tow CHRYSLER VOYAGER 2005 Service Manual

OPERATION
The converter impeller (Fig. 303) (driving member),
which is integral to the converter housing and bolted
to the engine drive plate, rotates at engine speed.
The converter turbine (driven member), which reacts
from fluid pressure generated by the impeller, rotates
and turns the transmission input shaft.
TURBINE
As the fluid that was put into motion by the impeller
blades strikes the blades of the turbine, some of the
energy and rotational force is transferred into the tur-
bine and the input shaft. This causes both of them (tur-
bine and input shaft) to rotate in a clockwise direction
following the impeller. As the fluid is leaving the trail-
ing edges of the turbine's blades it continues in a ªhin-
deringº direction back toward the impeller. If the fluid
is not redirected before it strikes the impeller, it will
strike the impeller in such a direction that it would
tend to slow it down.
STATOR
Torque multiplication is achieved by locking the sta-
tor's over-running clutch to its shaft (Fig. 304). Under
stall conditions (the turbine is stationary), the oil leaving
the turbine blades strikes the face of the stator blades
and tries to rotate them in a counterclockwise direction.
When this happens the over±running clutch of the stator
locks and holds the stator from rotating. With the stator
locked, the oil strikes the stator blades and is redirected
into a ªhelpingº direction before it enters the impeller.This circulation of oil from impeller to turbine, turbine to
stator, and stator to impeller, can produce a maximum
torque multiplication of about 2.4:1. As the turbine
begins to match the speed of the impeller, the fluid that
was hitting the stator in such as way as to cause it to
lock±up is no longer doing so. In this condition of opera-
tion, the stator begins to free wheel and the converter
acts as a fluid coupling.
Fig. 303 Torque Converter Fluid Operation
1 - APPLY PRESSURE 3 - RELEASE PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD
Fig. 304 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
21 - 128 40TE AUTOMATIC TRANSAXLERS
TORQUE CONVERTER (Continued)

NO. 4 THRUST PLATE CHART
PART NUMBER THICKNESS
4431665AB 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. 143).(54) Install #1 caged needle bearing (Fig. 144).
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. 145).
Fig. 143 Install Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 144 Install Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 145 Install Cooler Bypass Valve
1 - COOLER BYPASS VALVE
21 - 192 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(21) Install the OD clutch pack (four frictions/three
steels) (Fig. 260).
(22) Install OD pressure plate waved snap ring
(Fig. 261).(23) Install the OD/Reverse pressure plate with
large step down (towards OD clutch pack) (Fig. 262).
(24) Install OD pressure plate flat snap ring (Fig.
263) (Fig. 264).
Fig. 260 Install OD Clutch Pack
1 - OVERDRIVE CLUTCH PACK
Fig. 261 Install Waved Snap Ring
1 - OVERDRIVE PRESSURE PLATE WAVED SNAP RING
2 - SCREWDRIVER
Fig. 262 OD/Reverse Pressure Plate
1 - OVERDRIVE/REVERSE PRESSURE PLATE
2 - (STEP SIDE DOWN)
Fig. 263 Install Flat Snap Ring
1 - ARBOR PRESS RAM
2 - TOOL 5059A
3 - FLAT SNAP RING
21 - 254 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(25) Measure OD clutch pack clearance. Set up
dial indicator on top of the OD/Reverse pressure
plate as shown in (Fig. 265).
(26) Zero dial indicator and apply 30 psi (206 kPa)
air pressure to the overdrive clutch hose on Tool
8391. Measure and record OD clutch pack measure-
ment in four (4) places, 90É apart.
(27) Take average of four measurements and com-
pare with OD clutch pack clearance specification.
The overdrive (OD) clutch pack clearance is
1.07-3.25 mm (0.042-0.128 in.).
If not within specifications, the clutch is not
assembled properly. There is no adjustment for the
OD clutch clearance.
(28) Install reverse clutch pack (two frictions/one
steel) (Fig. 266).
(29) Install reverse clutch reaction plate with the
flat side down towards reverse clutch (Fig. 267).
Fig. 265 Measure OD Clutch Pack Clearance
1 - DIAL INDICATOR
2 - OD/REVERSE REACTION PLATE
Fig. 266 Install Reverse Clutch Pack
1 - REVERSE CLUTCH PLATE
2 - REVERSE CLUTCH DISCS
Fig. 267 Install Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)
21 - 256 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

ing the trailing edges of the turbine's blades it con-
tinues in a ªhinderingº direction back toward the
impeller. If the fluid is not redirected before it strikes
the impeller, it will strike the impeller in such a
direction that it would tend to slow it down.
STATOR
Torque multiplication is achieved by locking the
stator's over-running clutch to its shaft (Fig. 328).
Under stall conditions (the turbine is stationary), the
oil leaving the turbine blades strikes the face of the
stator blades and tries to rotate them in a counter-
clockwise direction. When this happens the over±run-
ning clutch of the stator locks and holds the stator
from rotating. With the stator locked, the oil strikes
the stator blades and is redirected into a ªhelpingº
direction before it enters the impeller. This circula-
tion of oil from impeller to turbine, turbine to stator,
and stator to impeller, can produce a maximum
torque multiplication of about 2.4:1. As the turbine
begins to match the speed of the impeller, the fluid
that was hitting the stator in such as way as to
cause it to lock±up is no longer doing so. In this con-
dition of operation, the stator begins to free wheel
and the converter acts as a fluid coupling.
TORQUE CONVERTER CLUTCH (TCC)
In a standard torque converter, the impeller and
turbine are rotating at about the same speed and the
stator is freewheeling, providing no torque multipli-
cation. By applying the turbine's piston to the front
cover's friction material, a total converter engage-
Fig. 327 Torque Converter Fluid Operation
1 - APPLY PRESSURE 3 - RELEASE PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD
Fig. 328 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
RS41TE AUTOMATIC TRANSAXLE21 - 279
TORQUE CONVERTER (Continued)

(5)Match Mounting.If the wheel runout is
within specifications, tire and wheel assembly runout
can be improved by re-indexing (match mounting)
the tire to the wheel as described below.
(a) Remount the tire on the rim 180 degrees
from its original location (Fig. 6). Ensure the tire
bead is properly seated.
(b) Re-measure the total runout. Mark the tire
at the high spot and record the measurement.
If runout is still excessive, perform the following:
²If the new high spot is within 102 mm (4.0 inch)
of the first high spot on the tire, replace the tire.
²If the new high spot is within 102 mm (4.0 inch)
of the first high spot on the wheel, the wheel may be
out of specification. Refer to Wheel Runout above.
²If the new high spot is NOT within 102 mm (4.0
inch) of either high spot, draw an arrow on the tread
from new high spot toward the original (Fig. 7).
Break down the tire and remount it 90 degrees on
rim in that direction, then re-measure runout. This
will normally reduce the runout to an acceptable
amount.
(6) Once back together, road test the vehicle for at
least 5 miles, following the format described in Road
Test. If vibration persists, and all components tested
are within specification, the tires may have an exces-
sive radial force condition. Radial force variation can
only be checked as indicated below. If this equipment
is not available, consult with the tire manufacturer.
Fig. 5 Checking Lateral Runout Of Wheel
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
Fig. 6 Remount Tire 180 Degrees
1 - VALVE STEM
2 - REFERENCE MARK
Fig. 7 Remount Tire 90 Degrees In Direction of
Arrow
1 - 2ND HIGH SPOT ON TIRE
2 - 1ST HIGH SPOT ON TIRE
22 - 4 TIRES/WHEELSRS
TIRES/WHEELS (Continued)

(10) Verify door latch and power door lock opera-
tion.
(11) Install watershield and front door trim panel.
LATCH STRIKER
REMOVAL
(1) Mark outline of door striker on B-pillar to aid
in installation.
(2) Remove screws attaching door latch striker to
B-pillar (Fig. 10).
(3) Remove door latch striker from vehicle.
(4) Retrieve any shims found between latch striker
and B-pillar.
INSTALLATION
(1) Position latch striker and any shims retrieved
on vehicle.
(2) Loosely install screws attaching latch striker to
B-pillar.
(3) Align latch striker to outline on B-pillar made
previously.
(4) Tighten fasteners to 28 N´m (21 ft. lbs.) torque.
(5) Verify door fit and operation. Adjust latch
striker as necessary.
LOCK CYLINDER
REMOVAL
(1) Roll door glass up.
(2) Remove front door watershield as necessary to
gain access to the outside door handle. (Refer to 23 -
BODY/DOOR - FRONT/WATERSHIELD -
REMOVAL)
(3) Through access hole at rear of inner door
panel, disconnect Vehicle Theft Security System
(VTSS) switch connector from door harness, if
equipped.
(4) Disengage push in fasteners attaching VTSS
switch harness to inner door reinforcement bar, if
equipped.
(5) Disengage clip holding door latch linkage to
door latch (Fig. 11).
(6) Remove latch linkage from latch.
(7) Disengage clip holding door lock linkage to
door latch.
(8) Remove lock linkage from latch.
(9) Remove nuts attaching outside door handle to
door outer panel.
(10) Remove outside door handle from vehicle.
(11) Disengage clip holding lock cylinder into out-
side handle.
(12) Pull lock cylinder from door handle.
INSTALLATION
(1) Engage clip into outside handle to hold lock
cylinder (Fig. 11).
(2) With link arm toward rear of vehicle, push lock
cylinder into door handle until clip snaps into place.
(3) Insert lock linkage into door latch.
(4) Engage clip to hold door lock linkage to latch.
(5) Insert latch linkage into door latch.
(6) Engage clip to hold door latch linkage to latch.
(7) Install push in fasteners attaching VTSS
switch harness to inner door reinforcement bar, if
equipped.
(8) Connect VTSS switch connector into door har-
ness, if equipped.
(9) Verify door latch operation.
(10) Install watershield and door trim panel.
Fig. 10 DOOR LATCH STRIKER
1 - B-PILLAR
2 - SHIM
3 - DOOR LATCH STRIKER
RSDOOR - FRONT23-19
LATCH (Continued)

(4) Place front door trim panel in position on door.
(5) Install trim panel into inner belt molding at
top of door.
(6) Install clips to attach door trim to door frame
around perimeter of panel.
(7) If equipped, install screw to attach door trim to
door panel behind inside latch release handle.
(8) If equipped, connect power switch into wire
connector.
(9) Place power accessary switch in position on
door trim.
(10) Connect wire connector into memory seat/mir-
ror switch and install switch into trim panel.
(11) Install screws to attach accessary switch
panel to door trim.
(12) Install screw cover into switch panel.
(13) If equipped, install window crank.
(14) If equipped, install screws to attach trim
panel to door inside map pocket.
(15) If equipped, install screw to attach door pull
cup to inner door panel.
(16) If equipped, install screws to attach door
assist handle to inner door panel.
(17) Connect wire connector into courtesy lamp.
(18) Install lamp in door trim.
(19) Install switch bezel.
WATERSHIELD
REMOVAL
(1) Remove door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(2) Remove the front door speaker. (Refer to 8 -
ELECTRICAL/AUDIO/SPEAKER - REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
INSTALLATION
(1) Insure that enough adhesive remains to
securely retain the water dam. Replace as necessary.
(2) Place the shield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(3) Install the front door speaker. (Refer to 8 -
ELECTRICAL/AUDIO/SPEAKER - INSTALLATION)
(4) Install door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION)
WINDOW CRANK
REMOVAL
(1) Using a window crank removal tool, disengage
clip attaching window crank to regulator shaft (Fig.
13).
NOTE: Wrap a shop towel around the window crank
to catch the clip when it springs out.
(2) Pull window crank from regulator shaft.
INSTALLATION
(1) Place the clip on to the window crank handle.
(2) Position window crank to regulator shaft.
(3) Push window crank onto regulator shaft to
engage retaining clip.
EXTERIOR HANDLE
REMOVAL
(1) Roll door glass up.
(2) Remove the watershield as necessary to gain
access to the outside door handle. (Refer to 23 -
BODY/DOOR - FRONT/WATERSHIELD -
REMOVAL)
(3) Through access hole at rear of inner door
panel, disconnect Vehicle Theft Security System
(VTSS) switch connector from door harness, if
equipped.
(4) Disengage push in fasteners attaching VTSS
switch harness to inner door reinforcement bar, if
equipped.
(5) Disengage clip holding door latch linkage to
door latch (Fig. 11).
(6) Remove latch linkage from latch.
Fig. 13 WINDOW CRANK - TYPICAL
1 - WINDOW CRANK REMOVAL TOOL
2 - WINDOW CRANK
RSDOOR - FRONT23-21
TRIM PANEL (Continued)

(12) Open door half way and remove lower hinge
bolt access plug.
(13) Loosen bolts as necessary to move the front of
door up or down.
(14) Check the upper hinge for possible bind,
adjust as necessary.
(15) Close the door and check the sliding door
alignment.
(16) Fully open door and apply thread lock nut
onto the center hinge bolt. Tighten nut until till it
butts up against the welded nut on the center hinge.
Tighten nut to 13 N´m (115 in. lbs.) torque. It may be
necessary to hold the center hinge bolt to prevent it
from turning while tightening nut.
(17) Verify alignment, adjust as necessary.
DOOR GAP ADJUSTMENT - FORE/AFT
(1) Check C-pillar and B-pillar for door to aperture
gaps (5 mm + 1 mm), and door to door gap (5 mm +
1 mm).
(2) If adjust gaps require adjustment, loosen cen-
ter hinge screws as necessary to move center hinge
forward or rearward.
(3) Moving center hinge rearward increases the
gap at C-pillar and decreases gap at B-pillar. Moving
center hinge forward decreases gap at the C-pillar
and increases gap at the B-pillar
(4) Move center hinge as necessary, and tighten
screws.
(5) Close the door and check the sliding door align-
ment.
(6) Verify door alignment, adjust as necessary.
(7) Tighten center hinge screws to 13 N´m (115 in.
lbs.) torque.
DOOR SEAL COMPRESSION
(1) First check Gap & Flush (Refer to 23 - BODY/
BODY STRUCTURE/GAP AND FLUSH - SPECIFI-
CATIONS). Check seal compression near the middle
of the door even with the latch assembly. Using a
piece of paper, place it across door seal and close
door. Pull paper out of door opening. If paper tears
setting is to tight, if paper slides thought to easily
the compression is insufficient and needs to be
adjusted.
(2) Adjust seal compression at the top of the B-pil-
lar seal;
(a) Open door to mid-point of travel.
(b) Mark outline of upper roller arm on door to
assist in making adjustments.
(c) Loosen bolts attaching upper roller arm to
door (Fig. 16).
(d) Decrease the length of the upper roller arm
to increase seal compression.
(e) Increase the length of the upper roller arm to
decrease seal compression.
(f) Tighten all upper roller arm bolts to 13 N´m
(115 in. lbs.) torque.
(g) Verify door alignment, adjust as necessary.
(3) Adjust seal compression at the bottom of B-pil-
lar seal.
(a) Open door to mid-point of travel.
(b) Mark outline of lower roller arm on lower
roller arm bracket to assist in making adjustments
(Fig. 17).
(c) Loosen bolts holding lower roller arm to
lower roller arm bracket.
(d) Pivot lower roller arm toward center of vehi-
cle to decrease seal compression.
Fig. 15 SLIDING DOOR LOWER ROLLER ARM
1 - LOWER ROLLER ARM BRACKET
2 - BOLTS
3 - SLIDING DOOR
Fig. 16 Sliding Door Upper Roller Arm
1 - UPPER STOP PLATE
2 - SLIDING DOOR
3 - UPPER SLIDING DOOR HINGE
23 - 32 DOORS - SLIDINGRS
SLIDING DOOR (Continued)

COWL GRILLE
REMOVAL
(1) Remove wiper arms. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS -
REMOVAL)
(2) Remove four (4) screws securing cowl cover to
wiper module (Fig. 6).
(3) Disengage quarter turn fasteners at outboard
ends of cowl grill from body.
(4) Release hood latch and open hood.
CAUTION: To prevent hood scratching of cowl grille
before removal, cover outboard exterior ends of
cowl grille with masking tape or equivalent method.
NOTE: Do not over bend cowl grille during removal.
Bend cowl grille just enough to clear top of wiper
pivot shaft and bottom rear corner of hood.
(5) Remove cowl grill by raising above driver side
wiper pivot shaft and swinging away towards engine
compartment. The cowl grille will need to be bent onoutboard end to clear simultaneously top of wiper
pivot shaft and bottom corner of hood.
(6) Close hood. Do not latch. Remove outboard
screws. (Fig. 7).
(7) Disconnect washer hose in line connector.
(8) Disconnect washer hose and grommet from
hole in wiper module and pull out.
(9) Remove cowl grille by raising over opposite
wiper pivot shaft and removing away from vehicle.
(10) Remove cowl cover from vehicle.
INSTALLATION
(1) Reverse removal procedure.
(2) When installing cowl cover over wiper module,
make sure fore aft locator on the underside of cowl
grill seat into the locator grooves on top of wiper
module.
(3) Start all cowl grille mounting screws by hand
before torquing to specifications.
(4) Assure washer hose is properly routed and not
pinched.
(5) Center cowl grille to body and windshield.
(6) Assure ªarrowº indicator head of quarter turn
fasteners is pointing toward windshield.
Fig. 5 BODY SIDE MOLDINGS WITH APPLIQUE - TYPICAL
1 - FRONT ROCKER PANEL APPLIQUE
2 - FRONT DOOR MOLDING
3 - SLIDING DOOR MOLDING4 - REAR ROCKER PANEL APPLIQUE
5 - LIFTGATE MOLDING
6 - POP-RIVET
23 - 50 EXTERIORRS
BODY SIDE MOLDINGS (Continued)