Engine DODGE TOWN AND COUNTRY 2001 Service Manual

(18) Remove left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - REMOVAL)
(19) Disconnect exhaust pipe at manifold (Fig. 13).
(20) Remove cradle plate.
(21) AWD models: Remove power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - REMOVAL)
(22) Remove rear mount bracket-to-transaxle case
lower (horizontal) bolt (Fig. 12).
(23) Remove rear mount heat shield (Fig. 14).
(24) Remove rear mount-to-bracket thru-bolt and
nut (Fig. 15).
(25) Remove front mount/bracket assembly.
(26) Remove starter motor.
(27) Remove lateral bending brace.(28) Remove inspection cover.
(29) Remove torque converter-to-drive plate bolts.
(30) Support engine/transaxle assembly at engine
oil pan with screw jack and wood block.
(31) Partially remove left wheelhouse splash shield
to gain access to and remove upper mount thru-bolt
(Fig. 16).
(32) Lower engine/transaxle assembly with screw
jack.
(33) Obtain helper and transmission jack. Secure
transmission jack to transaxle assembly.
(34) Remove upper mount bracket from transaxle
(Fig. 16).
(35) Remove remaining transaxle bellhousing-to-
engine bolts.
(36) Remove transaxle assembly from vehicle.
Fig. 12 Rear Mount Bracket - Typical
1 - BOLT - VERTICAL
2 - BRACKET - REAR MOUNT3 - BOLT - HORIZONTAL
RSAUTOMATIC - 41TE21 - 167
AUTOMATIC - 41TE (Continued)
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(9) Using a screwdriver, push park rod rollers
away from guide bracket (Fig. 22) and remove valve
body assembly (Fig. 23).
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. 20 Remove Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 21 Remove Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 22 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
Fig. 23 Remove Valve Body
1 - VALVE BODY
21 - 170 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)
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(59) Install low/reverse accumulator (Fig. 152).
(60) Install low/reverse accumulator plug (Fig.
153).(61) Install low/reverse accumulator snap ring
(Fig. 154).
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. 155) (Fig. 156) (Fig. 157).
Fig. 152 Install Low/Reverse Accumulator
1 - ACCUMULATOR PISTON
2 - SEAL RINGS
3 - RETURN SPRINGS
4 - (NOTE NOTCH)
Fig. 153 Install Low/Reverse Accumulator Plug
(Cover)
1 - ADJUSTABLE PLIERS
2 - PLUG
Fig. 154 Install Low/Reverse Accumulator Snap
Ring
1 - SNAP RING
2 - PLUG
Fig. 155 Accumulator (Underdrive)
1 - ACCUMULATOR PISTON (UNDERDRIVE)
2 - RETURN SPRINGS
3 - SEAL RING
4 - SEAL RING
21 - 206 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)
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INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perfrom the TCM Quick Learn proce-
dure. (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
NOTE: If torque converter assembly has been
replaced, it is necessary to reset the TCC Break-In
Strategy. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Using a transmission jack and a helper, posi-
tion transaxle assembly to engine. Install and torque
bolts to 95 N´m (70 ft. lbs.).
(2) Install upper mount assembly to transaxle and
torque bolts to 54 N´m (40 ft. lbs.) (Fig. 164).
(3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 164).
(4) Remove transmission jack and screw jack.
(5) Secure left wheelhouse splash shield.
(6) Install torque converter-to-drive plate bolts and
torque to 88 N´m (65 ft. lbs.)
(7) Install inspection cover.(8) Install lateral bending brace.
(9) Install starter motor.
(10) Install front mount/bracket assembly.
(11) Install rear mount and bracket assembly into
position (Fig. 165).
(12) Install and torque rear mount bolts to 54 N´m
(40 ft. lbs.) (Fig. 166).
(13) Lower vehicle.
(14) Install and torque rear mount bracket-to-tran-
saxle vertical bolts (Fig. 165) to 102 N´m (75 ft. lbs.).
(15) Raise vehicle.
(16) Install rear mount bracket-to-transaxle hori-
zontal bolt (Fig. 165) and torque to 102 N´m (75 ft.
lbs.).
(17) Install rear mount thru-bolt and torque to 54
N´m (40 ft. lbs.) (Fig. 166).
(18) Install rear mount heat shield (Fig. 167).
(19) AWD models: Install power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - INSTALLATION)
(20) Install cradle plate.
(21) Install exhaust pipe to manifold (Fig. 168).
(22) Install left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
(23) Install front wheel/tire assemblies.
(24) Lower vehicle.
(25) Install transaxle upper bellhousing-to-block
bolts and torque to 95 N´m (70 ft. lbs.).
(26) Install wiper module assembly. (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION)
(27) Connect crank position sensor (if equipped).
(28) Connect gearshift cable to upper mount
bracket and transaxle manual valve lever (Fig. 169).
(29) Connect solenoid/pressure switch assembly
(Fig. 170).
(30) Connect transmission range sensor connector
(Fig. 170).
(31) Connect input and output speed sensor con-
nectors (Fig. 170).
(32) Remove plugs and install transaxle oil cooler
line service splice kit. Refer to instructions included
with kit.
(33) Remove plug and Install fluid level indicator/
tube assembly.
(34) Install coolant recovery bottle (Fig. 171).
(35) Install battery shield.
(36) Connect battery cables.
(37) Fill transaxle with suitable amount of ATF+4
(Automatic Transmission FluidÐType 9602). (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE/FLUID - STANDARD PROCEDURE)
Fig. 164 Left Mount to Bracket and Transaxle
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
RSAUTOMATIC - 41TE21 - 209
AUTOMATIC - 41TE (Continued)
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FLUID
STANDARD PROCEDURE - FLUID LEVEL AND
CONDITION CHECK
NOTE: Only transmission fluid of the type labeled
Mopar ATF+4 (Automatic Transmission Fluid±Type
9602) should be used in this transaxle.
FLUID LEVEL CHECK
The transmission sump has a fluid level indicator
(dipstick) to check oil similar to most automatic
transmissions. It is located on the left side of the
engine. Be sure to wipe all dirt from dipstick handle
before removing.
The torque converter fills in both the P Park and N
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate.The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground.At normal operating temperature (approxi-
mately 82 C. or 180 F.), the fluid level is correct if it
is in the HOT region (cross-hatched area) on the oil
level indicator (Fig. 214). The fluid level should be
within the WARM range of the dipstick at 70É F fluid
temperature.
FLUID LEVEL CHECK USING DRB
NOTE: Engine and Transaxle should be at normal
operating temperature before performing this proce-
dure.
(1) Start engine and apply parking brake.
(2) Hook up DRB scan tool and select transmis-
sion.(3) Select sensors.
(4) Read the transmission temperature value.
(5) Compare the fluid temperature value with the
fluid temperature chart (Fig. 215).
(6) Adjust transmission fluid level shown on the
indicator according to the chart.
(7) Check transmission for leaks.
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transaxle vent where it may be mistaken
for a leak.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle recondition is proba-
bly required. Be sure to examine the fluid on the dip-
stick closely. If there is any doubt about its condition,
drain out a sample for a double check.
Moparž ATF+4 (Automatic Transmission Fluid-
Type 9602) when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
the vehicle such as engine oil or antifreeze. The red
color is not permanent and is not an indicator of fluid
condition. As the vehicle is driven, the ATF will begin
to look darker in color and may eventually become
brown. This is normal. A dark brown/black fluid
accompanied with a burnt odor and/or deterioration
in shift quality may indicate fluid deterioration or
transmission component failure.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
STANDARD PROCEDURE - FLUID AND FILTER
SERVICE
NOTE: Refer to the maintenance schedules in
LUBRICATION and MAINTENANCE, or the vehicle
owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
Fig. 214 Transaxle Fluid Level Indicator
1 - TRANSAXLE DIPSTICK
21 - 246 AUTOMATIC - 41TERS
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(5) Pour four quarts of Moparž ATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick
opening.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 217).
(8) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.). Refer
to Fluid Level and Condition Check for the proper
fluid fill procedure.
(9) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
DIPSTICK TUBE FLUID SUCTION METHOD
(ALTERNATIVE)
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (VaculaŸ
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Pour four quarts of Moparž ATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick
opening.(7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 217).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/FLUID - STANDARD PROCEDURE)
(10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
GEAR SHIFT CABLE
REMOVAL
(1) Disconnect battery cables.
(2) Remove battery shield.
(3) Remove battery.
(4) Remove speed control servo and position out of
way.
(5) Disconnect gear shift cable at manual valve
lever (Fig. 218).
(6) Disconnect gear shift cable from upper mount
bracket (Fig. 218).
Fig. 217 Transaxle Fluid Level Indicator
1 - TRANSAXLE DIPSTICK
Fig. 218 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 248 AUTOMATIC - 41TERS
FLUID (Continued)
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INSTALLATION
(1) Fish gear shift cable dash panel opening into
engine compartment and secure grommet (Fig. 223).
(2) Install gear shift cable through column bracket
(Fig. 224) until audible ªclickº is heard.
(3) Connect gear shift cable to gear shift lever (Fig.
224).(4) Install knee bolster (Fig. 225).
(5) Install instrument panel lower silencer (Fig.
226).
(6) Install gear shift cable to transaxle upper
mount bracket (Fig. 227). An audible ªclickº should
be heard.
(7) Connect gear shift cable end to transaxle man-
ual valve lever (Fig. 227).
(8) Adjust gearshift cable. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 41TE/GEAR
SHIFT CABLE - ADJUSTMENTS)
(9) Install speed control servo into position.
(10) Install battery.
(11) Install battery shield.
(12) Connect battery cables.
Fig. 223 Gearshift Cable/Grommet at Dash Panel
1 - CABLE GROMMET
2 - DASH PANEL
Fig. 224 Gearshift Cable at Column
1 - GEAR SHIFT CABLE
Fig. 225 Knee Bolster
1 - KNEE BOLSTER
Fig. 226 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
21 - 250 AUTOMATIC - 41TERS
GEAR SHIFT CABLE (Continued)
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GEARSHIFT CABLE ADJUSTMENT
VERIFICATION
(1) Place gearshift lever in gated park (P).
(2) Attempt to move vehicle by rocking back and
forth on level ground. If vehicle does not move,
attempt to start engine. If engine starts, the park
position is correct.
(3) Set parking brake.
(4) Turn key to on/run and depress brake pedal.
Place gearshift lever in neutral (N).
(5) Attempt to start engine. If engine starts in
both neutral (N) or park (P), gearshift cable is
adjusted properly. No adjustment is required.
(6) If engine does not start in either park (P) or
neutral (N), perform adjustment procedure.
ADJUSTMENT
(1) Park the vehicle on level ground and set the
parking brake.
(2) Place the gearshift lever in gated park (P) and
remove ignition key.
(3) Loosen the cable adjustment screw at the
transaxle manual valve lever (Fig. 228).(4) Pull the gearshift lever fully forward to the
park detent position.
(5) Release the park brake, then rock the vehicle
to assure it is in park. Reset the park brake.
(6) Tighten the cable adjustment screw to 8 N´m
(70 in. lbs.). Gearshift cable should now be properly
adjusted.
(7) Verify adjustment by using the verification pro-
cedure.
HOLDING CLUTCHES
DESCRIPTION
Two hydraulically applied multi-disc clutches are
used to hold planetary geartrain components station-
ary while the input clutches drive others. The 2/4
and Low/Reverse clutches are considered holding
clutches and are contained at the rear of the trans-
axle case. (Fig. 229) .
OPERATION
NOTE: Refer to the ªElements In Useº chart in Diag-
nosis and Testing for a collective view of which
clutch elements are applied at each position of the
selector lever.
2/4 CLUTCH
The 2/4 clutch is hydraulically applied in second
and fourth gears by pressurized fluid against the 2/4
clutch piston. When the 2/4 clutch is applied, the
front sun gear assembly is held or grounded to the
transaxle case.
Fig. 227 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 228 Gearshift Cable Adjustment
1 - GEARSHIFT CABLE ADJUSTMENT SCREW
2 - GEARSHIFT CABLE
RSAUTOMATIC - 41TE21 - 251
GEAR SHIFT CABLE (Continued)
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OIL PUMP
DESCRIPTION
The oil pump is located in the pump housing inside
the bell housing of the transaxle case (Fig. 295). The
oil pump consists of an inner and outer gear, a hous-
ing, and a cover that also serves as the reaction shaft
support.
OPERATION
As the torque converter rotates, the converter hub
rotates the inner and outer gears. As the gears
rotate, the clearance between the gear teeth
increases in the crescent area, and creates a suctionat the inlet side of the pump. This suction draws
fluid through the pump inlet from the oil pan. As the
clearance between the gear teeth in the crescent area
decreases, it forces pressurized fluid into the pump
outlet and to the valve body.
STANDARD PROCEDURE - OIL PUMP VOLUME
CHECK
Measuring oil pump output volume will determine
if sufficient flow to the transmission oil cooler exists,
and whether or not an internal transmission failure
is present.
Verify that transmission fluid is at the proper
level. If adding fluid is necessary, fill to the proper
level with Moparž ATF+4 (Automatic Transmission
Fluid±Type 9602). The following procedure is to
check oil pump output volume:
(1) Using hose cutters or a suitable blade, cut the
ªto coolerº (Fig. 296) line off flush with the cooler
inlet fitting and place a collection container under
the open line .
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Start engine and runat curb idle speed, with
the shift selector in neutral.
Fig. 293 Install No. 3 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - DABS OF PETROLATUM (FOR RETENTION)
3 - #3 THRUST PLATE (NOTE 3 TABS)
Fig. 294 Install Overdrive Shaft Assembly
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #3 THRUST PLATE
3 - #3 THRUST WASHER
Fig. 295 Oil Pump Assembly
1 - PUMP HOUSING
2 - OUTER PUMP GEAR
3 - INNER PUMP GEAR
4 - REACTION SHAFT SUPPORT
5 - SEAL RINGS (4)
6 - REACTION SHAFT
7 - CRESCENT
RSAUTOMATIC - 41TE21 - 269
INPUT CLUTCH ASSEMBLY (Continued)
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ing state. The result is an apply or release of a fric-
tional element.
The 2/4 and UD solenoids are normally applied,
which by design allow fluid to pass through in their
relaxed or ªoffº state. This allows transaxle limp-in
(P,R,N,2) in the event of an electrical failure.
The continuity of the solenoids and circuits are
periodically tested. Each solenoid is turned on or off
depending on its current state. An inductive spike
should be detected by the TCM during this test. It no
spike is detected, the circuit is tested again to verify
the failure. In addition to the periodic testing, the
solenoid circuits are tested if a speed ratio or pres-
sure switch error occurs.
PRESSURE SWITCHES
The TCM relies on three pressure switches to mon-
itor fluid pressure in the L/R, 2/4, and OD hydraulic
circuits. The primary purpose of these switches is to
help the TCM detect when clutch circuit hydraulic
failures occur. The range for the pressure switch clos-
ing and opening points is 11-23 psi. Typically the
switch opening point will be approximately one psi
lower than the closing point. For example, a switch
may close at 18 psi and open at 17 psi. The switches
are continuously monitored by the TCM for the cor-
rect states (open or closed) in each gear as shown in
the following chart:
PRESSURE SWITCH STATES
GEAR L/R 2/4 OD
ROPOPOP
P/N CL OP OP
1st CL OP OP
2nd OP CL OP
DOPOPCL
OD OP CL CL
OP = OPEN
CL = CLOSED
A Diagnostic Trouble Code (DTC) will set if the
TCM senses any switch open or closed at the wrong
time in a given gear.
The TCM also tests the 2/4 and OD pressure
switches when they are normally off (OD and 2/4 are
tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd
gear). The test simply verifies that they are opera-
tional, by looking for a closed state when the corre-
sponding element is applied. Immediately after a
shift into 1st, 2nd, or 3rd gear with the engine speed
above 1000 rpm, the TCM momentarily turns on ele-
ment pressure to the 2/4 and/or OD clutch circuits to
identify that the appropriate switch has closed. If it
doesn't close, it is tested again. If the switch fails toclose the second time, the appropriate Diagnostic
Trouble Code (DTC) will set.
REMOVAL
NOTE: If solenoid/pressure switch assembly is
being replaced, it is necessary to perform the TCM
Quick Learn Procedure. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly.
(3) Disconnect solenoid/pressure switch assembly
connector.
(4) Disconnect input speed sensor connector.
(5) Remove input speed sensor (Fig. 318).
(6) Remove three (3) solenoid/pressure switch
assembly-to-transaxle case bolts (Fig. 319).
(7) Remove solenoid/pressure switch assembly and
gasket (Fig. 320). Use care to prevent gasket mate-
rial and foreign objects from become lodged in the
transaxle case ports.
INSTALLATION
NOTE: If solenoid/pressure switch assembly is
being replaced, it is necessary to perform the TCM
Quick Learn Procedure. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install solenoid/pressure switch assembly and
new gasket to transaxle (Fig. 320).
Fig. 318 Input Speed Sensor
1 - INPUT SPEED SENSOR
RSAUTOMATIC - 41TE21 - 277
SOLENOID/PRESSURE SWITCH ASSY (Continued)
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