torque CHRYSLER VOYAGER 2004 Service Manual

(14)OUTPUT GEAR BEARING ADJUST-
MENT: (a) With output gear removed, install a 4.50 mm
(0.177 in.) gauging shim (Fig. 87) 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. 86). (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. 86). (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. 86 Checking Output Gear Bearings End Play
1 - TOOL L-4432
2 - DIAL INDICATOR
3 - SPECIAL SCREWS TOOL 6260
4 - OUTPUT GEAR
Fig. 87 Output Gear and (Select) Shim
1 - REAR CARRIER ASSEMBLY
2 - SHIM (SELECT)
3 - OUTPUT GEAR
21s - 188 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(15) Install the output gear and bearing assembly
using Tool 6261 (Fig. 88).
(16) Install NEW output gear retaining bolt and
washer (Fig. 89). Using Tool 6259, torque output gear
retaining bolt to 271 N´m (200 ft. lbs.) (Fig. 90). (17) Using an inch pound torque wrench (Fig. 91),
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. 88 Install Output Gear
1 - WRENCHES
2 - TOOL 6261 WITH STUD
3 - OUTPUT GEAR
Fig. 89 Output Gear Bolt and Washer
1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
Fig. 90 Tighten Output Gear to 271 N²m (200 ft.
lbs.)
1 - OUTPUT GEAR
2 - TORQUE WRENCH
3 - 200 FT. LBS.
4 - TOOL 6259
Fig. 91 Check Output Gear Bearings Turning Torque
1 - INCH-POUND TORQUE WRENCH
2 - OUTPUT GEAR
21s - 190 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(18) Install output gear stirrup with serrated side
out (Fig. 92).
(19) Install retaining strap.
(20) Install strap bolts but do not tighten at this
time (Fig. 93). (21) Rotate stirrup clockwise against flats of
retaining bolt (Fig. 94).
(22) Torque stirrup strap bolts to 23 N´m (200 in.
lbs.) (Fig. 95).
Fig. 92 Install Stirrup
1 - STIRRUP
2 - OUTPUT GEAR RETAINING BOLT
Fig. 93 Install Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
Fig. 94 Turn Stirrup Clockwise Against Bolt Flats
1 - RETAINING STRAP
2 - STIRRUP
Fig. 95 Tighten Stirrup Strap Bolts To 23 N´m (200 in.) lbs.)
1 - RETAINING STRAP
2 - STIRRUP
RS 41TE AUTOMATIC TRANSAXLE21s - 191
41TE AUTOMATIC TRANSAXLE (Continued)

(32) Install the transfer shaft gear using Tool 6261
(Fig. 105).
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. 106). (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 Mopar tATF RTV (MS-GF41)
to transfer gear cover (Fig. 107).
(37) Install transfer gear cover-to-case bolts and
torque to 20 N´m (175 in. lbs.) torque (Fig. 108).
Fig. 105 Install Transfer Shaft Gear
1 - WRENCHES
2 - SPECIAL TOOL 6261
3 - OUTPUT GEAR
4 - TRANSFER SHAFT GEAR
Fig. 106 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. 107 Install Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPAR TATF RTV (MS-GF41) AS SHOWN
Fig. 108 Install Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
21s - 196 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)

(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)

(61) Install low/reverse accumulator snap ring
(Fig. 137).
NOTE: Depending on engine application, some
accumulators will have two springs, and others will
have one spring. The springs are color-coded for
application and year.
(62) Install underdrive and overdrive accumulators
(Fig. 138). (63) Install valve body to transaxle (Fig. 139).
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. 140).
Fig. 137 Install Low/Reverse Accumulator Snap Ring
1 - SNAP RING
2 - PLUG
Fig. 138 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 139 Install Valve Body
1 - VALVE BODY
Fig. 140 Install Valve Body-to-Case Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
21s - 204 41TE AUTOMATIC TRANSAXLERS
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)

(10) Install transfer plate to valve body and sepa-
rator plate. Make sure oil screen and #5 check valve
do not bind (Fig. 178).
(11) Install twenty-four transfer plate to valve
body screws (Fig. 179) and torque to 5 N´m (45 in.
lbs.). (12) Install 2/4 Accumulator components as shown
in (Fig. 180).
(13) Torque 2/4 Accumulator retainer to 5 N´m (45
in. lbs.) (Fig. 181).
Fig. 178 Install Transfer Plate
1 - TRANSFER PLATE
Fig. 179 Install Valve Body to Transfer Plate Screws
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
Fig. 180 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
Fig. 181 2/4 Accumulator Retaining Plate
1 - 2±4 ACCUMULATOR RETAINING PLATE
2 - DETENT SPRING
21s - 216 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(14) Install Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 182).
(15) Make sure Manual Valve control pin is con-
tained within the rooster comb slot (Fig. 183). Install
Transmission Range Sensor retaining screw (Fig.
183) and torque to 5 N´m (45 in. lbs.). (16) Install manual shaft seal (Fig. 184).
INSTALLATION
NOTE: If valve body assembly is being replaced or
reconditioned, it is necessary to perform the TCM
Quick Learn Procedure. (Refer t
o 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install valve body assembly to transaxle (Fig.
185). Install and torque valve body-to-transaxle case
bolts (Fig. 186) to 12 N´m (105 in. lbs.).
Fig. 182 Install Manual Shaft/Rooster Comb and Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
Fig. 183 Install Transmission Range Sensor Retaining Screw
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
Fig. 184 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 185 Valve Body Removal/Installation
1 - VALVE BODY
RS 41TE AUTOMATIC TRANSAXLE21s - 217
VALVE BODY (Continued)