accumulator CHRYSLER VOYAGER 2005 Owner's Manual

(5) Remove 2/4 Accumulator components as shown
in (Fig. 321).
(6) Remove Valve Body to Transfer Plate screws
(Fig. 322).(7) Invert assembly and remove Transfer Plate
(Fig. 323). Beware of loose check balls.
(8) Remove oil screen (Fig. 324).
Fig. 321 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
Fig. 322 Remove Valve Body to Transfer Plate
Screws
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
Fig. 323 Remove Transfer Plate
1 - TRANSFER PLATE
Fig. 324 Remove Oil Screen
1 - OIL SCREEN
21 - 136 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)

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

VALVE BODY
DESCRIPTION........................283
OPERATION..........................283
REMOVAL............................284DISASSEMBLY........................286
ASSEMBLY...........................291
INSTALLATION........................295
41TE AUTOMATIC
TRANSAXLE
DESCRIPTION
The 41TE (Fig. 1) is a four-speed transaxle that is
a conventional hydraulic/mechanical assembly with
an integral differential, and is controlled with adap-
tive electronic controls and monitors. The hydraulic
system of the transaxle consists of the transaxle
fluid, fluid passages, hydraulic valves, and various
line pressure control components. An input clutch
assembly which houses the underdrive, overdrive,
and reverse clutches is used. It also utilizes separate
holding clutches: 2nd/4th gear and Low/Reverse. The
primary mechanical components of the transaxle con-
sist of the following:
²Three multiple disc input clutches
²Two multiple disc holding clutches
²Four hydraulic accumulators
²Two planetary gear sets
²Hydraulic oil pump
²Valve body²Solenoid/Pressure switch assembly
²Integral differential assembly
Control of the transaxle is accomplished by fully
adaptive electronics. Optimum shift scheduling is
accomplished through continuous real-time sensor
feedback information provided to the Powertrain
Control Module (PCM) or Transmission Control Mod-
ule (TCM).
The PCM/TCM is the heart of the electronic control
system and relies on information from various direct
and indirect inputs (sensors, switches, etc.) to deter-
mine driver demand and vehicle operating condi-
tions. With this information, the PCM/TCM can
calculate and perform timely and quality shifts
through various output or control devices (solenoid
pack, transmission control relay, etc.).
The PCM/TCM also performs certain self-diagnos-
tic functions and provides comprehensive information
(sensor data, DTC's, etc.) which is helpful in proper
diagnosis and repair. This information can be viewed
with the DRB scan tool.
RS41TE AUTOMATIC TRANSAXLE21 - 147

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)

(6) Remove oil filter (Fig. 18).
(7) Turn manual valve fully clock-wise to get park
rod into position for removal.
(8) Remove valve body-to-case bolts (Fig. 19).
CAUTION: Do not handle the valve body assembly
from the manual valve. Damage can result.(9) Using a screwdriver, push park rod rollers
away from guide bracket (Fig. 20) and remove valve
body assembly (Fig. 21).
NOTE: Depending on engine application, some
accumulators will have two springs and others will
have one spring. The springs are color-coded
according to application and year. When disassem-
bling, mark accumulator spring location to ease
assembly.
Fig. 18 Remove Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 19 Remove Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 20 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
Fig. 21 Remove Valve Body
1 - VALVE BODY
21 - 158 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(10) Remove underdrive and overdrive accumula-
tors (Fig. 22).
(11) Remove low/reverse accumulator snap ring
(Fig. 23).(12) Remove low/reverse accumulator plug (Fig.
24).
(13) Remove low/reverse accumulator piston using
suitable pliers (Fig. 25) (Fig. 26).
Fig. 22 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 23 Remove Low/Reverse Accumulator Snap
Ring
1 - SNAP RING
2 - PLUG
Fig. 24 Remove Low/Reverse Accumulator Plug
(Cover)
1 - ADJUSTABLE PLIERS
2 - PLUG
Fig. 25 Low/Reverse Accumulator Piston
1 - ACCUMULATOR PISTON
RS41TE AUTOMATIC TRANSAXLE21 - 159
41TE AUTOMATIC TRANSAXLE (Continued)

(14) Measure input shaft end play. Place transaxle
so input shaft is vertical. Set up end play set and
dial indicator as shown in (Fig. 27).Input shaft end
play should be within 0.13-0.64 mm (0.005-0.025
in.)If outside of this range, a #4 thrust plate change
is required. Record indicator reading for reference
upon reassembly.(15) Remove oil pump-to-case bolts (Fig. 28).
CAUTION: Be sure input speed sensor is removed
before removing oil pump.
(16) Install pullers Tool C-3752 as shown in (Fig.
29).
Fig. 26 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
Fig. 27 Measure Input Shaft End Play Using End
Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
Fig. 28 Remove Pump Attaching Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 29 Install Tool C-3752
1 - PULLERS TOOL C-3752
2 - PUMP
21 - 160 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(56) Install oil pump gasket (Fig. 146).
(57) Install oil pump assembly (Fig. 147).(58) Install oil pump-to-case bolts and torque to 27
N´m (20 ft. lbs.) (Fig. 148).
(59) Install low/reverse accumulator (Fig. 149).
Fig. 146 Install Oil Pump Gasket
1 - PUMP GASKET
Fig. 147 Install Oil Pump
1 - OIL PUMP
2 - GASKET
Fig. 148 Install Pump-to-Case Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 149 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
RS41TE AUTOMATIC TRANSAXLE21 - 193
41TE AUTOMATIC TRANSAXLE (Continued)

(60) Install low/reverse accumulator plug (Fig.
150).
(61) Install low/reverse accumulator snap ring
(Fig. 151).
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. 152).
(63) Install valve body to transaxle (Fig. 153).
Rotate manual valve shaft fully clockwise to ease
installation. Make sure park rod rollers are posi-
tioned within park guide bracket.
Fig. 150 Install Low/Reverse Accumulator Plug
(Cover)
1 - ADJUSTABLE PLIERS
2 - PLUG
Fig. 151 Install Low/Reverse Accumulator Snap
Ring
1 - SNAP RING
2 - PLUG
Fig. 152 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 153 Install Valve Body
1 - VALVE BODY
21 - 194 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)