CHRYSLER VOYAGER 2005 Service Manual

(10) Install the UD clutch pack. Leave out upper
disc, until snap ring is installed (Fig. 226).
(11) Install the UD clutch flat snap ring (Fig. 227).
(12) Install the last UD clutch disc (Fig. 228).
(13) Install the OD/UD clutch reaction plate and
snap ring (Fig. 229) (Fig. 230). The OD/UD clutches
reaction plate has a step on both sides. Install the
OD/UD clutches reaction plate tapered step side up.
Fig. 226 Install Underdrive Clutch Pack
1 - CLUTCH DISC
2 - CLUTCH PLATE
Fig. 227 UD Clutch Flat Snap Ring
1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
Fig. 228 Install Last UD Clutch Disc
1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 229 OD/UD Reaction Plate
1 - OD/UD CLUTCH REACTION PLATE (TAPERED STEP SIDE UP)
Fig. 230 Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
21 - 100 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

NOTE: Snap ring ends must be located within one
finger of the input clutch hub. Be sure that snap
ring is fully seated, by pushing with screwdriver,
into snap ring groove all the way around.
(14) Seat tapered snap ring to ensure proper
installation (Fig. 231) (Fig. 232).
Fig. 231 Seating Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER
Fig. 232 Underdrive Clutch Assembly
1 - SNAP RING (TAPERED)
2 - OD/UD REACTION PLATE
3 - CLUTCH DISC (3)4 - SNAP RING (FLAT)
5 - CLUTCH PLATE (3)
6 - INPUT CLUTCH ASSEMBLY
RS40TE AUTOMATIC TRANSAXLE21 - 101
INPUT CLUTCH ASSEMBLY (Continued)

(15) Install input clutch assembly to the Input
Clutch Pressure Fixture±Tool 8391 (Fig. 233).
(16) Set up dial indicator on the UD clutch pack as
shown in (Fig. 234).
(17) Using moderate pressure, press down and
hold (near indicator) the UD clutch pack with screw-
driver or suitable tool and zero dial indicator (Fig.
235). When releasing pressure on clutch pack, indica-
tor reading should advance 0.005±0.010.
CAUTION: Do not apply more than 30 psi (206 kPa)
to the underdrive clutch pack.
(18) Apply 30 psi (206 kPa) to the underdrive hose
on Tool 8391 and measure UD clutch clearance. Mea-
sure and record UD clutch pack measurement in four
(4) places, 90É apart.
(19) Take average of four measurements and com-
pare with UD clutch pack clearance specification.
Underdrive clutch pack clearance must be 0.94-
1.50 mm (0.037-0.059 in.).
(20) If necessary, select the proper reaction plate
to achieve specifications:
UNDERDRIVE REACTION PLATE THICKNESS
4659939AB 5.837-5.937 mm (0.230-0.234 in.)
4659940AB 6.147-6.248 mm (0.242-0.246 in.)
4659941AB 6.457-6.557 mm (0.254-0.258 in.)
Fig. 233 Input Clutch Assembly on Pressure Fixture
Tool 8391
1 - INPUT CLUTCH ASSEMBLY
2 - INPUT CLUTCH PRESSURE FIXTURE 8391
Fig. 234 Set Up Dial Indicator to Measure UD Clutch
Clearance
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
Fig. 235 Press Down on UD Clutch Pack and Zero
Dial Indicator
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
21 - 102 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(21) Install the OD clutch pack (Fig. 236).
(22) Install OD pressure plate waved snap ring
(Fig. 237).(23) Install the OD/Reverse pressure plate with
large step down (towards OD clutch pack) (Fig. 238).
(24) Install OD pressure plate flat snap ring (Fig.
239) (Fig. 240).
Fig. 236 Install Overdrive Clutch Pack
1 - CLUTCH DISC
2 - CLUTCH PLATE
Fig. 237 Install Waved Snap Ring
1 - OVERDRIVE PRESSURE PLATE WAVED SNAP RING
2 - SCREWDRIVER
Fig. 238 OD/Reverse Reaction Plate
1 - OVERDRIVE/REVERSE PRESSURE PLATE
2 - (STEP SIDE DOWN)
Fig. 239 Install Flat Snap Ring
1 - ARBOR PRESS RAM
2 - TOOL 5059A
3 - FLAT SNAP RING
RS40TE AUTOMATIC TRANSAXLE21 - 103
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 240 Overdrive Clutch Assembly
1 - SNAP RING
2 - OD/REVERSE PRESSURE PLATE
3 - SNAP RING (WAVE)4 - CLUTCH DISC (3)
5 - CLUTCH STEEL (2)
6 - INPUT CLUTCH ASSEMBLY
21 - 104 40TE 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. 241).
(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. 242).
(29) Install reverse clutch reaction plate with the
flat side down towards reverse clutch (Fig. 243).
Fig. 241 Measure OD Clutch Pack Clearance
1 - DIAL INDICATOR
2 - OD/REVERSE REACTION PLATE
Fig. 242 Install Reverse Clutch Pack
1 - REVERSE CLUTCH PLATE
2 - REVERSE CLUTCH DISCS
Fig. 243 Install Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)
RS40TE AUTOMATIC TRANSAXLE21 - 105
INPUT CLUTCH ASSEMBLY (Continued)

(30) Tap reaction plate down to allow installation
of the reverse clutch snap ring. Install reverse clutch
snap ring (Fig. 244) (Fig. 245).(31) Pry up reverse reaction plate to seat against
snap ring (Fig. 246).
Fig. 245 Reverse Clutch Assembly
1 - SNAP RING
2 - REACTION PLATE
3 - CLUTCH DISC (2)4 - CLUTCH PLATE (1)
5 - INPUT CLUTCH ASSEMBLY
Fig. 244 Install Reverse Clutch Snap Ring
1 - REVERSE CLUTCH SNAP RING (SELECT)
2 - SCREWDRIVER
3 - REVERSE CLUTCH REACTION PLATE
Fig. 246 Pry Up Reaction Plate
1 - SCREWDRIVER
2 - SNAP RING
3 - SCREWDRIVER
4 - MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP
RING
21 - 106 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(32) Set up a dial indicator on the reverse clutch
pack as shown in (Fig. 247).
(33) Using moderate pressure, press down and
hold (near indicator) reverse clutch disc with screw-
driver or suitable tool and zero dial indicator (Fig.
248). When releasing pressure, indicator should
advance 0.005-0.010. as clutch pack relaxes.
(34) Apply 30 psi (206 kPa) air pressure to the
reverse clutch hose on Tool 8391. Measure and record
reverse clutch pack measurement in four (4) places,
90É apart.
(35) Take average of four measurements and com-
pare with reverse clutch pack clearance specification.
The reverse clutch pack clearance is 0.89-1.37
mm (0.035-0.054 in.).Select the proper reverse
clutch snap ring to achieve specifications:
REVERSE CLUTCH SNAP RING THICKNESS
4377195 1.53-1.58 mm (0.060-0.062 in.)
4412871 1.77-1.83 mm (0.070-0.072 in.)
4412872 2.02-2.07 mm (0.080-0.082 in.)
4412873 2.27-2.32 mm (0.090-0.091 in.)(36) To complete the assembly, reverse clutch and
overdrive clutch must be removed.
(37) Install the #2 needle bearing (Fig. 249).
Fig. 247 Measure Reverse Clutch Pack Clearance
1 - DIAL INDICATOR
2 - REVERSE CLUTCH
Fig. 248 Press Down on Reverse Clutch and Zero
Indicator
1 - DIAL INDICATOR
2 - REVERSE CLUTCH
Fig. 249 Install No. 2 Needle Bearing
1 - #2 NEEDLE BEARING (NOTE 3 SMALL TABS)
2 - TABS UP
RS40TE AUTOMATIC TRANSAXLE21 - 107
INPUT CLUTCH ASSEMBLY (Continued)

(38) Install the underdrive shaft assembly (Fig.
250).
(39) Install the #3 thrust washer to the underdrive
shaft assembly. Be sure five tabs are seated properly
(Fig. 251).(40) Install the #3 thrust plate to the bottom of the
overdrive shaft assembly. Retain with petrolatum or
transmission assembly gel (Fig. 252).
(41) Install the overdrive shaft assembly (Fig. 253)
(Fig. 254).
(42) Reinstall overdrive and reverse clutch as
shown.Rechecking these clutch clearances is
not necessary.
Fig. 250 Install Underdrive Shaft Assembly
1 - UNDERDRIVE SHAFT ASSEMBLY
2 - #2 NEEDLE BEARING
Fig. 251 Install No. 3 Thrust Washer
1 - #3 THRUST WASHER (NOTE 5 TABS)
2 - UNDERDRIVE SHAFT ASSEMBLY
Fig. 252 Install No. 3 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - DABS OF PETROLATUM (FOR RETENTION)
3 - #3 THRUST PLATE (NOTE 3 TABS)
Fig. 253 Install Overdrive Shaft Assembly
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #3 THRUST PLATE
3 - #3 THRUST WASHER
21 - 108 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 254 Overdrive/Underdrive Shafts
1 - OVERDRIVE SHAFT
2 - #3 THRUST PLATE (3 TABS)
3 - #3 THRUST WASHER (5 TABS)4 - UNDERDRIVE SHAFT
5 - #2 NEEDLE BEARING (3 TABS)
6 - INPUT CLUTCH ASSEMBLY
RS40TE AUTOMATIC TRANSAXLE21 - 109
INPUT CLUTCH ASSEMBLY (Continued)