torque CHRYSLER VOYAGER 2005 Service Manual

(8) Install the overdrive clutch (#5) check valve to
separator plate (Fig. 339)
(9) Install oil screen to separator plate (Fig. 340).(10) Install transfer plate to valve body and sepa-
rator plate. Make sure oil screen and #5 check valve
do not bind (Fig. 341).
(11) Install twenty-four transfer plate to valve
body screws (Fig. 342) and torque to 5 N´m (45 in.
lbs.).
Fig. 339 Install Overdrive Clutch (#5) Check Valve
1 - OVERDRIVE CLUTCH (#5) CHECK VALVE
Fig. 340 Install Oil Screen
1 - OIL SCREEN
Fig. 341 Install Transfer Plate
1 - TRANSFER PLATE
Fig. 342 Install Valve Body to Transfer Plate Screws
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
21 - 142 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(12) Install 2/4 Accumulator components as shown
in (Fig. 343).
(13) Torque 2/4 Accumulator retainer to 5 N´m (45
in. lbs.) (Fig. 344).
(14) Install Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 345).
(15) Make sure Manual Valve control pin is con-
tained within the rooster comb slot (Fig. 346). Install
Transmission Range Sensor retaining screw (Fig.
346) and torque to 5 N´m (45 in. lbs.).
Fig. 343 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
Fig. 344 2/4 Accumulator Retaining Plate
1 - 2±4 ACCUMULATOR RETAINING PLATE
2 - DETENT SPRING
Fig. 345 Install Manual Shaft/Rooster Comb and
Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
Fig. 346 Install Transmission Range Sensor
Retaining Screw
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
RS40TE AUTOMATIC TRANSAXLE21 - 143
VALVE BODY (Continued)

(16) Install manual shaft seal (Fig. 347).
INSTALLATION
NOTE: If valve body assembly is being replaced or
reconditioned, the ªQuick-Learnº procedure must
be performed. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install valve body assembly to transaxle (Fig.
348). Install and torque valve body-to-transaxle case
bolts (Fig. 349) to 12 N´m (105 in. lbs.).(2) Install transaxle oil filter (Fig. 350). Inspect
the o-ring and replace if necessary.
Fig. 347 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 348 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 349 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 350 Oil Filter
1 - OIL FILTER
2 - O-RING
21 - 144 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(3) Ensure the transaxle oil pan and transaxle
case sealing surfaces are clean and dry. Install an
1/8º bead of MopartSilicone Rubber Adhesive Seal-
ant to the oil pan and install (Fig. 351). Torque oil
pan-to-transaxle case bolts (Fig. 352) to 19 N´m (165
in. lbs.).
(4) Lower vehicle.(5) Connect transmission range sensor connector.
(6) Install manual valve lever to manual shaft.
(7) Install gearshift cable to manual valve lever.
(8) Connect battery negative cable.
(9) Fill transaxle with MopartATF +4 Transmis-
sion fluid. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
Fig. 351 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 352 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
RS40TE AUTOMATIC TRANSAXLE21 - 145
VALVE BODY (Continued)

41TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
41TE AUTOMATIC TRANSAXLE
DESCRIPTION........................147
OPERATION..........................149
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - 4XTE
TRANSAXLE GENERAL DIAGNOSIS......149
DIAGNOSIS AND TESTING - ROAD TEST . . 150
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS...................150
DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS...................153
DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE . . 154
REMOVAL............................154
DISASSEMBLY........................157
ASSEMBLY...........................174
INSTALLATION........................196
SCHEMATICS AND DIAGRAMS
4XTE TRANSAXLE HYDRAULIC
SCHEMATICS.......................199
SPECIFICATIONS - 41TE TRANSAXLE......211
SPECIAL TOOLS
41TE AUTOMATIC TRANSAXLE.........213
ACCUMULATOR
DESCRIPTION........................218
OPERATION..........................218
DRIVING CLUTCHES
DESCRIPTION........................219
OPERATION..........................219
FINAL DRIVE
DESCRIPTION........................219
OPERATION..........................220
DISASSEMBLY........................220
ASSEMBLY...........................224
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL BEARING
PRELOAD..........................228
FLUID
STANDARD PROCEDURE
FLUID LEVEL AND CONDITION CHECK . . . 230
STANDARD PROCEDURE - FLUID AND
FILTER SERVICE.....................231
GEAR SHIFT CABLE
REMOVAL............................233
INSTALLATION........................234
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT.......235
HOLDING CLUTCHES
DESCRIPTION........................236
OPERATION..........................236INPUT CLUTCH ASSEMBLY
DISASSEMBLY........................237
ASSEMBLY...........................246
OIL PUMP
DESCRIPTION........................261
OPERATION..........................261
DISASSEMBLY........................261
ASSEMBLY...........................263
PLANETARY GEARTRAIN
DESCRIPTION........................263
OPERATION..........................263
SEAL - OIL PUMP
REMOVAL............................264
INSTALLATION........................264
SHIFT INTERLOCK SOLENOID
DESCRIPTION........................264
OPERATION..........................265
DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK
SOLENOID..........................266
REMOVAL............................266
INSTALLATION........................267
SOLENOID/PRESSURE SWITCH ASSY
DESCRIPTION........................268
OPERATION..........................268
REMOVAL............................269
INSTALLATION........................270
SPEED SENSOR - INPUT
DESCRIPTION........................271
OPERATION..........................271
REMOVAL............................272
INSTALLATION........................272
SPEED SENSOR - OUTPUT
DESCRIPTION........................273
OPERATION..........................273
REMOVAL............................274
INSTALLATION........................274
TORQUE CONVERTER
DESCRIPTION........................275
OPERATION..........................278
REMOVAL............................280
INSTALLATION........................280
TRANSMISSION CONTROL RELAY
DESCRIPTION........................281
OPERATION..........................281
TRANSMISSION RANGE SENSOR
DESCRIPTION........................281
OPERATION..........................282
REMOVAL............................282
INSTALLATION........................282
21 - 146 41TE AUTOMATIC TRANSAXLERS

Fig. 1 41TE Automatic Transaxle
1 - TRANSAXLE CASE 7 - REVERSE CLUTCH 13 - OUTPUT SHAFT GEAR
2 - TORQUE CONVERTER 8 - FRONT PLANET CARRIER 14 - TRANSFER SHAFT GEAR
3 - OIL PUMP 9 - 2/4 CLUTCH 15 - TRANSFER SHAFT
4 - INPUT SPEED SENSOR 10 - L/R CLUTCH 16 - DIFFERENTIAL
5 - UNDERDRIVE CLUTCH 11 - OUTPUT SPEED SENSOR 17 - CONVERTER DRIVE PLATE
6 - OVERDRIVE CLUTCH 12 - REAR PLANET CARRIER/OUTPUT
SHAFT18 - INPUT SHAFT
21 - 148 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

DIAGNOSIS AND TESTING - ROAD TEST
Prior to performing a road test, verify that the
fluid level, fluid condition, and linkage adjustment
have been approved.
During the road test, the transaxle should be oper-
ated in each position to check for slipping and any
variation in shifting.
If the vehicle operates properly at highway speeds,
but has poor acceleration, the converter stator over-
running clutch may be slipping. If acceleration is nor-
mal, but high throttle opening is needed to maintain
highway speeds, the converter stator clutch mayhave seized. Both of these stator defects require
replacement of the torque converter and thorough
transaxle cleaning.
Slipping clutches can be isolated by comparing the
ªElements in Useº chart with clutch operation
encountered on a road test. This chart identifies
which clutches are applied at each position of the
selector lever.
A slipping clutch may also set a DTC and can be
determined by operating the transaxle in all selector
positions.
ELEMENTS IN USE AT EACH POSITION OF SELECTOR LEVER
Shift Lever
PositionINPUT CLUTCHES HOLDING CLUTCHES
Underdrive Overdrive Reverse 2/4 Low/Reverse
P - PARKX
R - REVERSE X X
N - NEUTRALX
OD -
OVERDRIVE
First XX
Second X X
Direct X X
Overdrive X X
D - DRIVE*
First XX
Second X X
Direct X X
L - LOW*
First XX
Second X X
Direct X X
* Vehicle upshift and downshift speeds are increased when in these selector positions.
The process of elimination can be used to detect
any unit which slips and to confirm proper operation
of good units. Road test analysis can diagnose slip-
ping units, but the cause of the malfunction cannot
be determined. Practically any condition can be
caused by leaking hydraulic circuits or sticking
valves.
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS
Pressure testing is a very important step in the
diagnostic procedure. These tests usually reveal the
cause of most hydraulic transaxle problems.Before performing pressure tests, be certain that
fluid level and condition, and shift cable adjustments
have been checked and approved. Fluid must be at
operating temperature (150 to 200 degrees F.).
Install an engine tachometer, raise vehicle on hoist
which allows front wheels to turn, and position
tachometer so it can be read.
21 - 150 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

Attach 300 psi gauge (C-3293SP) to port(s)
required for test(s) being conducted. Use adapter set
L-4559 to adapt gauge(s) to transaxle.
Test port locations are shown in (Fig. 4).
TEST ONE-SELECTOR IN LOW (1st GEAR)
(1) Attach pressure gauge to the low/reverse clutch
tap.
(2) Move selector lever to the (L) position.
(3) Allow vehicle wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
to 20 mph.
(4) Low/reverse clutch pressure should read 115 to
145 psi.
(5) This test checks pump output, pressure regula-
tion and condition of the low/reverse clutch hydraulic
circuit and shift schedule.
TEST TWO-SELECTOR IN DRIVE (2nd GEAR)
NOTE: This test checks the underdrive clutch
hydraulic circuit as well as the shift schedule.
(1) Attach gauge to the underdrive clutch tap.
(2) Move selector lever to the 3 position.
(3) Allow vehicle wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
of 30 mph.
(4) In second gear the underdrive clutch pressure
should read 110 to 145 psi.
TEST TWO A±SELECTOR IN OD (4th Gear)
NOTE: This test checks the underdrive clutch
hydraulic circuit as well as the shift schedule.(1) Attach gauge to the underdrive clutch tap.
(2) Move selector lever to the (OD) position.
(3) Allow wheels to rotate freely and increase
throttle opening to achieve an indicated speed of 40
mph.
(4) Underdrive clutch pressure should read below
5 psi. If not, then either the solenoid assembly or
PCM/TCM is at fault.
TEST THREE-OVERDRIVE CLUTCH CHECK (3rd and
2nd Gear)
(1) Attach gauge to the overdrive clutch tap.
(2) Move selector lever to the (OD) position.
(3) Allow vehicle wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
of 20 mph. Vehicle should be in 3rd gear.
(4) Overdrive clutch pressure should read 74 to 95
psi.
(5) Move selector lever to the (3) position and
increase indicated vehicle speed to 30 mph.
(6) The vehicle should be in second gear and over-
drive clutch pressure should be less than 5 psi.
(7) This test checks the overdrive clutch hydraulic
circuit as well as the shift schedule.
TEST FOUR-SELECTOR IN OVERDRIVE (4th Gear)
(1) Attach gauge to the 2/4 clutch tap.
(2) Move selector lever to the (OD) position.
(3) Allow vehicle front wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
of 30 mph. Vehicle should be in 4th gear.
(4) The 2/4 clutch pressure should read 75 to 95
psi.
(5) This test checks the 2/4 clutch hydraulic cir-
cuit.
TEST FIVE-SELECTOR IN OVERDRIVE (4th Gear-CC
on)
(1) Attach gauge to the torque converter clutch off
pressure tap.
(2) Move selector lever to the (OD) position.
(3) Allow vehicle wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
of 50 mph. Vehicle should be in 4th gear, CC on.
CAUTION: Both wheels must turn at the same
speed.
(4) Torque converter clutch off pressure should be
less than 5 psi.
(5) This test checks the torque converter clutch
hydraulic circuit.
TEST SIX-SELECTOR IN REVERSE
(1) Attach gauges to the reverse and LR clutch
tap.
Fig. 4 Pressure Taps
1 - OVERDRIVE CLUTCH
2 - TORQUE CONVERTER OFF
3 - LOW/REVERSE CLUTCH
4 - 2/4 CLUTCH
5 - REVERSE CLUTCH
6 - UNDERDRIVE CLUTCH
RS41TE AUTOMATIC TRANSAXLE21 - 151
41TE AUTOMATIC TRANSAXLE (Continued)

(2) Move selector lever to the (R) position.
(3) Read reverse clutch pressure with output sta-
tionary (foot on brake) and throttle opened to achieve
1500 rpm.
(4) Reverse and LR clutch pressure should read
165 to 235 psi.
(5) This test checks the reverse clutch hydraulic
circuit.
TEST RESULT INDICATIONS
(1) If proper line pressure is found in any one test,
the pump and pressure regulator are working prop-
erly.(2) Low pressure in all positions indicates a defec-
tive pump, a clogged filter, or a stuck pressure regu-
lator valve.
(3) Clutch circuit leaks are indicated if pressures
do not fall within the specified pressure range.
(4) If the overdrive clutch pressure is greater than
5 psi in Step 4 of Test Three, a worn reaction shaft
seal ring or a defective solenoid assembly is indi-
cated.
(5) If the underdrive clutch pressure is greater
than 5 psi in Step 4 of Test Two A, a defective sole-
noid assembly or PCM/TCM is the cause.
PRESSURE CHECK SPECIFICATIONS
Pressure Taps
Gear Selector
PositionActual GearUnderdrive
ClutchOverdrive
ClutchReverse
ClutchTorque
Converter
Clutch
Off2/4
ClutchLow/
Reverse
Clutch
Park *
PARK 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
REVERSE *
REVERSE 0-2 0-7 165-235 50-100 0-2 165-235
0 mph
NEUTRAL *
NEUTRAL 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
L#
FIRST 110-145 0-5 0-2 60-110 0-2 115-145
20 mph
3#
SECOND 110-145 0-5 0-2 60-110 115-145 0-2
30 mph
3#
DIRECT 75-95 75-95 0-2 60-90 0-2 0-2
45 mph
OD #
OVERDRIVE 0-2 75-95 0-2 60-90 75-95 0-2
30 mph
OD #
OVERDRIVE
WITH TCC0-2 75-95 0-2 0-5 75-95 0-2
50 mph
* Engine speed at 1500 rpm
# CAUTION: Both front wheels must be turning at the same speed.
21 - 152 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS
Inoperative clutches can be located using a series
of tests by substituting air pressure for fluid pressure
(Fig. 5) (Fig. 6). The clutches may be tested by apply-
ing air pressure to their respective passages. The
valve body must be removed and Tool 6056 installed.
To make air pressure tests, proceed as follows:
NOTE: The compressed air supply must be free of
all dirt and moisture. Use a pressure of 30 psi.
Remove oil pan and valve body. See Valve body
removal.
OVERDRIVE CLUTCH
Apply air pressure to the overdrive clutch apply
passage and watch for the push/pull piston to move
forward. The piston should return to its starting
position when the air pressure is removed.
REVERSE CLUTCH
Apply air pressure to the reverse clutch apply pas-
sage and watch for the push/pull piston to move rear-
ward. The piston should return to its starting
position when the air pressure is removed.
2/4 CLUTCH
Apply air pressure to the feed hole located on the
2/4 clutch retainer. Look in the area where the 2/4
piston contacts the first separator plate and watch
carefully for the 2/4 piston to move rearward. The
piston should return to its original position after the
air pressure is removed.
LOW/REVERSE CLUTCH
Apply air pressure to the low/reverse clutch feed
hole (rear of case, between 2 bolt holes). Then, look
in the area where the low/reverse piston contacts the
first separator plate. Watch carefully for the piston to
move forward. The piston should return to its origi-
nal position after the air pressure is removed.
UNDERDRIVE CLUTCH
Because this clutch piston cannot be seen, its oper-
ation is checked by function. Air pressure is applied
to the low/reverse and the 2/4 clutches. This locks the
output shaft. Use a piece of rubber hose wrapped
around the input shaft and a pair of clamp-on pliers
to turn the input shaft. Next apply air pressure to
the underdrive clutch. The input shaft should not
rotate with hand torque. Release the air pressure
and confirm that the input shaft will rotate.
Fig. 5 Air Pressure Test Plate
1 - TOOL 6056
2 - ACCUMULATORS
Fig. 6 Testing Reverse Clutch
1 - TOOL 6056
2 - AIR NOZZLE
RS41TE AUTOMATIC TRANSAXLE21 - 153
41TE AUTOMATIC TRANSAXLE (Continued)