oil CHRYSLER VOYAGER 2004 Service Manual

(44) Using tool 5049A, remove transfer shaft from
transaxle (Fig. 46).
(45) Slip bearing cup retainer and oil baffle off of
shaft (Fig. 47). (46) Using tool P-334, press transfer shaft bearing
cone off of shaft (Fig. 48).
(47) Bend output gear retaining strap ears flat to
allow bolt removal. (48) Remove output shaft stirrup strap bolts (Fig.
49).
Fig. 46 Remove Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
Fig. 47 Bearing Cup Removed
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
Fig. 48 Remove Transfer Shaft Bearing Cone
1 - ARBOR PRESS RAM
2 - TRANSFER SHAFT
3 - TOOL P-334
4 - BEARING CONE
Fig. 49 Remove Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
21s - 178 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(23) Bend tabs on strap up against flats of bolts
(Fig. 96).
(24) Install transfer shaft bearing cone using Tool
6052 (Fig. 97). (25) Install bearing cup and oil baffle to transfer
shaft (Fig. 98).
(26) Using Tool 5049A, install transfer shaft (Fig.
99).
Fig. 96 Bend Tabs On Strap Up Against Flats Of Bolts
1 - RETAINING STRAP TABS
2 - RETAINING STRAP
3 - STIRRUP
Fig. 97 Install Transfer Shaft Bearing Cone
1 - TOOL 6052
2 - NEW BEARING CONE
3 - TRANSFER SHAFT
4 - ARBOR PRESS RAM
Fig. 98 Install Bearing Cup to Shaft
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
Fig. 99 Install Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
21s - 192 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(52)DETERMINING #4 THRUST PLATE
THICKNESS / INPUT SHAFT END PLAY: (a) Select the thinnest #4 thrust plate thickness
and install to input clutch assembly (Fig. 125). Use
petrolatum to retain. (b)
Install input clutch assembly into position and
verify that it is completely seated by viewing through
input speed sensor hole. If view through input speed
sensor hole is not as shown in (Fig. 126), the input
clutch assembly is not seated properly.
(c) Remove oil pump o-ring (Fig. 127). Be sure
to reinstall oil pump o-ring after selecting the
proper #4 thrust plate. (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. 128). (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. 125 Select Thinnest No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 126 View Through Input Speed Sensor Hole
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
Fig. 127 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 128 Measure Input Shaft End Play Using End Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
RS 41TE AUTOMATIC TRANSAXLE21s - 201
41TE AUTOMATIC TRANSAXLE (Continued)

NO. 4 THRUST PLATE CHART
PART NUMBER THICKNESS4431665AB 1.60mm (0.063 in.)
3836237AB 1.73mm (0.068 in.)
4431666AB 1.80mm (0.071 in.)
3836238AB 1.96mm (0.077 in.)
4431667AB 2.03mm (0.080 in.)
3836239AB 2.16mm (0.085 in.)
4431668AB 2.24mm (0.088 in.)
3836240AB 2.39mm (0.094 in.)
4431669AB 2.46mm (0.097 in.)
3836241AB 2.62mm (0.103 in.)
4446670AB 2.67mm (0.105 in.)
4446671AB 2.90mm (0.114 in.)
(53) Install input clutch assembly (Fig. 129).
(54) Install #1 caged needle bearing (Fig. 130).
CAUTION: The cooler bypass valve must be
replaced if transaxle failure has occurred. Do not
attempt to reuse or clean old valve. (55) Install cooler bypass valve with o-ring end
towards rear of case (Fig. 131). (56) Install oil pump gasket (Fig. 132).
Fig. 129 Install Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 130 Install Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 131 Install Cooler Bypass Valve
1 - COOLER BYPASS VALVE
Fig. 132 Install Oil Pump Gasket
1 - PUMP GASKET
21s - 202 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(57) Install oil pump assembly (Fig. 133).
(58) Install oil pump-to-case bolts and torque to 27
N´m (20 ft. lbs.) (Fig. 134). (59) Install low/reverse accumulator (Fig. 135).
(60) Install low/reverse accumulator plug (Fig.
136).
Fig. 133 Install Oil Pump
1 - OIL PUMP
2 - GASKET
Fig. 134 Install Pump-to-Case Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 135 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
Fig. 136 Install Low/Reverse Accumulator Plug (Cover)
1 - ADJUSTABLE PLIERS
2 - PLUG
RS 41TE AUTOMATIC TRANSAXLE21s - 203
41TE AUTOMATIC TRANSAXLE (Continued)

(65) Install oil filter and new o-ring (Fig. 141).
(66) Apply an 1/8º bead of MopartATF RTV (MS-
GF41) to oil pan and immediately install to case (Fig.
142).
(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. 143). (69) Install and tighten solenoid/pressure switch
assembly-to-transaxle case bolts to 12 N´m (110 in.
lbs.) (Fig. 144). (70) Install and torque input and output speed
sensors to case to 27 N´m (20 ft. lbs.).
Fig. 141 Install Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 142 Install Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPAR TATF RTV (MS-GF41)
3 - OIL FILTER
Fig. 143 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 144 Solenoid Pack-to-Transaxle Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
RS 41TE AUTOMATIC TRANSAXLE21s - 205
41TE AUTOMATIC TRANSAXLE (Continued)

ACCUMULATOR
DESCRIPTION
The 4XTE underdrive, overdrive, low/reverse, and 2/4
clutch hydraulic circuits each contain an accumulator.
An accumulator typically consists of a piston, return
spring(s), and a cover or plug. The overdrive and under-
drive accumulators are located within the transaxle
case, and are retained by the valve body (Fig. 145).
The low reverse accumulator (Fig. 146) is also
located within the transaxle case, but the assembly is
retained by a cover and a snap-ring.
The 2/4 accumulator is located in the valve body. It is
retained by a cover and retaining screws (Fig. 147).
VALVE BODY
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. 148).
Fig. 145 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 146 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
Fig. 147 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
Fig. 148 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
21s - 206 41TE AUTOMATIC TRANSAXLERS

(6) Remove oil pan (Fig. 149).
(7) Remove oil filter (Fig. 150).(8) Remove the valve body-to-transaxle case bolts
(Fig. 151).
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. 152) (Fig.
153).
Fig. 149 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 150 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
Fig. 151 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 152 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
RS 41TE AUTOMATIC TRANSAXLE21s - 207
VALVE BODY (Continued)

(8) Remove oil screen (Fig. 161).
(9) Remove the overdrive clutch (#5) check valve
(Fig. 162) (10) Remove separator plate (Fig. 163).
(11) Remove thermal valve (Fig. 164).
Fig. 161 Remove Oil Screen
1 - OIL SCREEN
Fig. 162 Remove Overdrive Clutch (#5) Check Valve
1 - OVERDRIVE CLUTCH (#5) CHECK VALVE
Fig. 163 Remove Separator Plate
1 - SEPARATOR PLATE
2 - VALVE BODY
Fig. 164 Remove Thermal Valve
1 - THERMAL VALVE
21s - 210 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(6) Install thermal valve into transfer plate (Fig.
174).
(7) Install separator plate to valve body (Fig. 175). (8) Install the overdrive clutch (#5) check valve to
separator plate (Fig. 176)
(9) Install oil screen to separator plate (Fig. 177).
Fig. 174 Install Thermal Valve
1 - THERMAL VALVE
Fig. 175 Install Separator Plate
1 - SEPARATOR PLATE
2 - VALVE BODY
Fig. 176 Install Overdrive Clutch (#5) Check Valve
1 - OVERDRIVE CLUTCH (#5) CHECK VALVE
Fig. 177 Install Oil Screen
1 - OIL SCREEN
RS 41TE AUTOMATIC TRANSAXLE21s - 215
VALVE BODY (Continued)