service CHRYSLER VOYAGER 2004 Service Manual

OPERATION
The differential assembly is driven by the transfer
shaft by way of the differential ring gear. The ring
gear drives the differential case, and the case drives
the driveshafts through the differential gears. The
differential pinion and side gears are supported in
the case by thrust washers and a pinion shaft. Dif-
ferential pinion and side gears make it possible for
front tires to rotate at different speeds while corner-
ing.
DISASSEMBLY
NOTE: The differential is serviced as an assembly.
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
any other part fails within the differential, you must
replace the differential assembly along with the
transfer shaft.
The transfer shaft should be removed for differen-
tial repair and bearing turning torque checking. (1) Remove the differential cover and bolts (Fig.
169) (Fig. 170).
(2) Remove the differential bearing retainer and
bolts (Fig. 171) (Fig. 172). (3) Using a plastic hammer, remove extension
housing/adapter plate on the right side of the trans-
axle.
WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
(4) Remove differential assembly.
Fig. 169 Differential Cover Bolts
1 - DIFFERENTIAL COVER BOLTS
2 - DIFFERENTIAL COVER
Fig. 170 Remove Differential Cover
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL COVER
Fig. 171 Differential Retainer Bolts
1 - DIFFERENTIAL RETAINER BOLTS
Fig. 172 Remove Bearing Retainer
1 - DIFFERENTIAL BEARING RETAINER
2 - TOOL L-4435
21s - 96 40TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)

(8) Using Miller Special Tool L-4518, remove the
differential bearing race from the extension housing/
adapter plate. (9) Using Miller Special Tool 6062A, remove the
differential bearing race from the bearing retainer
(Fig. 178) (Fig. 179).
DIFFERENTIAL SERVICE TOOLS
COMPONENT REMOVER INSTALLER
Diff. Bear. On
Retainer Side 5048, 5048-4
Collets,
L-4539-2
Button5052, C-4171
Diff. Bear. On
Ext. Hous. Side 5048, 5048-3
Collets,
L-4539-2
ButtonL-4410, C-4171
Diff. Race. On
Retainer Side 6062-A 6061, C-4171
Diff. Race. On
Ext. Hous. Side L-4518 L-4520, C-4171
Extension
Housing Seal 7794-A, C-637
Slide HammerL-4520, C-4171
Bearing
Retainer Seal 794-A, C-637
Slide HammerL-4520, C-4171
Fig. 177 Remove Differential Bearing Cone (Ring
Gear Side)
1 - SPECIAL TOOL 5048
2 - RING GEAR
Fig. 178 Position Bearing Cup Remover Tool in Retainer
1 - SPECIAL TOOL 6062A
2 - DIFFERENTIAL BEARING RETAINER
Fig. 179 Remove Bearing Cup
1 - SPECIAL TOOL 6062A
2 - DIFFERENTIAL BEARING RETAINER
21s - 98 40TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)

ASSEMBLY
NOTE: The differential is serviced as an assembly.
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
any other part fails within the differential, you must
replace the differential assembly along with the
transfer shaft.
NOTE: Use MoparTATF RTV (MS-GF41), or equiva-
lent, on retainer and extension housing/adapter
plate to seal to case.
(1) Using Miller Special Tool L-4410, and C-4171,
install differential bearing to differential (extension
housing side) (Fig. 180).
(2) Using Miller Special Tool 5052 and C-4171,
install differential bearing to differential (bearing
retainer side). (3) Using Miller Special Tool 6061 and C-4171,
install differential bearing race to bearing retainer
(Fig. 181). (4) Using Miller Special Tool L±4520 and C-4171,
install differential bearing cup to extension housing. (5) Measure and adjust differential bearing pre-
load (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 41TE/FINAL DRIVE -
ADJUSTMENTS) . (6) Install differential assembly to case. Install
extension housing/adapter plate and bearing retainer. (7) Install bearing retainer with a bead of Mopar t
ATF RTV (MS-GF41) and torque bolts (Fig. 182) to
28 N´m (250 in. lbs.).
(8) Install extension housing/adapter plate with a
bead of Mopar tATF RTV (MS-GF41) and torque
bolts to 28 N´m (250 in. lbs.).
Fig. 180 Position Bearing Cone Onto Differential
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL BEARING
Fig. 181 Differential Bearing Retainer
1 - DIFFERENTIAL BEARING CUP
2 - DIFFERENTIAL BEARING RETAINER
Fig. 182 Differential Retainer Bolts
1 - DIFFERENTIAL RETAINER BOLTS
RS 40TE AUTOMATIC TRANSAXLE21s-99
FINAL DRIVE (Continued)

STANDARD PROCEDURE - FLUID AND FILTER
SERVICE
NOTE: Refer to the maintenance schedules in
LUBRICATION and MAINTENANCE, or the vehicle
owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
NOTE: Only fluids of the type labeled MoparTATF+4
should be used. A filter change should be made at
the time of the transmission oil change. The magnet
(on the inside of the oil pan) should also be cleaned
with a clean, dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Refer to LUBRICA-
TION and MAINTENANCE for proper procedures.
Place a drain container with a large opening, under
transaxle oil pan. (2) Remove both engine mount-to-engine cross-
member cradle nuts. Using suitable screw jack and
wood block, raise engine and transmission slightly to
facilitate transaxle oil pan removal and installation. (3) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan. (4) Install a new filter and o-ring on bottom of the
valve body (Fig. 189). (5) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.). (6) Pour four quarts of Mopar tATF+4 through the
dipstick opening. (7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position. (8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 190).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.). Refer
to Fluid Level and Condition Check for the proper
fluid fill procedure. (10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
DIPSTICK TUBE FLUID SUCTION METHOD
(ALTERNATIVE)
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature. (2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (VaculaŸ
or equivalent). (3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
Fig. 189 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
Fig. 190 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
21s - 104 40TE AUTOMATIC TRANSAXLERS
FLUID (Continued)

(5) Remove the suction line from the dipstick tube.
(6) Pour four quarts of MopartATF+4 through the
dipstick opening. (7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position. (8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 190). (9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/FLUID - STANDARD PROCEDURE) (10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
GEAR SHIFT CABLE
REMOVAL
(1) Disconnect battery cables.
(2) Remove battery shield.
(3) Remove battery.
(4) Remove speed control servo and position out of
way. (5) Disconnect gear shift cable at manual valve
lever (Fig. 191). (6) Disconnect gear shift cable from upper mount
bracket (Fig. 191). (7) Remove instrument panel lower silencer (Fig.
192).
(8) Remove knee bolster (Fig. 193).
Fig. 191 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 192 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 193 Knee Bolster
1 - KNEE BOLSTER
RS 40TE AUTOMATIC TRANSAXLE21s - 105
FLUID (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)

TORQUE CONVERTER
DESCRIPTION
The torque converter (Fig. 293) is a hydraulic
device that couples the engine crankshaft to the
transmission. The torque converter consists of an
outer shell with an internal turbine, a stator, an
overrunning clutch, an impeller and an electronically
applied converter clutch. The converter clutch pro-
vides reduced engine speed and greater fuel economy
when engaged. Clutch engagement also provides
reduced transmission fluid temperatures. The con-
verter clutch engages in third gear. The torque con-
verter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that
is not repairable and is serviced as an assembly.
Fig. 293 Torque Converter Assembly
1 - TURBINE
2 - IMPELLER
3 - HUB
4-STATOR
5 - CONVERTER CLUTCH DISC
6 - DRIVE PLATE
21s - 144 40TE AUTOMATIC TRANSAXLERS

(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)

(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)

(59) Using a suitable punch , drive out park guide
bracket pivot shaft plug (Fig. 62).
(60) Using ordinary pliers, remove pivot shaft and
guide bracket assembly (Fig. 63). (61) Inspect guide bracket components for exces-
sive wear and replace if necessary (Fig. 64).
NOTE: The Low/Reverse Clutch Piston has bonded
seals which are not individually serviceable. Seal
replacement requires replacement of the piston
assembly.
(62) Remove low/reverse clutch piston (Fig. 65).
Fig. 62 Remove Anchor Shaft and Plug
1 - GUIDE BRACKET ANCHOR SHAFT
2 - PIVOT SHAFT
3 - ANCHOR SHAFT PLUG
Fig. 63 Pivot Shaft and Guide Bracket
1 - ANTIRACHET SPRING
2 - GUIDE BRACKET
3 - PIVOT SHAFT
4-PAWL
Fig. 64 Guide Bracket Disassembled
1 - ANTIRATCHET SPRING
2 - GUIDE BRACKET
3 - SPLIT SLEEVE
4 - SPACER
5-PAWL
6 - STEPPED SPACER
Fig. 65 Remove Low/Reverse Clutch Piston
1 - LOW/REVERSE CLUTCH PISTON
2 - BONDED SEAL
3 - BONDED SEAL
21s - 182 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)