DODGE TOWN AND COUNTRY 2004 Service Manual

(31)TRANSFER GEAR BEARING ADJUST-
MENT:
(a) Install a 4.66 mm (0.184 in.) gauging shim
on the transfer shaft (Fig. 120).
(b) Install transfer shaft gear using Tool 6261.
Using Tool 6259, install transfer shaft gear retain-
ing nut to 271 N´m (200 ft. lbs.).
(c) Measure end play. Attach Tool L4432 to the
transfer gear.
(d) Mount a steel ball with grease into the end
of the transfer shaft.
(e) Push and pull the gear while rotating back
and forth to ensure seating of the bearing rollers.
(f) Using a dial indicator, measure transfer shaft
end play.
(g) Refer to the transfer shaft bearing shim
chart for the required shim combination to obtain
the proper bearing setting.
(h) Use Tool 6259 to remove the retaining nut
and washer. Remove the transfer shaft gear using
Tool L4407A.
(i) Remove the gauging shim (Fig. 120) and
install the proper shim indicated by the chart.
TRANSFER SHAFT BEARING SHIM CHART
End Play Shim Needed Part Number End Play Shim Needed Part Number
0.05mm
(0.002 in.)4.66mm
(0.183 in.)4505588AB0.76mm
(0.030 in.)3.94mm
(0.155 in.)4412818AB
0.08mm
(0.003 in.)4.62mm
(0.182 in.)4412835AB0.79mm
(0.031 in.)3.90mm
(0.154 in.)4412817AB
0.10mm
(0.004 in.)4.58mm
(0.180 in.)4412834AB0.81mm
(0.032 in.)3.90mm
(0.154 in.)4412817AB
0.13mm
(0.005 in.)4.58mm
(0.180 in.)4412834AB0.84mm
(0.033 in.)3.86mm
(0.152 in.)4412816AB
0.15mm
(0.006 in.)4.54mm
(0.178 in.)4412833AB0.86mm
(0.034 in.)3.82mm
(0.150 in.)4412815AB
0.18mm
(0.007 in.)4.50mm
(0.177 in.)4412832AB0.89mm
(0.035 in.)3.82mm
(0.150 in.)4412815AB
0.20mm
(0.008 in.)4.50mm
(0.177 in.)4412832AB0.91mm
(0.036 in.)3.78mm
(0.149 in.)4412814AB
0.23mm
(0.009 in.)4.46mm
(0.175 in.)4412831AB0.94mm
(0.037 in.)3.74mm
(0.147 in.)4412813AB
0.25mm
(0.010 in.)4.46mm
(0.175 in.)4412831AB0.97mm
(0.038 in.)3.74mm
(0.147 in.)4412813AB
0.28mm
(0.011 in.)4.42mm
(0.174 in.)4412830AB0.99mm
(0.039 in.)3.70mm
(0.146 in.)4412812AB
0.30mm
(0.012 in.)4.38mm
(0.172 in.)4412829AB1.02mm
(0.040 in.)3.66mm
(0.144 in.)4412811AB
0.33mm
(0.013 in.)4.38mm
(0.172 in.)4412829AB1.04mm
(0.041 in.)3.66mm
(0.144 in.)4412811AB
Fig. 120 Install Transfer Shaft Gear and (Select)
Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM (SELECT)
21 - 154 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

End Play Shim Needed Part Number End Play Shim Needed Part Number
0.36mm
(0.014 in.)4.34mm
(0.171 in.)4412828AB1.07mm
(0.042 in.)3.62mm
(0.143 in.)4412810AB
0.38mm
(0.015 in.)4.30mm
(0.169 in.)4412827AB1.08mm
(0.043 in.)3.62mm
(0.143 in.)4412810AB
0.41mm
(0.016 in.)4.30mm
(0.169 in.)4412827AB1.12mm
(0.044 in.)3.58mm
(0.141)4412809AB
0.43mm
(0.017 in.)4.26mm
(0.168 in.)4412826AB1.14mm
(0.045 in.)3.54mm
(0.139 in.)4412808AB
0.46mm
(0.018 in.)4.22mm
(0.166 in.)4412825AB1.17mm
(0.046 in.)3.54mm
(0.139 in.)4412808AB
0.48mm
(0.019 in.)4.22mm
(0.166 in.)4412825AB1.19mm
(0.047 in.)3.50mm
(0.138 in.)4412807AB
0.50mm
(0.020 in.)4.18mm
(0.165 in.)4412824AB1.22mm
(0.048 in.)3.46mm
(0.136 in.)4412806AB
0.53mm
(0.021 in.)4.18mm
(0.165 in.)4412824AB1.24mm
(0.049 in.)3.46mm
(0.136 in.)4412806AB
0.56mm
(0.022 in.)4.14mm
(0.163 in.)4412823AB1.27mm
(0.050 in.)3.42mm
(0.135 in.)4412805AB
0.58mm
(0.023 in.)4.10mm
(0.161 in.)4412822AB1.30mm
(0.051 in.)3.38mm
(0.133 in.)4412804AB
0.61mm
(0.024 in.)4.10mm
(0.161 in.)4412822AB1.32mm
(0.052 in.)3.38mm
(0.133 in.)4412804AB
0.64mm
(0.025 in.)4.06mm
(0.160 in.)4412821AB1.35mm
(0.053 in.)3.34mm
(0.132 in.)4412803AB
0.66mm
(0.026 in.)4.02mm
(0.158 in.)4412820AB1.37mm
(0.054 in.)3.34mm
(0.132 in.)4412803AB
0.69mm
(0.027 in.)4.02mm
(0.158 in.)4412820AB1.40mm
(0.055 in.)3.30mm
(0.130 in.)4412802AB
0.71mm
(0.028 in.)3.98mm
(0.157 in.)4412819AB1.45mm
(0.057 in3.26mm
(0.128 in.)4412801AB
0.74mm
(0.029 in.)3.94mm
(0.155 in.)4412818AB1.47mm
(0.058 in.)2.22mm
(0.127 in.)4505570AB
RS41TE AUTOMATIC TRANSAXLE21 - 155
41TE AUTOMATIC TRANSAXLE (Continued)

(32) Install the transfer shaft gear using Tool 6261
(Fig. 121).
CAUTION: Install a NEW retaining nut, as the origi-
nal nut MUST NOT be reused.
(33) Install the new retaining nut and washer.
(34) Using Tool 6259, torque transfer gear retain-
ing nut to 271 N´m (200 ft. lbs.) (Fig. 122).(35) Measure transfer shaft end play.Transfer
shaft end play should be within 0.05-0.10 mm
(0.002-0.004 in.).If the end play is too high, install a
0.04 mm (0.0016 in.) thicker shim. If the end play is
too low, install a 0.04 mm (0.0016 in.) thinner shim.
Repeat until 0.05-0.10 mm (0.002-0.004 in.) end play
is obtained.
(36) Install a bead of MopartATF RTV (MS-GF41)
to transfer gear cover (Fig. 123).
(37) Install transfer gear cover-to-case bolts and
torque to 20 N´m (175 in. lbs.) torque (Fig. 124).
Fig. 121 Install Transfer Shaft Gear
1 - WRENCHES
2 - SPECIAL TOOL 6261
3 - OUTPUT GEAR
4 - TRANSFER SHAFT GEAR
Fig. 122 Tighten Transfer Gear Nut to 271 N²m (200
ft. lbs.)
1 - TRANSFER SHAFT GEAR
2 - 200 FT. LBS.
3 - TORQUE WRENCH
4 - SPECIAL TOOL 6259
Fig. 123 Install Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPARTATF RTV (MS-GF41) AS SHOWN
Fig. 124 Install Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
21 - 156 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(38) Install low/reverse clutch pack (Fig. 125).
Leave uppermost disc out until snap ring is installed.
(39) Install low/reverse reaction plate flat snap
ring (Fig. 126).(40) Install remaining low/reverse clutch disc (Fig.
127).
(41) Install low/reverse reaction plate with flat
side up (Fig. 128).
Fig. 125 Install Low/Reverse Clutch Pack
1 - CLUTCH PLATES (5)
2 - CLUTCH DISCS (5)
Fig. 126 Install Low/Reverse Reaction Plate Snap
Ring
1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
Fig. 127 Install One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
Fig. 128 Install Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
RS41TE AUTOMATIC TRANSAXLE21 - 157
41TE AUTOMATIC TRANSAXLE (Continued)

(42) Install tapered snap ring (with tapered side
up) as shown in (Fig. 129) (Fig. 130).
(43) Set up dial indicator as shown in (Fig. 131) to
measure low/reverse clutch clearance. Press down on
clutch pack with finger and zero dial indicator.Low/
Reverse clutch pack clearance is 0.89-1.47 mm
(0.035-0.058 in.). Set up indicator and record mea-
surement in four (4) places. Take average of readings
and select the proper low/reverse reaction plate to
achieve specifications.
LOW/REVERSE REACTION PLATE CHART
PART NUMBER THICKNESS
4799846AA 5.88 mm (0.232 in.)
4799847AA 6.14 mm (0.242 in.)
4799848AA 6.40 mm (0.252 in.)
4799849AA 6.66 mm (0.262 in.)
4799855AA 6.92 mm (0.273 in.)
(44) Install 2/4 clutch pack (Fig. 132).
(45) Orient 2/4 clutch return spring to retainer as
shown in (Fig. 133), and install to transaxle (Fig.
134).
Fig. 129 Tapered Snap Ring Instructions
Fig. 130 Snap Ring Installed
1 - SCREWDRIVER
2 - TAPERED SNAP RING (INSTALL AS SHOWN)
Fig. 131 Check Low/Reverse Clutch Clearance
1 - DIAL INDICATOR
2 - DIAL INDICATOR TIP TOOL 6268
3 - HOOK TOOL
Fig. 132 Install 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
21 - 158 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(46) Using tool 5058, compress 2/4 clutch return
spring just enough to install snap ring (Fig. 135).(47) Install snap ring.
(48) Set up dial indicator as shown in (Fig. 136)
and measure 2/4 clutch clearance. Press down on
clutch pack with finger and zero dial indicator.2/4
clutch pack clearance is 0.76-2.64 mm
(0.030-0.104 in.).Set up indicator and record mea-
surement in four (4) places. Take average of read-
ings. If clearance is outside this range, the clutch is
assembled improperly.There is no adjustment for
2/4 clutch clearance.
Fig. 133 Proper Orientation of 2/4 Clutch Retainer
and Spring
1 - NOTE POSITION
2 - RETURN SPRING
3 - 2/4 CLUTCH RETAINER
Fig. 134 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 135 Install 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
Fig. 136 Check 2/4 Clutch Clearance
1 - DIAL INDICATOR
2 - HOOK TOOL
3 - DIAL INDICATOR TIP TOOL 6268
RS41TE AUTOMATIC TRANSAXLE21 - 159
41TE AUTOMATIC TRANSAXLE (Continued)

(49) Install rear sun gear and #7 needle bearing
(Fig. 138).
NOTE: The number seven needle bearing has three
anti-reversal tabs and is common with the number
five and number two position. The orientation
should allow the bearing to seat flat against the
rear sun gear (Fig. 137). A small amount of petrola-
tum can be used to hold the bearing to the rear sun
gear.
(50) Install front carrier/rear annulus assembly
and #6 needle bearing (Fig. 139).
(51) Install front sun gear assembly and #4 thrust
washer (Fig. 140).(52)DETERMINING #4 THRUST PLATE
THICKNESS / INPUT SHAFT END PLAY:
(a) Select the thinnest #4 thrust plate thickness
and install to input clutch assembly (Fig. 141). Use
petrolatum to retain.
(b) Install input clutch assembly into position
and verify that it is completely seated by viewing
through input speed sensor hole. If view through
input speed sensor hole is not as shown in (Fig.
142), the input clutch assembly is not seated prop-
erly.
(c) Remove oil pump o-ring (Fig. 143).Be sure
to reinstall oil pump o-ring after selecting the
proper #4 thrust plate.
Fig. 137 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 138 Install Rear Sun Gear and #7 Needle
Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 139 Install Front Carrier and Rear Annulus
Assembly
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 140 Install Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
21 - 160 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(d) Install pump and gasket to transmission.
Install and torque bolts.
(e) Set up input shaft for measurement with
Indicator Set C3339 and End Play Set 8266 as
shown in (Fig. 144).
(f) Measure the input shaft end play with the
transaxle in the vertical position.Input shaft end
play must be within 0.005 to 0.025 inch.For
example, if end play reading is 0.055 inch, select
No. 4 Thrust Plate which is 0.071 to 0.074 thick.
This should provide an input shaft end play read-
ing of 0.020 inch which is within specifications.
(g) Refer to the No. 4 thrust plate chart to select
the proper No. 4 thrust plate:
Fig. 141 Select Thinnest No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 142 View Through Input Speed Sensor Hole
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
Fig. 143 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 144 Measure Input Shaft End Play Using End
Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
RS41TE AUTOMATIC TRANSAXLE21 - 161
41TE AUTOMATIC TRANSAXLE (Continued)

NO. 4 THRUST PLATE CHART
PART NUMBER THICKNESS
4431665AB 1.60mm (0.063 in.)
3836237AB 1.73mm (0.068 in.)
4431666AB 1.80mm (0.071 in.)
3836238AB 1.96mm (0.077 in.)
4431667AB 2.03mm (0.080 in.)
3836239AB 2.16mm (0.085 in.)
4431668AB 2.24mm (0.088 in.)
3836240AB 2.39mm (0.094 in.)
4431669AB 2.46mm (0.097 in.)
3836241AB 2.62mm (0.103 in.)
4446670AB 2.67mm (0.105 in.)
4446671AB 2.90mm (0.114 in.)
(53) Install input clutch assembly (Fig. 145).
(54) Install #1 caged needle bearing (Fig. 146).
CAUTION: The cooler bypass valve must be
replaced if transaxle failure has occurred. Do not
attempt to reuse or clean old valve.
(55) Install cooler bypass valve with o-ring end
towards rear of case (Fig. 147).
(56) Install oil pump gasket (Fig. 148).
Fig. 145 Install Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 146 Install Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 147 Install Cooler Bypass Valve
1 - COOLER BYPASS VALVE
Fig. 148 Install Oil Pump Gasket
1 - PUMP GASKET
21 - 162 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(57) Install oil pump assembly (Fig. 149).
(58) Install oil pump-to-case bolts and torque to 27
N´m (20 ft. lbs.) (Fig. 150).(59) Install low/reverse accumulator (Fig. 151).
(60) Install low/reverse accumulator plug (Fig.
152).
Fig. 149 Install Oil Pump
1 - OIL PUMP
2 - GASKET
Fig. 150 Install Pump-to-Case Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 151 Install Low/Reverse Accumulator
1 - ACCUMULATOR PISTON
2 - SEAL RINGS
3 - RETURN SPRINGS
4 - (NOTE NOTCH)
Fig. 152 Install Low/Reverse Accumulator Plug
(Cover)
1 - ADJUSTABLE PLIERS
2 - PLUG
RS41TE AUTOMATIC TRANSAXLE21 - 163
41TE AUTOMATIC TRANSAXLE (Continued)