DODGE TOWN AND COUNTRY 2004 Service Manual

(9) Install 2nd gear blocker ring (Fig. 64).
(10) Install 2nd gear friction cone (Fig. 65).(11) Install 2nd gear reactor ring (Fig. 66).
(12) Install 2nd gear and needle bearing to inter-
mediate shaft (Fig. 67) (Fig. 68).
Fig. 64 2nd Gear Blocker Ring
1 - 2ND GEAR BLOCKER RING
Fig. 65 2nd Gear Friction Cone
1 - 2ND GEAR FRICTION CONE
Fig. 66 2nd Gear Reactor Ring
1 - 2ND GEAR REACTOR RING
Fig. 67 2nd Gear Removal/Installation
1 - 2ND GEAR
2 - NEEDLE BEARING
21s - 20 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)

(13) Press 3/4 cluster gear onto intermediate shaft
using cup 8481 (Fig. 69). (14) Install
NEW3/4 cluster gear snap ring (Fig.
70).
(15) Install 5th gear and needle bearing to inter-
mediate shaft (Fig. 71) (Fig. 72).
Fig. 68 2nd Gear Needle Bearing Removal/Installation
1 - NEEDLE BEARING
Fig. 69 Install 3/4 Cluster Gear using Tool 8481
1 - ARBOR PRESS
2 - INSTALLER 8481
3 - 3/4 CLUSTER GEAR
Fig. 70 3/4 Cluster Gear Snap Ring
1 - SNAP RING
Fig. 71 5th Gear Removal/Installation
1 - 5TH GEAR
2 - NEEDLE BEARING
RS T850 MANUAL TRANSAXLE21s-21
INTERMEDIATE SHAFT (Continued)

(16) Install 5th gear blocker ring to synchronizer
(Fig. 73). (17) Install 5th gear synchronizer assembly to
intermediate shaft (Fig. 74). When installing 5/R
synchronizer, make sure to align oil slots on
synchronizer hub face with oil hole in the shaft
splined hub journal.
(18) Install NEW5/R synchro snap ring (Fig. 75).
Fig. 72 5th Gear Needle Bearing Removal/
Installation
1 - 5TH GEAR NEEDLE BEARING
Fig. 73 5th Gear Blocker Ring to Synchro
1 - 5th GEAR BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 74 Install 5/R Synchro and 5th Blocker Ring to 5th Gear
1 - 5/R SYNCHRONIZER
2 - 5TH GEAR BLOCKER RING
3 - 5TH GEAR
Fig. 75 5/R Synchro Snap Ring
1 - SNAP RING
21s - 22 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)

(19) Install reverse gear blocker ring (Fig. 76).
(20) Install reverse gear needle bearing (Fig. 77).
(21) Install reverse gear to intermediate shaft.
(22) Install intermediate shaft sealed roller bear-
ing and thrust washer using installer 8482 (Fig. 78). (23) Install NEWintermediate shaft sealed bear-
ing snap ring (Fig. 79).
Fig. 76 Reverse Gear Blocker Ring
1 - REVERSE BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 77 Reverse Gear Needle Bearing
1 - NEEDLE BEARING
Fig. 78 Sealed Roller Bearing Installatiion
1 - ARBOR PRESS
2 - REMOVER/INSTALLER 8482
3 - SEALED ROLLER BEARING
4 - THRUST WASHER
Fig. 79 Intermediate Shaft Bearing Snap Ring
1 - SNAP RING
2 - BEARING
RS T850 MANUAL TRANSAXLE21s-23
INTERMEDIATE SHAFT (Continued)

40TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
40TE AUTOMATIC TRANSAXLE DESCRIPTION .........................25
OPERATION ...........................27
DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - 4XTETRANSAXLE GENERAL DIAGNOSIS .......27
DIAGNOSIS AND TESTING - ROAD TEST . . . 27
DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TESTS ....................28
DIAGNOSIS AND TESTING - CLUTCH AIR PRESSURE TESTS ....................30
DIAGNOSIS AND TESTING - TORQUE CONVERTER HOUSING FLUID LEAKAGE . . . 31
REMOVAL .............................31
DISASSEMBLY .........................34
ASSEMBLY ............................51
INSTALLATION .........................73
SCHEMATICS AND DIAGRAMS 4XTE TRANSAXLE HYDRAULICSCHEMATICS ........................75
SPECIFICATIONS - 41TE TRANSAXLE .......87
SPECIAL TOOLS .......................89
ACCUMULATOR DESCRIPTION .........................94
OPERATION ...........................94
DRIVING CLUTCHES DESCRIPTION .........................95
OPERATION ...........................95
FINAL DRIVE DESCRIPTION .........................95
OPERATION ...........................96
DISASSEMBLY .........................96
ASSEMBLY ............................99
ADJUSTMENTS DIFFERENTIAL BEARING PRELOADMEASUREMENT AND ADJUSTMENT ......100
FLUID STANDARD PROCEDURE FLUID LEVEL AND CONDITION CHECK . . . 102
STANDARD PROCEDURE - FLUID ANDFILTER SERVICE .....................104
GEAR SHIFT CABLE REMOVAL ............................105
HOLDING CLUTCHES DESCRIPTION ........................106
OPERATION ..........................106
INPUT CLUTCH ASSEMBLY DISASSEMBLY ........................107
ASSEMBLY ...........................116 OIL PUMP
DESCRIPTION ........................131
OPERATION ..........................131
DISASSEMBLY ........................131
ASSEMBLY ...........................132
PLANETARY GEARTRAIN DESCRIPTION ........................132
OPERATION ..........................132
SEAL - OIL PUMP REMOVAL ............................133
INSTALLATION ........................133
SHIFT INTERLOCK SOLENOID DESCRIPTION ........................133
OPERATION ..........................134
DIAGNOSIS AND TESTING - BRAKE/ TRANSMISSION SHIFT INTERLOCK
SOLENOID ..........................135
REMOVAL ............................135
INSTALLATION ........................136
SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION ........................137
OPERATION ..........................137
REMOVAL ............................138
INSTALLATION ........................139
SPEED SENSOR - INPUT DESCRIPTION ........................140
OPERATION ..........................140
REMOVAL ............................141
INSTALLATION ........................141
SPEED SENSOR - OUTPUT DESCRIPTION ........................142
OPERATION ..........................142
REMOVAL ............................143
INSTALLATION ........................143
TORQUE CONVERTER DESCRIPTION ........................144
OPERATION ..........................148
REMOVAL ............................149
INSTALLATION ........................149
TRANSMISSION CONTROL RELAY DESCRIPTION ........................150
OPERATION ..........................150
TRANSMISSION RANGE SENSOR DESCRIPTION ........................150
OPERATION ..........................151
REMOVAL ............................151
INSTALLATION ........................152
VALVE BODY DESCRIPTION ........................152
21s - 24 40TE AUTOMATIC TRANSAXLERS

OPERATION..........................152
REMOVAL ............................153
DISASSEMBLY ........................155 ASSEMBLY
...........................159
INSTALLATION ........................164
40TE AUTOMATIC
TRANSAXLE
DESCRIPTION
The 40TE (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
Fig. 1 40TE Automatic Transaxle
1 - TRANSAXLE CASE 7 - REVERSE CLUTCH 13 - OUTPUT SHAFT GEAR
2 - TORQUE CONVERTER 8 - FRONT PLANET CARRIER 14 - TRANSFER SHAFT GEAR
3 - OIL PUMP 9 - 2/4 CLUTCH 15 - TRANSFER SHAFT
4 - INPUT SPEED SENSOR 10 - L/R CLUTCH 16 - DIFFERENTIAL
5 - UNDERDRIVE CLUTCH 11 - OUTPUT SPEED SENSOR 17 - CONVERTER DRIVE PLATE
6 - OVERDRIVE CLUTCH 12 - REAR PLANET CARRIER/OUTPUT
SHAFT18 - INPUT SHAFT
RS
40TE AUTOMATIC TRANSAXLE21s-25

holding clutches: 2nd/4th gear and Low/Reverse. The
primary mechanical components of the transaxle con-
sist of the following:² Three multiple disc input clutches
² Two multiple disc holding clutches
² Four hydraulic accumulators
² Two planetary gear sets
² Hydraulic oil pump
² Valve body
² Solenoid/Pressure switch assembly
² Integral 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.
TRANSAXLE IDENTIFICATION
The 40TE transaxle is identified by a barcode label
that is fixed to the transaxle case as shown in (Fig.
2). The label contains a series of digits that can be
translated into useful information such as transaxle
part number, date of manufacture, manufacturing
origin, plant shift number, build sequence number,
etc. Refer to (Fig. 3) for identification label break-
down. If the tag is not legible or missing, the ªPKº num-
ber, which is stamped into the transaxle case behind
the transfer gear cover, can be referred to for identi-
fication. This number differs slightly in that it con-
tains the entire transaxle part number, rather than
the last three digits.
Fig. 2 Transaxle Identification Label
1 - IDENTIFICATION LABEL
Fig. 3 Identification Label Breakdown
1 - T=TRACEABILITY
2 - SUPPLIER CODE (PK=KOKOMO)
3 - COMPONENT CODE (TK=KOKOMO TRANSMISSION)
4 - BUILD DAY (344=DEC. 9)
5 - BUILD YEAR (9=1999)
6 - LINE/SHIFT CODE (3=3RD SHIFT)
7 - BUILD SEQUENCE NUMBER
8 - LAST THREE OF P/N
9 - ALPHA
10 - TRANSAXLE PART NUMBER
11 - P=PART NUMBER
21s - 26 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

OPERATION
Transmission output is directed to an integral dif-
ferential by a transfer gear system in the following
input-to-output ratios:
First ............................... 2.84 : 1
Second ............................. 1.57 : 1
Third .............................. 1.00 : 1
Overdrive ........................... 0.69 : 1
Reverse ............................ 2.21 : 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - 4XTE TRANSAXLE
GENERAL DIAGNOSIS
NOTE: Before attempting any repair on a 4XTE four-
speed automatic transaxle, check for diagnostic trou-
ble codes (DTC's) using the DRB scan tool. Refer to
the Transmission Diagnostic Procedures Manual.
Transaxle malfunctions may be caused by these
general conditions: ² Poor engine performance
² Improper adjustments
² Hydraulic malfunctions
² Mechanical malfunctions
² Electronic malfunctions
Diagnosis of these problems should always begin by
checking the easily accessible variables: fluid level and
condition, gearshift cable adjustment. Then perform a
road test to determine if the problem has been corrected
or that more diagnosis is necessary. If the problem per-
sists after the preliminary tests and corrections are com-
pleted, hydraulic pressure checks should be performed.
DIAGNOSIS AND TESTING - ROAD TEST
Prior to performing a road test, verify that the
fluid level, fluid condition, and linkage adjustment
have been approved. During the road test, the transaxle should be oper-
ated in each position to check for slipping and any
variation in shifting. If the vehicle operates properly at highway speeds,
but has poor acceleration, the converter stator over-
running clutch may be slipping. If acceleration is nor-
mal, but high throttle opening is needed to maintain
highway speeds, the converter stator clutch may
have seized. Both of these stator defects require
replacement of the torque converter and thorough
transaxle cleaning. Slipping clutches can be isolated by comparing the
ªElements in Useº chart with clutch operation
encountered on a road test. This chart identifies
which clutches are applied at each position of the
selector lever.
A slipping clutch may also set a DTC and can be deter-
mined by operating the transaxle in all selector positions.
ELEMENTS IN USE AT EACH POSITION OF SELECTOR LEVER
Shift Lever Position INPUT CLUTCHES HOLDING CLUTCHES
Underdrive Overdrive Reverse 2/4 Low/Reverse
P - PARK X
R - REVERSE X X N - NEUTRAL X
OD - OVERDRIVE
First X X
Second X X Direct X X
Overdrive X X
D - DRIVE*
First X X
Second X X Direct X X
L - LOW*
First X X
Second X X
Direct X X
* Vehicle upshift and downshift speeds are increased when in these selector positions.
RS 40TE AUTOMATIC TRANSAXLE21s-27
40TE AUTOMATIC TRANSAXLE (Continued)

The process of elimination can be used to detect
any unit which slips and to confirm proper operation
of good units. Road test analysis can diagnose slip-
ping units, but the cause of the malfunction cannot
be determined. Practically any condition can be
caused by leaking hydraulic circuits or sticking
valves.
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS
Pressure testing is a very important step in the
diagnostic procedure. These tests usually reveal the
cause of most hydraulic transaxle problems. Before performing pressure tests, be certain that
fluid level and condition, and shift cable adjustments
have been checked and approved. Fluid must be at
operating temperature (150 to 200 degrees F.). Install an engine tachometer, raise vehicle on hoist
which allows front wheels to turn, and position
tachometer so it can be read. Attach 300 psi gauge (C-3293SP) to port(s)
required for test(s) being conducted. Use adapter set
L-4559 to adapt gauge(s) to transaxle. Test port locations are shown in (Fig. 4).
TEST ONE-SELECTOR IN LOW (1st GEAR)
(1) Attach pressure gauge to the low/reverse clutch
tap. (2) Move selector lever to the (L) position.
(3) Allow vehicle wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
to 20 mph. (4) Low/reverse clutch pressure should read 115 to
145 psi. (5) This test checks pump output, pressure regula-
tion and condition of the low/reverse clutch hydraulic
circuit and shift schedule.
TEST TWO-SELECTOR IN DRIVE (2nd GEAR)
NOTE: This test checks the underdrive clutch
hydraulic circuit as well as the shift schedule.
(1) Attach gauge to the underdrive clutch tap.
(2) Move selector lever to the 3 position.
(3) Allow vehicle wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
of 30 mph. (4) In second gear the underdrive clutch pressure
should read 110 to 145 psi.
TEST TWO A±SELECTOR IN OD (4th Gear)
NOTE: This test checks the underdrive clutch
hydraulic circuit as well as the shift schedule.
(1) Attach gauge to the underdrive clutch tap.
(2) Move selector lever to the (OD) position.
(3) Allow wheels to rotate freely and increase
throttle opening to achieve an indicated speed of 40
mph. (4) Underdrive clutch pressure should read below
5 psi. If not, then either the solenoid assembly or
PCM/TCM is at fault.
TEST THREE-OVERDRIVE CLUTCH CHECK (3rd and
2nd Gear)
(1) Attach gauge to the overdrive clutch tap.
(2) Move selector lever to the (OD) position.
(3) Allow vehicle wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
of 20 mph. Vehicle should be in 3rd gear. (4) Overdrive clutch pressure should read 74 to 95
psi. (5) Move selector lever to the (3) position and
increase indicated vehicle speed to 30 mph. (6) The vehicle should be in second gear and over-
drive clutch pressure should be less than 5 psi. (7) This test checks the overdrive clutch hydraulic
circuit as well as the shift schedule.
TEST FOUR-SELECTOR IN OVERDRIVE (4th Gear)
(1) Attach gauge to the 2/4 clutch tap.
(2) Move selector lever to the (OD) position.
(3) Allow vehicle front wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
of 30 mph. Vehicle should be in 4th gear. (4) The 2/4 clutch pressure should read 75 to 95
psi. (5) This test checks the 2/4 clutch hydraulic cir-
cuit.
Fig. 4 Pressure Taps
1 - OVERDRIVE CLUTCH
2 - TORQUE CONVERTER OFF
3 - LOW/REVERSE CLUTCH
4 - 2/4 CLUTCH
5 - REVERSE CLUTCH
6 - UNDERDRIVE CLUTCH
21s - 28 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

TEST FIVE-SELECTOR IN OVERDRIVE (4th Gear-CC
on)
(1) Attach gauge to the torque converter clutch off
pressure tap. (2) Move selector lever to the (OD) position.
(3) Allow vehicle wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
of 50 mph. Vehicle should be in 4th gear, CC on.
CAUTION: Both wheels must turn at the same
speed.
(4) Torque converter clutch off pressure should be
less than 5 psi. (5) This test checks the torque converter clutch
hydraulic circuit.
TEST SIX-SELECTOR IN REVERSE
(1) Attach gauges to the reverse and LR clutch
tap. (2) Move selector lever to the (R) position.
(3) Read reverse clutch pressure with output sta-
tionary (foot on brake) and throttle opened to achieve
1500 rpm. (4) Reverse and LR clutch pressure should read
165 to 235 psi. (5) This test checks the reverse clutch hydraulic
circuit.
TEST RESULT INDICATIONS
(1) If proper line pressure is found in any one test,
the pump and pressure regulator are working prop-
erly. (2) Low pressure in all positions indicates a defec-
tive pump, a clogged filter, or a stuck pressure regu-
lator valve. (3) Clutch circuit leaks are indicated if pressures
do not fall within the specified pressure range. (4) If the overdrive clutch pressure is greater than
5 psi in Step 4 of Test Three, a worn reaction shaft
seal ring or a defective solenoid assembly is indi-
cated. (5) If the underdrive clutch pressure is greater
than 5 psi in Step 4 of Test Two A, a defective sole-
noid assembly or PCM/TCM is the cause.
PRESSURE CHECK SPECIFICATIONS
Pressure Taps
Gear
Selector
Position Actual Gear
Underdrive
Clutch Overdrive
Clutch Reverse
Clutch Torque
Converter
Clutch Off 2/4 Clutch Low/
Reverse Clutch
Park * PARK 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
REVERSE * REVERSE 0-2 0-7 165-235 50-100 0-2 165-235
0 mph
NEUTRAL * NEUTRAL 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
L# FIRST 110-145 0-5 0-2 60-110 0-2 115-145
20 mph
3# SECOND 110-145 0-5 0-2 60-110 115-145 0-2
30 mph
3# DIRECT 75-95 75-95 0-2 60-90 0-2 0-2
45 mph
OD # OVERDRIVE 0-2 75-95 0-2 60-90 75-95 0-2
30 mph
OD # OVERDRIVE
WITH TCC 0-2 75-95 0-2 0-5 75-95 0-2
50 mph
* Engine speed at 1500 rpm
# CAUTION: Both front wheels must be turning at the same speed.
RS 40TE AUTOMATIC TRANSAXLE21s-29
40TE AUTOMATIC TRANSAXLE (Continued)