oil CHRYSLER VOYAGER 2004 Service Manual

(6) Install 1/2 synchro to fixture 8483. Insert 1st
gear blocker ring, friction cone, and reactor ring as
shown in (Fig. 61).
(7) Install intermediate shaft to synchro assembly
on fixture (Fig. 62). When installing 1/2 synchro-
nizer, make sure to align oil slots on synchro-
nizer hub face with oil hole in the shaft splined
hub journal. Line up friction cone and reactor ring
tabs to gear slots. Remove shaft assembly from fix-
ture. (8) Install NEW1/2 synchro snap ring (Fig. 63).
Fig. 61 1/2 Synchro on Fixture 8483
1 - FIXTURE 8483
2 - 1ST GEAR BLOCKER RING
3 - 1ST GEAR FRICTION CONE
4 - 1ST GEAR REACTOR RING
5 - 1/2 SYNCHRONIZER
Fig. 62 Install 1/2 Synchro to Intermediate Shaft
1 - INTERMEDIATE SHAFT
2 - 1ST GEAR
3 - 1/2 SYNCHRO ASSEMBLY
4 - FIXTURE 8483
Fig. 63 1/2 Synchro Snap Ring
1 - SNAP RING
2 - 1/2 SYNCHRO HUB
RS T850 MANUAL TRANSAXLE21s-19
INTERMEDIATE SHAFT (Continued)

(16) Install 5th gear blocker ring to synchronizer
(Fig. 73). (17) Install 5th gear synchronizer assembly to
intermediate shaft (Fig. 74). When installing 5/R
synchronizer, make sure to align oil slots on
synchronizer hub face with oil hole in the shaft
splined hub journal.
(18) Install NEW5/R synchro snap ring (Fig. 75).
Fig. 72 5th Gear Needle Bearing Removal/
Installation
1 - 5TH GEAR NEEDLE BEARING
Fig. 73 5th Gear Blocker Ring to Synchro
1 - 5th GEAR BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 74 Install 5/R Synchro and 5th Blocker Ring to 5th Gear
1 - 5/R SYNCHRONIZER
2 - 5TH GEAR BLOCKER RING
3 - 5TH GEAR
Fig. 75 5/R Synchro Snap Ring
1 - SNAP RING
21s - 22 T850 MANUAL TRANSAXLERS
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

OPERATION..........................152
REMOVAL ............................153
DISASSEMBLY ........................155 ASSEMBLY
...........................159
INSTALLATION ........................164
40TE AUTOMATIC
TRANSAXLE
DESCRIPTION
The 40TE (Fig. 1) is a four-speed transaxle that is
a conventional hydraulic/mechanical assembly with an integral differential, and is controlled with adap-
tive electronic controls and monitors. The hydraulic
system of the transaxle consists of the transaxle
fluid, fluid passages, hydraulic valves, and various
line pressure control components. An input clutch
assembly which houses the underdrive, overdrive,
and reverse clutches is used. It also utilizes separate
Fig. 1 40TE Automatic Transaxle
1 - TRANSAXLE CASE 7 - REVERSE CLUTCH 13 - OUTPUT SHAFT GEAR
2 - TORQUE CONVERTER 8 - FRONT PLANET CARRIER 14 - TRANSFER SHAFT GEAR
3 - OIL PUMP 9 - 2/4 CLUTCH 15 - TRANSFER SHAFT
4 - INPUT SPEED SENSOR 10 - L/R CLUTCH 16 - DIFFERENTIAL
5 - UNDERDRIVE CLUTCH 11 - OUTPUT SPEED SENSOR 17 - CONVERTER DRIVE PLATE
6 - OVERDRIVE CLUTCH 12 - REAR PLANET CARRIER/OUTPUT
SHAFT18 - INPUT SHAFT
RS
40TE AUTOMATIC TRANSAXLE21s-25

holding clutches: 2nd/4th gear and Low/Reverse. The
primary mechanical components of the transaxle con-
sist of the following:² Three multiple disc input clutches
² Two multiple disc holding clutches
² Four hydraulic accumulators
² Two planetary gear sets
² Hydraulic oil pump
² Valve body
² Solenoid/Pressure switch assembly
² Integral differential assembly
Control of the transaxle is accomplished by fully
adaptive electronics. Optimum shift scheduling is
accomplished through continuous real-time sensor
feedback information provided to the Powertrain
Control Module (PCM) or Transmission Control Mod-
ule (TCM). The PCM/TCM is the heart of the electronic control
system and relies on information from various direct
and indirect inputs (sensors, switches, etc.) to deter-
mine driver demand and vehicle operating condi-
tions. With this information, the PCM/TCM can
calculate and perform timely and quality shifts
through various output or control devices (solenoid
pack, transmission control relay, etc.). The PCM/TCM also performs certain self-diagnos-
tic functions and provides comprehensive information
(sensor data, DTC's, etc.) which is helpful in proper
diagnosis and repair. This information can be viewed
with the DRB scan tool.
TRANSAXLE IDENTIFICATION
The 40TE transaxle is identified by a barcode label
that is fixed to the transaxle case as shown in (Fig.
2). The label contains a series of digits that can be
translated into useful information such as transaxle
part number, date of manufacture, manufacturing
origin, plant shift number, build sequence number,
etc. Refer to (Fig. 3) for identification label break-
down. If the tag is not legible or missing, the ªPKº num-
ber, which is stamped into the transaxle case behind
the transfer gear cover, can be referred to for identi-
fication. This number differs slightly in that it con-
tains the entire transaxle part number, rather than
the last three digits.
Fig. 2 Transaxle Identification Label
1 - IDENTIFICATION LABEL
Fig. 3 Identification Label Breakdown
1 - T=TRACEABILITY
2 - SUPPLIER CODE (PK=KOKOMO)
3 - COMPONENT CODE (TK=KOKOMO TRANSMISSION)
4 - BUILD DAY (344=DEC. 9)
5 - BUILD YEAR (9=1999)
6 - LINE/SHIFT CODE (3=3RD SHIFT)
7 - BUILD SEQUENCE NUMBER
8 - LAST THREE OF P/N
9 - ALPHA
10 - TRANSAXLE PART NUMBER
11 - P=PART NUMBER
21s - 26 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS
Inoperative clutches can be located using a series
of tests by substituting air pressure for fluid pressure
(Fig. 5) (Fig. 6). The clutches may be tested by apply-
ing air pressure to their respective passages. The
valve body must be removed and Tool 6056 installed.
To make air pressure tests, proceed as follows:
NOTE: The compressed air supply must be free of
all dirt and moisture. Use a pressure of 30 psi.
Remove oil pan and valve body. See Valve body
removal.
OVERDRIVE CLUTCH
Apply air pressure to the overdrive clutch apply
passage and watch for the push/pull piston to move
forward. The piston should return to its starting
position when the air pressure is removed.
REVERSE CLUTCH
Apply air pressure to the reverse clutch apply pas-
sage and watch for the push/pull piston to move rear-
ward. The piston should return to its starting
position when the air pressure is removed.
2/4 CLUTCH
Apply air pressure to the feed hole located on the
2/4 clutch retainer. Look in the area where the 2/4 piston contacts the first separator plate and watch
carefully for the 2/4 piston to move rearward. The
piston should return to its original position after the
air pressure is removed.
LOW/REVERSE CLUTCH
Apply air pressure to the low/reverse clutch feed
hole (rear of case, between 2 bolt holes). Then, look
in the area where the low/reverse piston contacts the
first separator plate. Watch carefully for the piston to
move forward. The piston should return to its origi-
nal position after the air pressure is removed.
UNDERDRIVE CLUTCH
Because this clutch piston cannot be seen, its oper-
ation is checked by function. Air pressure is applied
to the low/reverse and the 2/4 clutches. This locks the
output shaft. Use a piece of rubber hose wrapped
around the input shaft and a pair of clamp-on pliers
to turn the input shaft. Next apply air pressure to
the underdrive clutch. The input shaft should not
rotate with hand torque. Release the air pressure
and confirm that the input shaft will rotate.
Fig. 5 Air Pressure Test Plate
1 - TOOL 6056
2 - ACCUMULATORS
Fig. 6 Testing Reverse Clutch
1 - TOOL 6056
2 - AIR NOZZLE
21s - 30 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (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)

(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)

(12) Remove rear mount bracket-to-transaxle case
bolts (Fig. 13). (13) Remove transaxle upper bellhousing-to-block
bolts. (14) Raise vehicle on hoist.
(15) Remove transaxle oil pan and drain fluid into
suitable container. (16) Remove front wheel/tire assemblies.
(17) Remove left and right halfshaft assemblies.
(Refer t o 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - REMOVAL) (18) AWD models: Remove power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - REMOVAL) (19) Remove rear mount bracket-to-transaxle case
lower (horizontal) bolt (Fig. 13). (20) Remove front mount/bracket assembly.
(21) Remove starter motor.
(22) Remove lateral bending brace.
(23) Remove inspection cover.
(24) Remove torque converter-to-drive plate bolts.
(25) Support engine/transaxle assembly at engine
oil pan with screw jack and wood block. (26) Partially remove left wheelhouse splash shield
to gain access to and remove upper mount thru-bolt
(Fig. 14).
Fig. 13 Rear Mount Bracket - Typical
1 - BOLT - VERTICAL
2 - BRACKET - REAR MOUNT 3 - BOLT - HORIZONTAL
Fig. 14 Left Mount-to-Bracket
1 - BOLT - BRACKET TO FRAME RAIL
2 - BOLT - MOUNT TO RAIL THROUGH
3 - BOLT - LEFT MOUNT TO TRANSAXLE
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
RS
40TE AUTOMATIC TRANSAXLE21s-33
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)