DODGE TOWN AND COUNTRY 2001 Service Manual

(7) Remove OD/Reverse reaction plate (Fig. 236) .
(8) Remove OD/Reverse reaction plate wave snap
ring (Fig. 237) .(9) Remove OD shaft/hub and OD clutch pack (Fig.
238) (Fig. 239) .
NOTE: Tag overdrive clutch pack for reassembly
identification.
Fig. 236 OD/Reverse Reaction Plate
1 - OD/REVERSE PRESSURE PLATE (STEP SIDE DOWN)
2 - (STEP SIDE DOWN)
Fig. 237 Waved Snap Ring
1 - OVERDRIVE SHAFT ASSEMBLY
2 - OD/REVERSE CLUTCH WAVED SNAP RING
3 - SCREWDRIVER
Fig. 238 Remove OD Clutch Pack
1 - OVERDRIVE SHAFT ASSEMBLY AND OD CLUTCH PACK
2 - #3 THRUST PLATE
3 - #3 THRUST WASHER
4 - UNDERDRIVE SHAFT ASSEMBLY
Fig. 239 Overdrive Clutch Pack
1 - OVERDRIVE CLUTCH PLATE
2 - OVERDRIVE SHAFT ASSEMBLY
3 - OVERDRIVE CLUTCH DISC
21 - 254 AUTOMATIC - 41TERS
INPUT CLUTCH ASSEMBLY (Continued)
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(10) Remove and inspect #3 & #4 thrust washers
(Fig. 240) .
(11) Remove the underdrive shaft assembly (Fig.
241) .(12) Remove the #2 needle bearing (Fig. 242) .
(13) Remove the OD/UD reaction plate tapered
snap ring (Fig. 243) .
NOTE: The OD/UD clutch reaction plate has a step
on both sides. Install the OD/UD clutches reaction
plate tapered step side up.
Fig. 240 #3&4 Thrust Washers
1 - #3 THRUST PLATE (3 TABS)
2 - OD SHAFT ASSEMBLY
3 - #4 THRUST PLATE (3 SLOTS)
Fig. 241 Underdrive Shaft Assembly
1 - #3 THRUST WASHER (5 TABS)
2 - UNDERDRIVE SHAFT ASSEMBLY
Fig. 242 No. 2 Needle Bearing
1 - #2 NEEDLE BEARING (NOTE 3 TABS)
Fig. 243 OD/UD Reaction Plate Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
RSAUTOMATIC - 41TE21 - 255
INPUT CLUTCH ASSEMBLY (Continued)
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(14) Remove the OD/UD reaction plate (Fig. 244) .
(15) Remove the first UD clutch disc (Fig. 245) .(16) Remove the UD clutch flat snap ring (Fig.
246) .
NOTE: Tag underdrive clutch pack for reassembly
identification.
(17) Remove the UD clutch pack (Fig. 247) .
CAUTION: Compress return spring just enough to
remove or install snap ring.
Fig. 244 OD/UD Reaction Plate
1 - OD/UD CLUTCH REACTION PLATE (STEP SIDE DOWN)
Fig. 245 Remove One UD Clutch Disc
1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 246 UD Clutch Flat Snap Ring
1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
Fig. 247 Underdrive Clutch Pack
1 - CLUTCH PLATE
2 - ONE UD CLUTCH DISC
3 - CLUTCH DISC
21 - 256 AUTOMATIC - 41TERS
INPUT CLUTCH ASSEMBLY (Continued)
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(18) Using Tool 5059A and an arbor press, com-
press UD clutch piston enough to remove snap ring
(Fig. 248) (Fig. 249) .
(19) Remove spring retainer (Fig. 249) .(20) Remove UD clutch piston (Fig. 250) .
(21) Remove input hub tapered snap ring (Fig.
251) .
Fig. 248 UD Spring Retainer Snap Ring
1 - SNAP RING PLIERS
2 - ARBOR PRESS RAM
3 - SNAP RING
4 - SPECIAL TOOL 5059A
Fig. 249 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 250 Underdrive Clutch Piston
1 - PISTON
Fig. 251 Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
RSAUTOMATIC - 41TE21 - 257
INPUT CLUTCH ASSEMBLY (Continued)
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(22) Tap on input hub with soft faced hammer and
separate input hub from OD/Reverse piston and
clutch retainer (Fig. 252) (Fig. 253) .(23) Separate clutch retainer from OD/Reverse pis-
ton (Fig. 254) .
(24) Using Tool 6057 and an arbor press, compress
return OD/Reverse piston return spring just enough
to remove snap ring (Fig. 255) (Fig. 256) .
Fig. 252 Tap on Input Hub
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - PLASTIC HAMMER
Fig. 253 Input Hub Removed
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - INPUT CLUTCHES RETAINER
3 - O-RING
4 - SEAL
5 - OVERDRIVE/REVERSE PISTON
Fig. 254 Pull Retainer from Piston
1 - OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
Fig. 255 Remove Snap Ring
1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST
ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
3 - SNAP RING
4 - SPECIAL TOOL 6057
5 - OD/REVERSE PISTON
6 - RETURN SPRING
21 - 258 AUTOMATIC - 41TERS
INPUT CLUTCH ASSEMBLY (Continued)
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(25) Remove input shaft to input clutch hub snap
ring (Fig. 257) .(26) Using a suitably sized socket and an arbor
press, remove input shaft from input shaft hub (Fig.
258) .
ASSEMBLY
Use petrolatum on all seals to ease assembly of
components.
(1) Using an arbor press, install input shaft to
input shaft hub (Fig. 259).
Fig. 256 Snap Ring and Return Spring
1 - OD/REVERSE PISTON
2 - RETURN SPRING
3 - SNAP RING
4 - O-RING
Fig. 257 Remove Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SHARP-POINTED TOOL
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 258 Remove Input Shaft
1 - ARBOR PRESS RAM
2 - SOCKET
3 - SEAL
4 - O-RINGS
5 - INPUT SHAFT
6 - SEAL
7 - INPUT SHAFT HUB ASSEMBLY
Fig. 259 Install Input Shaft
1 - INPUT SHAFT
2 - ARBOR PRESS RAM
3 - INPUT SHAFT HUB ASSEMBLY
RSAUTOMATIC - 41TE21 - 259
INPUT CLUTCH ASSEMBLY (Continued)
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(2) Install input shaft snap ring (Fig. 260).
(3) Using an arbor press and Tool 6057, Install
OD/Reverse piston return spring and snap ring (Fig.
261) (Fig. 262).(4) Install the OD/Reverse piston assembly to the
input clutch retainer as shown in (Fig. 263).
Fig. 260 Install Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 261 Return Spring and Snap Ring
1 - OD/REVERSE PISTON
2 - RETURN SPRING
3 - SNAP RING
4 - O-RING
Fig. 262 Install Snap Ring
1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST
ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
3 - SNAP RING
4 - SPECIAL TOOL 6057
5 - OD/REVERSE PISTON
6 - RETURN SPRING
Fig. 263 Install OD/Reverse Piston
1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
21 - 260 AUTOMATIC - 41TERS
INPUT CLUTCH ASSEMBLY (Continued)
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(5) Install the input hub/shaft assy. to the OD/Re-
verse piston/clutch retainer assy. (Fig. 264).
(6) Install input hub tapered snap ring (Fig. 265).(7) Install UD clutch piston (Fig. 266).
(8) Install UD piston return spring and Tool 5067
as shown in (Fig. 267).
(9) Using Tool 5059A and an arbor press, Install
the UD spring retainer and snap ring. (Fig. 268) (Fig.
269)Compress just enough to install snap ring.
CAUTION: Compress return spring just enough to
install snap ring.
Fig. 264 Install Input Shaft Hub Assembly
1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY
(ROTATE TO ALIGN SPLINES)
2 - OD/REV. PISTON
Fig. 265 Install Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
Fig. 266 Underdrive Clutch Piston
1 - PISTON
Fig. 267 Seal Compressor Special Tool 5067
1 - PISTON RETURN SPRING
2 - SPECIAL TOOL 5067
3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY
RSAUTOMATIC - 41TE21 - 261
INPUT CLUTCH ASSEMBLY (Continued)
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(10) Install the UD clutch pack. Leave out upper
disc, until snap ring is installed (Fig. 270).
(11) Install the UD clutch flat snap ring (Fig. 271).
Fig. 268 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 269 Install UD Spring Retainer and Snap Ring
1 - ARBOR PRESS RAM
2 - SNAP RING PLIERS
3 - SNAP RING
4 - OD/REVERSE PISTON
5 - TOOL 5067
6 - TOOL 5059A
Fig. 270 Underdrive Clutch Pack
1 - CLUTCH PLATE
2 - ONE UD CLUTCH DISC
3 - CLUTCH DISC
Fig. 271 UD Clutch Flat Snap Ring
1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
21 - 262 AUTOMATIC - 41TERS
INPUT CLUTCH ASSEMBLY (Continued)
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(12) Install the last UD clutch disc (Fig. 272).
(13) Install the OD/UD clutch reaction plate and
snap ring (Fig. 273) (Fig. 274). The OD/UD clutches
reaction plate has a step on both sides. Install the
OD/UD clutches reaction plate tapered step side up.
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. 275).
(15) Install input clutch assembly to the Input
Clutch Pressure Fixture±Tool 8391 (Fig. 276).
(16) Set up dial indicator on the UD clutch pack as
shown in (Fig. 277).
Fig. 272 Install Last UD Clutch Disc
1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 273 OD/UD Reaction Plate
1 - OD/UD CLUTCH REACTION PLATE (STEP SIDE DOWN)
Fig. 274 Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
Fig. 275 Seating Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER
RSAUTOMATIC - 41TE21 - 263
INPUT CLUTCH ASSEMBLY (Continued)
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