torque CHRYSLER VOYAGER 2004 Service Manual

(2) Install low/reverse piston retainer gasket (Fig.
88). Make sure gasket holes line up with case.
(3) Install low/reverse piston retainer (Fig. 89).(4) Install low/reverse piston retainer-to-case bolts
(Fig. 90) and torque to 5 N´m (45 in. lbs.).
(5) Install low/reverse clutch piston (Fig. 91).
Fig. 88 Install Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Fig. 89 Install Piston Retainer
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - GASKET
Fig. 90 Install Piston Retainer Attaching Screws
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - SCREWDRIVER
3 - TORX-LOC SCREWS
Fig. 91 Install Low/Reverse Clutch Piston
1 - LOW/REVERSE CLUTCH PISTON
2 - D-RING SEAL
3 - D-RING SEAL
RS41TE AUTOMATIC TRANSAXLE21 - 145
41TE AUTOMATIC TRANSAXLE (Continued)

(12) Install rear carrier assembly to transaxle case
(Fig. 100).
(13) Install output gear bearing cone using Tool
5052 (Fig. 101).
(14)OUTPUT GEAR BEARING ADJUST-
MENT:
(a) With output gear removed, install a 4.50 mm
(0.177 in.) gauging shim (Fig. 103) on the rear car-
rier assembly hub, using grease to hold the shim in
place.
(b) Using Tool 6259, install output gear and
bearing assembly. Torque to 271 N´m (200 ft. lbs.).
(c) Measure bearing end play. Attach Tool L-4432
to the gear (Fig. 102).(d) Push and pull the gear while rotating back
and forth to ensure seating of bearing rollers.
(e) Using a dial indicator mounted to the trans-
axle case, measure output gear end play as shown
in (Fig. 102).
(f) Refer to the output gear bearing shim chart
for the required shim to obtain proper bearing set-
ting.
(g) Use Tool 6259 to remove the output gear
retaining bolt and washer. To remove the output
gear, use Tool L4407A.
(h) Remove the gauging shim and install the
proper shim determined by the chart. Use grease
to hold the shim in place.
Fig. 100 Install Rear Carrier Assembly
1 - REAR CARRIER ASSEMBLY
Fig. 101 Install Output Gear Bearing Cone
1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - TOOL 5052
4 - OUTPUT GEAR
Fig. 102 Checking Output Gear Bearings End Play
1 - TOOL L-4432
2 - DIAL INDICATOR
3 - SPECIAL SCREWS TOOL 6260
4 - OUTPUT GEAR
Fig. 103 Output Gear and (Select) Shim
1 - REAR CARRIER ASSEMBLY
2 - SHIM (SELECT)
3 - OUTPUT GEAR
21 - 148 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(15) Install the output gear and bearing assembly
using Tool 6261 (Fig. 104).
(16) Install NEW output gear retaining bolt and
washer (Fig. 105). Using Tool 6259, torque output
gear retaining bolt to 271 N´m (200 ft. lbs.) (Fig.
106).(17) Using an inch pound torque wrench (Fig.
107), check output shaft turning torque.Output
shaft turning torque should be within 3-8 in.
lbs.If the turning torque is too high, install a 0.04
mm (0.0016 in.) thicker shim. If the turning torque is
too low, install a 0.04 mm (0.0016 in.) thinner shim.
Repeat until the proper turning torque of 3-8 in. lbs.
is obtained.
Fig. 104 Install Output Gear
1 - WRENCHES
2 - TOOL 6261 WITH STUD
3 - OUTPUT GEAR
Fig. 105 Output Gear Bolt and Washer
1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
Fig. 106 Tighten Output Gear to 271 N²m (200 ft.
lbs.)
1 - OUTPUT GEAR
2 - TORQUE WRENCH
3 - 200 FT. LBS.
4 - TOOL 6259
Fig. 107 Check Output Gear Bearings Turning
Torque
1 - INCH-POUND TORQUE WRENCH
2 - OUTPUT GEAR
21 - 150 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(18) Install output gear stirrup with serrated side
out (Fig. 108).
(19) Install retaining strap.
(20) Install strap bolts but do not tighten at this
time (Fig. 109).(21) Rotate stirrup clockwise against flats of
retaining bolt (Fig. 110).
(22) Torque stirrup strap bolts to 23 N´m (200 in.
lbs.) (Fig. 111).
Fig. 108 Install Stirrup
1 - STIRRUP
2 - OUTPUT GEAR RETAINING BOLT
Fig. 109 Install Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
Fig. 110 Turn Stirrup Clockwise Against Bolt Flats
1 - RETAINING STRAP
2 - STIRRUP
Fig. 111 Tighten Stirrup Strap Bolts To 23 N´m (200
in.) lbs.)
1 - RETAINING STRAP
2 - STIRRUP
RS41TE AUTOMATIC TRANSAXLE21 - 151
41TE AUTOMATIC TRANSAXLE (Continued)

(32) Install the transfer shaft gear using Tool 6261
(Fig. 121).
CAUTION: Install a NEW retaining nut, as the origi-
nal nut MUST NOT be reused.
(33) Install the new retaining nut and washer.
(34) Using Tool 6259, torque transfer gear retain-
ing nut to 271 N´m (200 ft. lbs.) (Fig. 122).(35) Measure transfer shaft end play.Transfer
shaft end play should be within 0.05-0.10 mm
(0.002-0.004 in.).If the end play is too high, install a
0.04 mm (0.0016 in.) thicker shim. If the end play is
too low, install a 0.04 mm (0.0016 in.) thinner shim.
Repeat until 0.05-0.10 mm (0.002-0.004 in.) end play
is obtained.
(36) Install a bead of MopartATF RTV (MS-GF41)
to transfer gear cover (Fig. 123).
(37) Install transfer gear cover-to-case bolts and
torque to 20 N´m (175 in. lbs.) torque (Fig. 124).
Fig. 121 Install Transfer Shaft Gear
1 - WRENCHES
2 - SPECIAL TOOL 6261
3 - OUTPUT GEAR
4 - TRANSFER SHAFT GEAR
Fig. 122 Tighten Transfer Gear Nut to 271 N²m (200
ft. lbs.)
1 - TRANSFER SHAFT GEAR
2 - 200 FT. LBS.
3 - TORQUE WRENCH
4 - SPECIAL TOOL 6259
Fig. 123 Install Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPARTATF RTV (MS-GF41) AS SHOWN
Fig. 124 Install Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
21 - 156 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(d) Install pump and gasket to transmission.
Install and torque bolts.
(e) Set up input shaft for measurement with
Indicator Set C3339 and End Play Set 8266 as
shown in (Fig. 144).
(f) Measure the input shaft end play with the
transaxle in the vertical position.Input shaft end
play must be within 0.005 to 0.025 inch.For
example, if end play reading is 0.055 inch, select
No. 4 Thrust Plate which is 0.071 to 0.074 thick.
This should provide an input shaft end play read-
ing of 0.020 inch which is within specifications.
(g) Refer to the No. 4 thrust plate chart to select
the proper No. 4 thrust plate:
Fig. 141 Select Thinnest No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 142 View Through Input Speed Sensor Hole
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
Fig. 143 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 144 Measure Input Shaft End Play Using End
Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
RS41TE AUTOMATIC TRANSAXLE21 - 161
41TE AUTOMATIC TRANSAXLE (Continued)

(57) Install oil pump assembly (Fig. 149).
(58) Install oil pump-to-case bolts and torque to 27
N´m (20 ft. lbs.) (Fig. 150).(59) Install low/reverse accumulator (Fig. 151).
(60) Install low/reverse accumulator plug (Fig.
152).
Fig. 149 Install Oil Pump
1 - OIL PUMP
2 - GASKET
Fig. 150 Install Pump-to-Case Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 151 Install Low/Reverse Accumulator
1 - ACCUMULATOR PISTON
2 - SEAL RINGS
3 - RETURN SPRINGS
4 - (NOTE NOTCH)
Fig. 152 Install Low/Reverse Accumulator Plug
(Cover)
1 - ADJUSTABLE PLIERS
2 - PLUG
RS41TE AUTOMATIC TRANSAXLE21 - 163
41TE AUTOMATIC TRANSAXLE (Continued)

(63) Install valve body to transaxle (Fig. 157).
Rotate manual valve shaft fully clockwise to ease
installation. Make sure park rod rollers are posi-
tioned within park guide bracket.
(64) Install and torque valve body-to-case bolts to
12 N´m (105 in. lbs.) (Fig. 158).(65) Install oil filter and new o-ring (Fig. 159).
(66) Apply an 1/8º bead of MopartATF RTV (MS-
GF41) to oil pan and immediately install to case (Fig.
160).
Fig. 157 Install Valve Body
1 - VALVE BODY
Fig. 158 Install Valve Body-to-Case Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 159 Install Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 160 Install Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPARTATF RTV (MS-GF41)
3 - OIL FILTER
RS41TE AUTOMATIC TRANSAXLE21 - 165
41TE AUTOMATIC TRANSAXLE (Continued)

(67) Install oil pan-to-case bolts and torque to 19
N´m (165 in. lbs.).
(68) Install solenoid/pressure switch assembly and
gasket to case (Fig. 161).
(69) Install and tighten solenoid/pressure switch
assembly-to-transaxle case bolts to 12 N´m (110 in.
lbs.) (Fig. 162).(70) Install and torque input and output speed
sensors to case to 27 N´m (20 ft. lbs.).
INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perfrom the TCM Quick Learn proce-
dure. (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL 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. 163).
(3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 163).
(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.
Fig. 161 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 162 Attaching Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
Fig. 163 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
21 - 166 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(11) Align and install rear mount bracket-to-case
bolts by hand (Fig. 164). 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)
(13) Install left and right halfshaft assemblies.
(Refer to 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. 164) 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. 165).
Fig. 164 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. 165 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
RS41TE AUTOMATIC TRANSAXLE21 - 167
41TE AUTOMATIC TRANSAXLE (Continued)