Pressure Switch Assembly-to- Case Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
Fig. 280 Solenoid/Pressure Switch Assembly and Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
RS 40TE AUTOMATIC TRANSAXLE21s - 139
SOLENOID/PRESSURE SWITCH ASSY (Continued)

(9)Fill the transmission with the recommended fluid.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/FLUID - STANDARD PROCEDURE)
TRANSMISSION CONTROL RELAY
DESCRIPTION
The transmission control relay (Fig. 302) is located
in the Intelligent Power Module (IPM), which is
located on the left side of the engine compartment
between the battery and left fender.
OPERATION
The Transmission Control Relay is supplied fused
B+ voltage, energized by the PCM, and is used to
supply power to the solenoid pack when the trans-
mission is in normal operating mode. When the relay
is ªoffº, no power is supplied to the solenoid pack and
the transmission is in ªlimp-inº mode. After a control-
ler reset (ignition key turned to the ªrunº position or
after cranking engine), the PCM energizes the relay.
Prior to this, the PCM verifies that the contacts are
open by checking for no voltage at the switched bat-
tery terminals. After this is verified, the voltage at
the solenoid pack pressure switches is checked. After
the relay is energized, the PCM monitors the termi-
nals to verify that the voltage is greater than 3 volts.
TRANSMISSION RANGE SENSOR
DESCRIPTION
The Transmission Range Sensor (TRS) is mounted
to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The
electrical connector extends through the transaxle
case (Fig. 303).
The Transmission Range Sensor (TRS) has four
switch contacts that monitor shift lever position and
send the information to the PCM/TCM.
Fig. 301 Checking Torque Converter Seating
1 - SCALE
2 - STRAIGHTEDGE
Fig. 302 Transmission Control Relay Location
1 - TRANSMISSION CONTROL RELAY
2 - LEFT FENDER
3 - INTELLIGENT POWER MODULE (IPM)
4 - BATTERY
Fig. 303 Transmission Range Sensor (TRS) Location
1 - TRANSMISSION RANGE SENSOR
21s - 150 40TE AUTOMATIC TRANSAXLERS
TORQUE CONVERTER (Continued)

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)