DODGE TOWN AND COUNTRY 2001 Service Manual

(8) Remove oil screen (Fig. 358).
(9) Remove the overdrive clutch (#5) check valve
(Fig. 359)(10) Remove separator plate (Fig. 360).
(11) Remove thermal valve (Fig. 361).
Fig. 358 Remove Oil Screen
1 - OIL SCREEN
Fig. 359 Remove Overdrive Clutch (#5) Check Valve
1 - OVERDRIVE CLUTCH (#5) CHECK VALVE
Fig. 360 Remove Separator Plate
1 - SEPARATOR PLATE
2 - VALVE BODY
Fig. 361 Remove Thermal Valve
1 - THERMAL VALVE
21 - 294 AUTOMATIC - 41TERS
VALVE BODY (Continued)
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(12) Remove check balls (Fig. 362).
Fig. 362 Ball Check Location
1 - (#4) BALL CHECK LOCATION
2 - (#2) BALL CHECK LOCATION
3 - RETAINER
4 - (#3) BALL CHECK LOCATION5 - LOW/REVERSE SWITCH VALVE
6 - T/C LIMIT VALVE
RSAUTOMATIC - 41TE21 - 295
VALVE BODY (Continued)
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NOTE: Tag all valve/spring assemblies for reassem-
bly identification.
(13) Remove dual retainer plate using Tool 6301
(Fig. 363).
(14) Remove regulator valve spring retainer (Fig.
364).(15) Remove remaining retainers as shown in (Fig.
365).
(16) Remove valves and springs as shown in (Fig.
366).
NOTE: Refer to Valve Body Cleaning and Inspection
for cleaning procedures.
ASSEMBLY
NOTE: If valve body assembly is reconditioned, the
TCM Quick Learn Procedure must be performed.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
(1) Install valves and springs as shown in (Fig.
366).
(2) Install regulator valve spring retainer (Fig.
367).
(3) Install dual retainer plate using Tool 6301 (Fig.
368).
Fig. 363 Remove Dual Retainer Plate using Tool
6301
1 - TOOL 6301
2 - RETAINER
Fig. 364 Remove Regulator Valve Spring Retainer
using Tool 6302
1 - TOOL 6302
2 - RETAINER
Fig. 365 Valve Retainer Location
1 - RETAINER
2 - RETAINER
21 - 296 AUTOMATIC - 41TERS
VALVE BODY (Continued)
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Fig. 366 Springs and Valves Location
1 - VALVE BODY
2 - T/C REGULATOR VALVE
3 - L/R SWITCH VALVE
4 - CONVERTER CLUTCH CONTROL VALVE
5 - MANUAL VALVE6 - CONVERTER CLUTCH SWITCH VALVE
7 - SOLENOID SWITCH VALVE
8 - REGULATOR VALVE
Fig. 367 Install Regulator Valve Spring Retainer
using Tool 6302
1 - TOOL 6302
2 - RETAINER
Fig. 368 Install Dual Retainer Plate using Tool 6301
1 - TOOL 6301
2 - RETAINER
RSAUTOMATIC - 41TE21 - 297
VALVE BODY (Continued)
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(4) Verify that all retainers are installed as shown
in (Fig. 369). Retainers should be flush or below
valve body surface.
(5) Install check balls into position as shown in
(Fig. 370). If necessary, secure them with petrolatum
or transmission assembly gel for assembly ease.
Fig. 369 Valve Retainer Location
1 - RETAINER
2 - RETAINER
Fig. 370 Ball Check Location
1 - (#4) BALL CHECK LOCATION
2 - (#2) BALL CHECK LOCATION
3 - RETAINER
4 - (#3) BALL CHECK LOCATION5 - LOW/REVERSE SWITCH VALVE
6 - T/C LIMIT VALVE
21 - 298 AUTOMATIC - 41TERS
VALVE BODY (Continued)
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(6) Install thermal valve into transfer plate (Fig.
371).
(7) Install separator plate to valve body (Fig. 372).(8) Install the overdrive clutch (#5) check valve to
separator plate (Fig. 373)
(9) Install oil screen to separator plate (Fig. 374).
Fig. 371 Install Thermal Valve
1 - THERMAL VALVE
Fig. 372 Install Separator Plate
1 - SEPARATOR PLATE
2 - VALVE BODY
Fig. 373 Install Overdrive Clutch (#5) Check Valve
1 - OVERDRIVE CLUTCH (#5) CHECK VALVE
Fig. 374 Install Oil Screen
1 - OIL SCREEN
RSAUTOMATIC - 41TE21 - 299
VALVE BODY (Continued)
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(10) Install transfer plate to valve body and sepa-
rator plate. Make sure oil screen and #5 check valve
do not bind (Fig. 375).
(11) Install twenty-four transfer plate to valve
body screws (Fig. 376) and torque to 5 N´m (45 in.
lbs.).(12) Install 2/4 Accumulator components as shown
in (Fig. 377).
(13) Torque 2/4 Accumulator retainer to 5 N´m (45
in. lbs.) (Fig. 378).
Fig. 375 Install Transfer Plate
1 - TRANSFER PLATE
Fig. 376 Install Valve Body to Transfer Plate Screws
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
Fig. 377 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - SPRINGS
5 - SEALS
6 - PISTON
Fig. 378 2/4 Accumulator Retaining Plate
1 - 2±4 ACCUMULATOR RETAINING PLATE
2 - DETENT SPRING
21 - 300 AUTOMATIC - 41TERS
VALVE BODY (Continued)
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(14) Install Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 379).
(15) Make sure Manual Valve control pin is con-
tained within the rooster comb slot (Fig. 380). Install
Transmission Range Sensor retaining screw (Fig.
380) and torque to 5 N´m (45 in. lbs.).(16) Install manual shaft seal (Fig. 381).
INSTALLATION
NOTE: If valve body assembly is being replaced or
reconditioned, it is necessary to perform the TCM
Quick Learn Procedure. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install valve body assembly to transaxle (Fig.
382). Install and torque valve body-to-transaxle case
bolts (Fig. 383) to 12 N´m (105 in. lbs.).
Fig. 379 Install Manual Shaft/Rooster Comb and
Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
Fig. 380 Install Transmission Range Sensor
Retaining Screw
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
Fig. 381 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 382 Valve Body Removal/Installation
1 - VALVE BODY
RSAUTOMATIC - 41TE21 - 301
VALVE BODY (Continued)
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(2) Install transaxle oil filter (Fig. 384). Inspect
the o-ring and replace if necessary.
(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. 385). Torque oil
pan-to-transaxle case bolts (Fig. 386) 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. 383 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 384 Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 385 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 386 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
21 - 302 AUTOMATIC - 41TERS
VALVE BODY (Continued)
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T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page
T850 MANUAL TRANSAXLE.................1
T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
T850 MANUAL TRANSAXLE
DESCRIPTION............................2
OPERATION.............................4
DIAGNOSIS AND TESTING.................11
DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES.....................11
REMOVAL..............................11
DISASSEMBLY...........................17
ASSEMBLY.............................22
INSTALLATION...........................31
SPECIFICATIONS........................37
SPECIAL TOOLS.........................39
AXLE SEALS
REMOVAL..............................42
INSTALLATION...........................42
BACK-UP LAMP SWITCH
REMOVAL..............................43
INSTALLATION...........................43
DIFFERENTIAL
DESCRIPTION...........................43
OPERATION.............................43
DISASSEMBLY...........................44
ASSEMBLY.............................47
ADJUSTMENTS..........................50
FLUID
STANDARD PROCEDURE..................52
STANDARD PROCEDURE - FLUID LEVEL
CHECK...............................52
STANDARD PROCEDURE - FLUID DRAIN
AND FILL.............................53
GEARSHIFT BOOT
REMOVAL..............................53
INSTALLATION...........................53
GEARSHIFT CABLE - CROSSOVER
REMOVAL..............................54INSTALLATION...........................56
ADJUSTMENTS..........................60
GEARSHIFT CABLE - SELECTOR
REMOVAL..............................61
INSTALLATION...........................64
GEARSHIFT KNOB
REMOVAL..............................67
INSTALLATION...........................67
GEARSHIFT MECHANISM
REMOVAL..............................68
INSTALLATION...........................70
INPUT SHAFT
DESCRIPTION...........................73
DISASSEMBLY...........................74
ASSEMBLY.............................77
INTERMEDIATE SHAFT
DESCRIPTION...........................81
DISASSEMBLY...........................81
ASSEMBLY.............................88
SHIFT COVER
DESCRIPTION...........................94
SHIFT FORK AND SHAFT
DESCRIPTION...........................95
SYNCHRONIZER
DESCRIPTION...........................95
DISASSEMBLY...........................95
CLEANING..............................95
INSPECTION............................95
ASSEMBLY.............................95
VEHICLE SPEED SENSOR
REMOVAL..............................96
INSTALLATION...........................96
RGT850 MANUAL TRANSAXLE21a-1
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