CHRYSLER VOYAGER 2005 Service Manual

(3) Install low/reverse piston retainer (Fig. 87).
(4) Install low/reverse piston retainer-to-case bolts
(Fig. 88) and torque to 5 N´m (45 in. lbs.).
NOTE: The Low/Reverse Clutch Piston has bonded
seals which are not individually serviceable. Seal
replacement requires replacement of the piston
assembly.(5) Install low/reverse clutch piston (Fig. 89).
(6) Assemble park guide bracket assembly (Fig.
91) (Fig. 90).
Fig. 87 Install Piston Retainer
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - GASKET
Fig. 88 Install Piston Retainer-to-Case Screws
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - SCREWDRIVER
3 - TORX-LOC SCREWS
Fig. 89 Install Low/Reverse Clutch Piston
1 - LOW/REVERSE CLUTCH PISTON
2 - BONDED SEAL
3 - BONDED SEAL
Fig. 90 Guide Bracket Disassembled
1 - ANTIRATCHET SPRING
2 - GUIDE BRACKET
3 - SPLIT SLEEVE
4 - SPACER
5-PAWL
6 - STEPPED SPACER
21 - 30 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(7) Install guide bracket into position and insert
pivot shaft (Fig. 92).(8) Install anchor shaft and plug (Fig. 93). Make
sure guide bracket and split sleeve are in contact
with the rear of the transaxle case.
(9) Install low/reverse piston return spring (Fig.
94).
Fig. 91 Guide Bracket
1 - GUIDE BRACKET
2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN)
3-PAWL
Fig. 92 Pivot Shaft and Guide Bracket
1 - ANTIRACHET SPRING
2 - GUIDE BRACKET
3 - PIVOT SHAFT
4-PAWL
Fig. 93 Install Anchor Shaft and Plug
1 - GUIDE BRACKET ANCHOR SHAFT
2 - PIVOT SHAFT
3 - ANCHOR SHAFT PLUG
Fig. 94 Low/Reverse Piston Return Spring
1 - LOW/REVERSE PISTON RETURN SPRING
2 - PISTON
RS40TE AUTOMATIC TRANSAXLE21-31
40TE AUTOMATIC TRANSAXLE (Continued)

(10) Install low/reverse spring compressor into
position (Fig. 95). Compress low/reverse piston and
install snap ring as shown in (Fig. 96).(11) Install rear carrier bearing cone using Tool
6053 (Fig. 97).
(12) Install rear carrier assembly to transaxle case
(Fig. 98).
Fig. 95 Compressor Tool in Use
1 - LOW/REVERSE CLUTCH RETURN SPRING
2 - SNAP RING (INSTALL AS SHOWN)
3 - TOOL 6057
4 - TOOL 5059
5 - TOOL 5058±3
Fig. 96 Install Snap Ring
1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS
(AS SHOWN)
2 - SNAP RING PLIERS
3 - TOOL 6057
Fig. 97 Install Rear Carrier Bearing Cone
1 - ARBOR PRESS RAM
2 - TOOL 6053
3 - NEW BEARING CONE
4 - REAR CARRIER ASSEMBLY
Fig. 98 Install Rear Carrier Assembly
1 - REAR CARRIER ASSEMBLY
21 - 32 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(13) Install output gear bearing cone using Tool
5052 (Fig. 99).
(14)OUTPUT GEAR BEARING ADJUST-
MENT:
(a) With output gear Installd, install a 4.50 mm
(0.177 in.) gauging shim (Fig. 101) 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. 100).
(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. 100).
(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. 99 Install Output Gear Bearing Cone
1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - TOOL 5052
4 - OUTPUT GEAR
Fig. 100 Checking Output Gear Bearings End Play
1 - TOOL L-4432
2 - DIAL INDICATOR
3 - SPECIAL SCREWS TOOL 6260
4 - OUTPUT GEAR
Fig. 101 Output Gear and (Select) Shim
1 - REAR CARRIER ASSEMBLY
2 - SHIM (SELECT)
3 - OUTPUT GEAR
RS40TE AUTOMATIC TRANSAXLE21-33
40TE AUTOMATIC TRANSAXLE (Continued)

OUTPUT GEAR BEARING SHIM CHART
End Play Shim Needed Part Number End Play Shim Needed Part Number
0.05mm
(0.002 in.)4.42mm
(0.174 in.)4412830AB0.53mm
(0.021 in.)3.94mm
(0.155 in.)4412818AB
0.08mm
(0.003 in.)4.38mm
(0.172 in.)4412829AB0.56mm
(0.022 in.)3.90mm
(0.154 in.)4412817AB
0.10mm
(0.004 in.)4.38mm
(0.172 in.)4412829AB0.58mm
(0.023 in.)3.90mm
(0.154 in.)4412817AB
0.13mm
(0.005 in.)4.34mm
(0.171 in.)4412828AB0.61mm
(0.024 in.)3.86mm
(0.152 in.)4412816AB
0.15mm
(0.006 in.)4.30mm
(0.169 in.)4412827AB0.64mm
(0.025 in.)3.82mm
(0.150 in.)4412815AB
0.18mm
(0.007 in.)4.30mm
(0.169 in.)4412827AB0.66mm
(0.026 in.)3.82mm
(0.150 in.)4412815AB
0.20mm
(0.008 in.)4.26mm
(0.168 in.)4412826AB0.69mm
(0.027 in.)3.78mm
(0.149 in.)4412814AB
0.23mm
(0.009 in.)4.22mm
(0.166 in.)4412825AB0.71mm
(0.028 in.)3.74mm
(0.147 in.)4412813AB
0.25mm
(0.010 in.)4.22mm
(0.166 in.)4412825AB0.74mm
(0.029 in.)3.74mm
(0.147 in.)4412813AB
0.28mm
(0.011 in.)4.18mm
(0.165 in.)4412824AB0.76mm
(0.030 in.)3.70mm
(0.146 in.)4412812AB
0.30mm
(0.012 in.)4.14mm
(0.163 in.)4412823AB0.79mm
(0.031 in.)3.66mm
(0.144 in.)4412811AB
0.33mm
(0.013 in.)4.14mm
(0.163 in.)4412823AB0.81mm
(0.032 in.)3.66mm
(0.144 in.)4412811AB
0.36mm
(0.014 in.)4.10mm
(0.161 in.)4412822AB0.84mm
(0.033 in.)3.62mm
(0.143 in.)4412810AB
0.38mm
(0.015 in.)4.10mm
(0.161 in.)4412822AB0.86mm
(0.034 in.)3.62mm
(0.143 in.)4412810AB
0.41mm
(0.016 in.)4.06mm
(0.160 in.)4412821AB0.89mm
(0.035 in.)3.58mm
(0.141)4412809AB
0.43mm
(0.017 in.)4.02mm
(0.158 in.)4412820AB0.91mm
(0.036in.)3.54mm
(0.139 in.)4412808AB
0.46mm
(0.018 in.)4.02mm
(0.158 in.)4412820AB0.94mm
(0.037 in.)3.54mm
(0.139 in.)4412808AB
0.48mm
(0.019 in.)3.98mm
(0.157 in.)4412819AB0.97mm
(0.038 in.)3.50mm
(0.138 in.)4412807AB
0.51mm
(0.020 in.)3.94mm
(0.155 in.)4412818AB
21 - 34 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(15) Install the output gear and bearing assembly
using Tool 6261 (Fig. 102).
(16) Install NEW output gear retaining bolt and
washer (Fig. 103). Using Tool 6259, torque output
gear retaining bolt to 271 N´m (200 ft. lbs.) (Fig.
104).(17) Using an inch pound torque wrench (Fig.
105), 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. 102 Install Output Gear
1 - WRENCHES
2 - TOOL 6261 WITH STUD
3 - OUTPUT GEAR
Fig. 103 Output Gear Bolt and Washer
1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
Fig. 104 Tighten Output Gear to 271 N²m (200 ft. lbs.)
1 - OUTPUT GEAR
2 - TORQUE WRENCH
3 - 200 FT. LBS.
4 - TOOL 6259
Fig. 105 Check Output Gear Bearings Turning
Torque
1 - INCH-POUND TORQUE WRENCH
2 - OUTPUT GEAR
RS40TE AUTOMATIC TRANSAXLE21-35
40TE AUTOMATIC TRANSAXLE (Continued)

(18) Install output gear stirrup with serrated side
out (Fig. 106).
(19) Install retaining strap (Fig. 107).
(20) Install strap bolts but do not tighten at this
time (Fig. 107).(21) Rotate stirrup clockwise against flats of
retaining bolt (Fig. 108).
(22) Torque stirrup strap bolts to 23 N´m (200 in.
lbs.) (Fig. 109).
Fig. 106 Install Stirrup
1 - STIRRUP
2 - OUTPUT GEAR RETAINING BOLT
Fig. 107 Install Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
Fig. 108 Turn Stirrup Clockwise Against Flats Of
Output Gear Retaining Bolt
1 - RETAINING STRAP
2 - STIRRUP
Fig. 109 Tighten Stirrup Strap Bolts to 23 N´m (200
in. lbs.)
1 - RETAINING STRAP
2 - STIRRUP
21 - 36 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(23) Bend tabs on strap up against flats of bolts
(Fig. 110).
(24) Install transfer shaft bearing cone using Tool
6052 (Fig. 111).(25) Install bearing cup and oil baffle to transfer
shaft (Fig. 112).
(26) Using Tool 5049A, install transfer shaft (Fig.
113).
Fig. 110 Bend Tabs On Strap Up Against Flats Of
Bolts
1 - RETAINING STRAP TABS
2 - RETAINING STRAP
3 - STIRRUP
Fig. 111 Install Transfer Shaft Bearing Cone
1 - TOOL 6052
2 - NEW BEARING CONE
3 - TRANSFER SHAFT
4 - ARBOR PRESS RAM
Fig. 112 Install Bearing Cup to Shaft
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
Fig. 113 Install Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
RS40TE AUTOMATIC TRANSAXLE21-37
40TE AUTOMATIC TRANSAXLE (Continued)

(27) Using Tool 6051, install transfer shaft bearing
snap ring (Fig. 114).
(28) Install transfer shaft bearing cup into retainer
using Tool 6061 (Fig. 115).(29) Install bearing cup retainer to transaxle (Fig.
116).
(30) Install transfer gear bearing cone to transfer
gear using Tool 5052 (Fig. 117).
Fig. 114 Install Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS TOOL 6051
2 - TRANSFER SHAFT BEARING SNAP RING
3 - TRANSFER SHAFT
Fig. 115 Install Transfer Shaft Bearing Cup Into
Retainer
1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - TOOL 6061
4 - TRANSFER SHAFT BEARING CUP RETAINER
5 - USE REMOVED BEARING CUP TO SUPPORT RETAINER
Fig. 116 Install Bearing Cup Retainer
1 - ALIGN INDEXING TAB TO SLOT
2 - BEARING CUP RETAINER
Fig. 117 Install Transfer Gear Bearing Cone
1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - NEW BEARING CONE
4 - TRANSFER SHAFT GEAR
5 - TOOL 5052
21 - 38 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(31)TRANSFER GEAR BEARING ADJUST-
MENT:
(a) Install a 4.66 mm (0.184 in.) gauging shim
on the transfer shaft (Fig. 118).
(b) Install transfer shaft gear using Tool 6261.
Using Tool 6259, install transfer shaft gear retain-
ing nut to 271 N´m (200 ft. lbs.).
(c) Measure end play. Attach Tool L4432 to the
transfer gear.
(d) Mount a steel ball with grease into the end
of the transfer shaft.
(e) Push and pull the gear while rotating back
and forth to ensure seating of the bearing rollers.
(f) Using a dial indicator, measure transfer shaft
end play.
(g) Refer to the transfer shaft bearing shim
chart for the required shim combination to obtain
the proper bearing setting.
(h) Use Tool 6259 to remove the retaining nut
and washer. Remove the transfer shaft gear using
Tool L4407A.
(i) Remove the gauging shim (Fig. 118) and
install the proper shim indicated by the chart.
TRANSFER SHAFT BEARING SHIM CHART
End Play Shim Needed Part Number End Play Shim Needed Part Number
0.05mm
(0.002 in.)4.66mm
(0.183 in.)4505588AB0.76mm
(0.030 in.)3.94mm
(0.155 in.)4412818AB
0.08mm
(0.003 in.)4.62mm
(0.182 in.)4412835AB0.79mm
(0.031 in.)3.90mm
(0.154 in.)4412817AB
0.10mm
(0.004 in.)4.58mm
(0.180 in.)4412834AB0.81mm
(0.032 in.)3.90mm
(0.154 in.)4412817AB
0.13mm
(0.005 in.)4.58mm
(0.180 in.)4412834AB0.84mm
(0.033 in.)3.86mm
(0.152 in.)4412816AB
0.15mm
(0.006 in.)4.54mm
(0.178 in.)4412833AB0.86mm
(0.034 in.)3.82mm
(0.150 in.)4412815AB
0.18mm
(0.007 in.)4.50mm
(0.177 in.)4412832AB0.89mm
(0.035 in.)3.82mm
(0.150 in.)4412815AB
0.20mm
(0.008 in.)4.50mm
(0.177 in.)4412832AB0.91mm
(0.036 in.)3.78mm
(0.149 in.)4412814AB
0.23mm
(0.009 in.)4.46mm
(0.175 in.)4412831AB0.94mm
(0.037 in.)3.74mm
(0.147 in.)4412813AB
0.25mm
(0.010 in.)4.46mm
(0.175 in.)4412831AB0.97mm
(0.038 in.)3.74mm
(0.147 in.)4412813AB
0.28mm
(0.011 in.)4.42mm
(0.174 in.)4412830AB0.99mm
(0.039 in.)3.70mm
(0.146 in.)4412812AB
0.30mm
(0.012 in.)4.38mm
(0.172 in.)4412829AB1.02mm
(0.040 in.)3.66mm
(0.144 in.)4412811AB
0.33mm
(0.013 in.)4.38mm
(0.172 in.)4412829AB1.04mm
(0.041 in.)3.66mm
(0.144 in.)4412811AB
Fig. 118 Install Transfer Shaft Gear and
(Select) Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM
(SELECT)
RS40TE AUTOMATIC TRANSAXLE21-39
40TE AUTOMATIC TRANSAXLE (Continued)