service CHRYSLER VOYAGER 2004 Service Manual

OPERATION
The relay is supplied fused B+ voltage, energized
by the PCM/TCM, and is used to supply power to the
solenoid pack when the transmission 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 controller reset (ignition
key turned to the ªrunº position or after cranking
engine), the PCM/TCM energizes the relay. Prior to
this, the PCM/TCM 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/TCM monitors the
terminals 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. 328).
The Transmission Range Sensor (TRS) has four
switch contacts that monitor shift lever position and
send the information to the PCM/TCM.The TRS also has an integrated temperature sen-
sor (thermistor) that communicates transaxle tem-
perature to the TCM and PCM (Fig. 329).
OPERATION
The Transmission Range Sensor (TRS) (Fig. 328)
communicates shift lever position (SLP) to the PCM/
TCM as a combination of open and closed switches.
Each shift lever position has an assigned combination
of switch states (open/closed) that the PCM/TCM
receives from four sense circuits. The PCM/TCM inter-
prets this information and determines the appropriate
transaxle gear position and shift schedule.
Fig. 327 Transmission Control Relay Location
1 - TRANSMISSION CONTROL RELAY
2 - LEFT FENDER
3 - INTELLIGENT POWER MODULE (IPM)
4 - BATTERY
Fig. 328 Transmission Range Sensor (TRS)
Location
1 - TRANSMISSION RANGE SENSOR
Fig. 329 Transmission Temperature Sensor
1 - TRANSMISSION RANGE SENSOR
2 - TEMPERATURE SENSOR
21 - 248 41TE AUTOMATIC TRANSAXLERS
TRANSMISSION CONTROL RELAY (Continued)

²1/2 Synchronizer
² 5/R Synchronizer
The intermediate shaft is supported by a caged
roller bearing at the front of the transaxle, and a
sealed roller bearing at the rear of the transaxle.
DISASSEMBLY
CAUTION: Do not re-use snap rings when servicing
the intermediate shaft assembly. Discard upon dis-
assembly and install new ones provided with avail-
able snap ring service kit.
(1) Install intermediate shaft assembly to arbor
press table with bearing splitter P-334 under the
reverse gear. (2) Install 8486-4 button to intermediate shaft.
Using arbor press ram, press reverse gear and inter-
mediate roller bearing off of shaft, while holding
remaining assembly with hand (Fig. 28). (3) Remove reverse gear blocker ring.
(4) Remove reverse gear needle bearing (Fig. 29).
(5) Remove 5/R synchro snap ring (Fig. 30).
Fig. 28 Bearing and Reverse Gear Removal
1 - ARBOR PRESS RAM
2 - ADAPTER
3 - SEALED ROLLER BEARING
4 - REVERSE GEAR
5 - BEARING SPLITTER P-334
Fig. 29 Reverse Gear Needle Bearing
1 - NEEDLE BEARING
Fig. 30 5/R Synchro Snap Ring
1 - SNAP RING
21s - 10 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)

ASSEMBLY
NOTE: Do not re-use snap rings when servicing the
intermediate shaft assembly. Discard snap rings
and install new ones provided with available snap
ring service kit.
NOTE: When installing 1/2 & 5/R synchronizers,
make sure to align oil slots on synchronizer hub
face with oil hold in the shaft splined hub journal.
NOTE: Refer to (Fig. 55) for intermediate shaft
assembly reference.(1) Press intermediate shaft into NEW roller bear-
ing with arbor press (Fig. 56).
Fig. 55 Intermediate Shaft Assembly
1 - INTERMEDIATE SHAFT 12 - THRUST WASHER
2 - ROLLER BEARING 13 - NEEDLE BEARING
3 - SNAP RING 14 - REVERSE GEAR
4 - NEEDLE BEARING 15 - SNAP RING
5 - 1ST SPEED GEAR 16 - 5/R SYNCHRO
6 - SNAP RING 17 - 5TH SPEED GEAR
7 - 2ND SPEED GEAR 18 - NEEDLE BEARING
8 - 3/4 CLUSTER GEAR 19 - NEEDLE BEARING
9 - SNAP RING 20 - 1/2 SYNCHRO
10 - SNAP RING 21 - THRUST BEARING
11 - SEALED ROLLER BEARING
Fig. 56 Intermediate Shaft Bearing Installation
1 - ARBOR PRESS
2 - INTERMEDIATE SHAFT
3 - CAGED ROLLER BEARING
4 - BEARING SPLITTER
RS T850 MANUAL TRANSAXLE21s-17
INTERMEDIATE SHAFT (Continued)

40TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
40TE AUTOMATIC TRANSAXLE DESCRIPTION .........................25
OPERATION ...........................27
DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - 4XTETRANSAXLE GENERAL DIAGNOSIS .......27
DIAGNOSIS AND TESTING - ROAD TEST . . . 27
DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TESTS ....................28
DIAGNOSIS AND TESTING - CLUTCH AIR PRESSURE TESTS ....................30
DIAGNOSIS AND TESTING - TORQUE CONVERTER HOUSING FLUID LEAKAGE . . . 31
REMOVAL .............................31
DISASSEMBLY .........................34
ASSEMBLY ............................51
INSTALLATION .........................73
SCHEMATICS AND DIAGRAMS 4XTE TRANSAXLE HYDRAULICSCHEMATICS ........................75
SPECIFICATIONS - 41TE TRANSAXLE .......87
SPECIAL TOOLS .......................89
ACCUMULATOR DESCRIPTION .........................94
OPERATION ...........................94
DRIVING CLUTCHES DESCRIPTION .........................95
OPERATION ...........................95
FINAL DRIVE DESCRIPTION .........................95
OPERATION ...........................96
DISASSEMBLY .........................96
ASSEMBLY ............................99
ADJUSTMENTS DIFFERENTIAL BEARING PRELOADMEASUREMENT AND ADJUSTMENT ......100
FLUID STANDARD PROCEDURE FLUID LEVEL AND CONDITION CHECK . . . 102
STANDARD PROCEDURE - FLUID ANDFILTER SERVICE .....................104
GEAR SHIFT CABLE REMOVAL ............................105
HOLDING CLUTCHES DESCRIPTION ........................106
OPERATION ..........................106
INPUT CLUTCH ASSEMBLY DISASSEMBLY ........................107
ASSEMBLY ...........................116 OIL PUMP
DESCRIPTION ........................131
OPERATION ..........................131
DISASSEMBLY ........................131
ASSEMBLY ...........................132
PLANETARY GEARTRAIN DESCRIPTION ........................132
OPERATION ..........................132
SEAL - OIL PUMP REMOVAL ............................133
INSTALLATION ........................133
SHIFT INTERLOCK SOLENOID DESCRIPTION ........................133
OPERATION ..........................134
DIAGNOSIS AND TESTING - BRAKE/ TRANSMISSION SHIFT INTERLOCK
SOLENOID ..........................135
REMOVAL ............................135
INSTALLATION ........................136
SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION ........................137
OPERATION ..........................137
REMOVAL ............................138
INSTALLATION ........................139
SPEED SENSOR - INPUT DESCRIPTION ........................140
OPERATION ..........................140
REMOVAL ............................141
INSTALLATION ........................141
SPEED SENSOR - OUTPUT DESCRIPTION ........................142
OPERATION ..........................142
REMOVAL ............................143
INSTALLATION ........................143
TORQUE CONVERTER DESCRIPTION ........................144
OPERATION ..........................148
REMOVAL ............................149
INSTALLATION ........................149
TRANSMISSION CONTROL RELAY DESCRIPTION ........................150
OPERATION ..........................150
TRANSMISSION RANGE SENSOR DESCRIPTION ........................150
OPERATION ..........................151
REMOVAL ............................151
INSTALLATION ........................152
VALVE BODY DESCRIPTION ........................152
21s - 24 40TE AUTOMATIC TRANSAXLERS

(3) Remove coolant recovery bottle (Fig. 10).
(4) Remove fluid level indicator/tube assembly.
Plug opening to prevent debris from entering trans-
axle. (5) Using a blade or suitable hose cutter, cut trans-
axle oil cooler lines off flush with fittings. Plug lines
and fittings to prevent debris from entering transaxle
or cooler circuit. A service splice kit will be installed
upon reassembly. (6) Disconnect input and output shaft speed sensor
connectors (Fig. 11). (7) Disconnect transmission range sensor (TRS)
connector (Fig. 11). (8) Disconnect solenoid/pressure switch assembly
connector (Fig. 11). (9) Disconnect gear shift cable from manual valve
lever and upper mount bracket (Fig. 12). (10) Disconnect crankshaft position sensor (if
equipped). Remove sensor from bellhousing. (11) Reposition leak detection pump harness and
hoses.
Fig. 10 Coolant Recovery Bottle
1 - COOLANT RECOVERY CONTAINER
2 - HOSE
3 - BOLT
4 - SUB FRAME RAIL
Fig. 11 Component Connector LocationÐTypical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 12 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21s - 32 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(24) Remove front carrier/rear annulus assembly
and #6 needle bearing (Fig. 38).
(25) Remove rear sun gear and #7 needle bearing
(Fig. 39).
NOTE: The number 7 needle bearing has three anti-
reversal tabs and is common with the number five
and number two position. The orientation should
allow the bearing to seat flat against the rear sun
gear (Fig. 40). A small amount of petrolatum can be
used to hold the bearing to the rear sun gear. (26) Setup tool 5058 as shown in (Fig. 41). 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.
Fig. 38 Remove Front Carrier/Rear Annulus Assembly
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 39 Remove Rear Sun Gear
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 40 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 41 Remove 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
21s - 40 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(58) Remove low/reverse spring compressor tool
and low reverse piston return spring (Fig. 75).
(59) Using a suitable punch , drive out park guide
bracket pivot shaft plug (Fig. 76). (60) Using ordinary pliers, remove pivot shaft and
guide bracket assembly (Fig. 77).
(61) Inspect guide bracket components for exces-
sive wear and replace if necessary (Fig. 78).
NOTE: The Low/Reverse Clutch Piston has bonded
seals which are not individually serviceable. Seal
replacement requires replacement of the piston
assembly.
Fig. 75 Low/Reverse Piston
1 - LOW/REVERSE PISTON RETURN SPRING
2 - PISTON
Fig. 76 Remove Anchor Shaft and Plug
1 - GUIDE BRACKET ANCHOR SHAFT
2 - PIVOT SHAFT
3 - ANCHOR SHAFT PLUG
Fig. 77 Pivot Shaft and Guide Bracket
1 - ANTIRACHET SPRING
2 - GUIDE BRACKET
3 - PIVOT SHAFT
4-PAWL
Fig. 78 Guide Bracket Disassembled
1 - ANTIRATCHET SPRING
2 - GUIDE BRACKET
3 - SPLIT SLEEVE
4 - SPACER
5-PAWL
6 - STEPPED SPACER
RS 40TE AUTOMATIC TRANSAXLE21s-49
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)

NOTE: The 2/4 Clutch Piston has bonded seals
which are not individually serviceable. Seal replace-
ment requires replacement of the piston assembly.(45) Orient 2/4 clutch return spring to retainer as
shown in (Fig. 131), and install to transaxle (Fig.
132).
(46) Using tool 5058, compress 2/4 clutch return
spring just enough to install snap ring (Fig. 133). (47) Install snap ring. (48) Set up dial indicator as shown in (Fig. 134)
and measure 2/4 clutch clearance. Press down on
clutch pack with finger and zero dial indicator. 2/4
clutch pack clearance is 0.76-2.64 mm
(0.030-0.104 in.). Set up indicator and record mea-
surement in four (4) places. Take average of read-
ings. If clearance is outside this range, the clutch is
assembled improperly. There is no adjustment for
2/4 clutch clearance.
Fig. 131 Proper Orientation of 2/4 Clutch Retainer and Spring
1 - NOTE POSITION
2 - RETURN SPRING
3 - 2/4 CLUTCH RETAINER
Fig. 132 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 133 Install 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
Fig. 134 Check 2/4 Clutch Clearance
1 - DIAL INDICATOR
2 - HOOK TOOL
3 - DIAL INDICATOR TIP TOOL 6268
21s - 66 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(13) Install left and right halfshaft assemblies.
(Refer t o 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION) (14) Install front wheel/tire assemblies.
(15) Lower vehicle.
(16) Torque remaining rear mount bracket-to-tran-
saxle vertical bolts (Fig. 160) to 102 N´m (75 ft. lbs.). (17) Install transaxle upper bellhousing-to-block
bolts and torque to 95 N´m (70 ft. lbs.). (18) Install and connect crank position sensor (if
equipped). (19) Connect gearshift cable to upper mount
bracket and transaxle manual valve lever (Fig. 161).
(20) Connect solenoid/pressure switch assembly
(Fig. 162). (21) Connect transmission range sensor connector
(Fig. 162). (22) Connect input and output speed sensor con-
nectors (Fig. 162). (23) Remove plugs and install transaxle oil cooler
line service splice kit. Refer to instructions included
with kit. (24) Remove plug and Install fluid level indicator/
tube assembly. (25) Install coolant recovery bottle (Fig. 163).
(26) Install battery shield.
(27) Connect battery cables.
(28) Fill transaxle with suitable amount of ATF+4
(Automatic Transmission FluidÐType 9602). (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE/FLUID - STANDARD PROCEDURE)
Fig. 161 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 162 Component Connector Location - Typical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 163 Coolant Recovery Bottle
1 - COOLANT RECOVERY CONTAINER
2 - HOSE
3 - BOLT
4 - SUB FRAME RAIL
21s - 74 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)