oil CHRYSLER VOYAGER 2004 Service Manual

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)

(7) Remove oil filter (Fig. 309).
(8) Remove the valve body-to-transaxle case bolts
(Fig. 310). NOTE: To ease removal of the valve body, turn the
manual valve lever fully clockwise to low or first
gear.
(9) Remove park rod rollers from guide bracket
and remove valve body from transaxle (Fig. 311) (Fig.
312).
CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
Fig. 309 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
Fig. 310 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 311 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
Fig. 312 Valve Body Removal/Installation
1 - VALVE BODY
21s - 154 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(5) Remove 2/4 Accumulator components as shown
in (Fig. 317).
(6) Remove Valve Body to Transfer Plate screws
(Fig. 318). (7) Invert assembly and remove Transfer Plate
(Fig. 319). Beware of loose check balls.
(8) Remove oil screen (Fig. 320).
Fig. 317 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
Fig. 318 Remove Valve Body to Transfer Plate Screws
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
Fig. 319 Remove Transfer Plate
1 - TRANSFER PLATE
Fig. 320 Remove Oil Screen
1 - OIL SCREEN
21s - 156 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(8) Install the overdrive clutch (#5) check valve to
separator plate (Fig. 335)
(9) Install oil screen to separator plate (Fig. 336). (10) Install transfer plate to valve body and sepa-
rator plate. Make sure oil screen and #5 check valve
do not bind (Fig. 337).
(11) Install twenty-four transfer plate to valve
body screws (Fig. 338) and torque to 5 N´m (45 in.
lbs.).
Fig. 335 Install Overdrive Clutch (#5) Check Valve
1 - OVERDRIVE CLUTCH (#5) CHECK VALVE
Fig. 336 Install Oil Screen
1 - OIL SCREEN
Fig. 337 Install Transfer Plate
1 - TRANSFER PLATE
Fig. 338 Install Valve Body to Transfer Plate Screws
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
21s - 162 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(16) Install manual shaft seal (Fig. 343).
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.
344). Install and torque valve body-to-transaxle case
bolts (Fig. 345) to 12 N´m (105 in. lbs.). (2) Install transaxle oil filter (Fig. 346). Inspect
the o-ring and replace if necessary.
Fig. 343 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 344 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 345 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 346 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
21s - 164 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(3) Ensure the transaxle oil pan and transaxle
case sealing surfaces are clean and dry. Install an
1/8º bead of Mopar tSilicone Rubber Adhesive Seal-
ant to the oil pan and install (Fig. 347). Torque oil
pan-to-transaxle case bolts (Fig. 348) to 19 N´m (165
in. lbs.).
(4) Lower vehicle.
(5) Connect transmission range sensor connector.
(6) Install manual valve lever to manual shaft.
(7) Install gearshift cable to manual valve lever.
(8) Connect battery negative cable.
(9) Fill transaxle with MopartATF +4 Transmis-
sion fluid. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
Fig. 348 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 347 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
RS 40TE AUTOMATIC TRANSAXLE21s - 165
VALVE BODY (Continued)

(4) Remove oil pan-to-case bolts (Fig. 2).
(5) Remove oil pan (Fig. 3).(6) Remove oil filter (Fig. 4).
(7) Turn manual valve fully clock-wise to get park
rod into position for removal. (8) Remove valve body-to-case bolts (Fig. 5).
Fig. 2 Remove Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 3 Remove Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPAR TATF RTV (MS-GF41)
3 - OIL FILTER
Fig. 4 Remove Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 5 Remove Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
RS 41TE AUTOMATIC TRANSAXLE21s - 167
41TE AUTOMATIC TRANSAXLE (Continued)

(15) Remove oil pump-to-case bolts (Fig. 14).
CAUTION: Be sure input speed sensor is removed
before removing oil pump. (16) Install pullers Tool C-3752 as shown in (Fig.
15). (17) Remove oil pump assembly (Fig. 16) (Fig. 17).
Fig. 14 Remove Pump Attaching Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 15 Install Tool C-3752
1 - PULLERS TOOL C-3752
2 - PUMP
Fig. 16 Remove Oil Pump
1 - ªPUSH INº ON INPUT SHAFT WHILE REMOVING PUMP
Fig. 17 Oil Pump Removed
1 - OIL PUMP
2 - GASKET
21s - 170 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(18) Remove oil pump gasket (Fig. 18).
CAUTION: If transaxle failure has occurred, the
cooler bypass valve must be replaced. Do not
re-use or attempt to clean valve. (19) Remove cooler bypass valve (Fig. 19). (20) Remove #1 needle bearing (Fig. 20).
(21) Remove input clutch assembly (Fig. 21).
Fig. 18 Remove Oil Pump Gasket
1 - PUMP GASKET
Fig. 19 Remove Bypass Valve
1 - COOLER BYPASS VALVE
Fig. 20 Remove Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 21 Remove Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
RS
41TE AUTOMATIC TRANSAXLE21s - 171
41TE AUTOMATIC TRANSAXLE (Continued)

(29) Remove 2/4 clutch pack (Fig. 30).Tag 2/4
clutch pack for reassembly identification.
(30) Remove tapered snap ring (Fig. 31). (31) Remove low/reverse reaction plate (Fig. 32).
(32) Remove one low/reverse clutch disc (Fig. 33).
Fig. 30 Remove 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
Fig. 31 Remove Tapered Snap Ring
1 - LOW/REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)
4 - OIL PAN FACE
5 - LONG TAB
Fig. 32 Remove Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Fig. 33 Remove One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
21s - 174 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)