DODGE TOWN AND COUNTRY 2004 Service Manual

(27) Using Tool 6051, install transfer shaft bearing
snap ring (Fig. 114).
(28) Install transfer shaft bearing cup into retainer
using Tool 6061 (Fig. 115). (29) Install bearing cup retainer to transaxle (Fig.
116).
(30) Install transfer gear bearing cone to transfer
gear using Tool 5052 (Fig. 117).
Fig. 114 Install Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS TOOL 6051
2 - TRANSFER SHAFT BEARING SNAP RING
3 - TRANSFER SHAFT
Fig. 115 Install Transfer Shaft Bearing Cup Into Retainer
1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - TOOL 6061
4 - TRANSFER SHAFT BEARING CUP RETAINER
5 - USE REMOVED BEARING CUP TO SUPPORT RETAINER
Fig. 116 Install Bearing Cup Retainer
1 - ALIGN INDEXING TAB TO SLOT
2 - BEARING CUP RETAINER
Fig. 117 Install Transfer Gear Bearing Cone
1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - NEW BEARING CONE
4 - TRANSFER SHAFT GEAR
5 - TOOL 5052
21s - 60 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(31)TRANSFER GEAR BEARING ADJUST-
MENT: (a) Install a 4.66 mm (0.184 in.) gauging shim
on the transfer shaft (Fig. 118). (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. 118) 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.) 4505588AB 0.76mm (0.030
in.) 3.94mm (0.155
in.) 4412818AB
0.08mm (0.003 in.) 4.62mm (0.182
in.) 4412835AB 0.79mm (0.031
in.) 3.90mm (0.154
in.) 4412817AB
0.10mm (0.004 in.) 4.58mm (0.180
in.) 4412834AB 0.81mm (0.032
in.) 3.90mm (0.154
in.) 4412817AB
0.13mm (0.005 in.) 4.58mm (0.180
in.) 4412834AB 0.84mm (0.033
in.) 3.86mm (0.152
in.) 4412816AB
0.15mm (0.006 in.) 4.54mm (0.178
in.) 4412833AB 0.86mm (0.034
in.) 3.82mm (0.150
in.) 4412815AB
0.18mm (0.007 in.) 4.50mm (0.177
in.) 4412832AB 0.89mm (0.035
in.) 3.82mm (0.150
in.) 4412815AB
0.20mm (0.008 in.) 4.50mm (0.177
in.) 4412832AB 0.91mm (0.036
in.) 3.78mm (0.149
in.) 4412814AB
0.23mm (0.009 in.) 4.46mm (0.175
in.) 4412831AB 0.94mm (0.037
in.) 3.74mm (0.147
in.) 4412813AB
0.25mm (0.010 in.) 4.46mm (0.175
in.) 4412831AB 0.97mm (0.038
in.) 3.74mm (0.147
in.) 4412813AB
0.28mm (0.011 in.) 4.42mm (0.174
in.) 4412830AB 0.99mm (0.039
in.) 3.70mm (0.146
in.) 4412812AB
0.30mm (0.012 in.) 4.38mm (0.172
in.) 4412829AB 1.02mm (0.040
in.) 3.66mm (0.144
in.) 4412811AB
0.33mm (0.013 in.) 4.38mm (0.172
in.) 4412829AB 1.04mm (0.041
in.) 3.66mm (0.144
in.) 4412811AB
Fig. 118 Install Transfer Shaft Gear and (Select)
Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM (SELECT)
RS 40TE AUTOMATIC TRANSAXLE21s-61
40TE 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.) 4412828AB 1.07mm (0.042
in.) 3.62mm (0.143
in.) 4412810AB
0.38mm (0.015 in.) 4.30mm (0.169
in.) 4412827AB 1.08mm (0.043
in.) 3.62mm (0.143
in.) 4412810AB
0.41mm (0.016 in.) 4.30mm (0.169
in.) 4412827AB 1.12mm (0.044
in.) 3.58mm (0.141) 4412809AB
0.43mm (0.017 in.) 4.26mm (0.168
in.) 4412826AB 1.14mm (0.045
in.) 3.54mm (0.139
in.) 4412808AB
0.46mm (0.018 in.) 4.22mm (0.166
in.) 4412825AB 1.17mm (0.046
in.) 3.54mm (0.139
in.) 4412808AB
0.48mm (0.019 in.) 4.22mm (0.166
in.) 4412825AB 1.19mm (0.047
in.) 3.50mm (0.138
in.) 4412807AB
0.50mm (0.020 in.) 4.18mm (0.165
in.) 4412824AB 1.22mm (0.048
in.) 3.46mm (0.136
in.) 4412806AB
0.53mm (0.021 in.) 4.18mm (0.165
in.) 4412824AB 1.24mm (0.049
in.) 3.46mm (0.136
in.) 4412806AB
0.56mm (0.022 in.) 4.14mm (0.163
in.) 4412823AB 1.27mm (0.050
in.) 3.42mm (0.135
in.) 4412805AB
0.58mm (0.023 in.) 4.10mm (0.161
in.) 4412822AB 1.30mm (0.051
in.) 3.38mm (0.133
in.) 4412804AB
0.61mm (0.024 in.) 4.10mm (0.161
in.) 4412822AB 1.32mm (0.052
in.) 3.38mm (0.133
in.) 4412804AB
0.64mm (0.025 in.) 4.06mm (0.160
in.) 4412821AB 1.35mm (0.053
in.) 3.34mm (0.132
in.) 4412803AB
0.66mm (0.026 in.) 4.02mm (0.158
in.) 4412820AB 1.37mm (0.054
in.) 3.34mm (0.132
in.) 4412803AB
0.69mm (0.027 in.) 4.02mm (0.158
in.) 4412820AB 1.40mm (0.055
in.) 3.30mm (0.130
in.) 4412802AB
0.71mm (0.028 in.) 3.98mm (0.157
in.) 4412819AB 1.45mm (0.057
in 3.26mm (0.128
in.) 4412801AB
0.74mm (0.029 in.) 3.94mm (0.155
in.) 4412818AB 1.47mm (0.058
in.) 2.22mm (0.127
in.) 4505570AB
21s - 62 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(32) Install the transfer shaft gear using Tool 6261
(Fig. 119).
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. 120). (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 Mopar tATF RTV (MS-GF41)
to transfer gear cover (Fig. 121).
(37) Install transfer gear cover-to-case bolts and
torque to 20 N´m (175 in. lbs.) torque (Fig. 122).
Fig. 119 Install Transfer Shaft Gear
1 - WRENCHES
2 - SPECIAL TOOL 6261
3 - OUTPUT GEAR
4 - TRANSFER SHAFT GEAR
Fig. 120 Tighten Nut to 271 N²m (200 ft. lbs.)
1 - TRANSFER SHAFT GEAR
2 - 200 FT. LBS.
3 - TORQUE WRENCH
4 - SPECIAL TOOL 6259
Fig. 121 Install Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPAR TATF RTV (MS-GF41) AS SHOWN
Fig. 122 Install Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
RS 40TE AUTOMATIC TRANSAXLE21s-63
40TE AUTOMATIC TRANSAXLE (Continued)

(38) Install low/reverse clutch pack (Fig. 123).
Leave uppermost disc out until snap ring is installed.
(39) Install low/reverse reaction plate flat snap
ring (Fig. 124). (40) Install remaining low/reverse clutch disc (Fig.
125).
(41) Install low/reverse reaction plate with flat
side up (Fig. 126).
Fig. 123 Install Low/Reverse Clutch
1 - CLUTCH PLATE
2 - CLUTCH DISC
Fig. 124 Install Low/Reverse Reaction Plate Snap Ring
1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
Fig. 125 Install One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
Fig. 126 Install Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
21s - 64 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(42) Install tapered snap ring (with tapered side
up) as shown in (Fig. 127) (Fig. 128).
(43) Set up dial indicator as shown in (Fig. 129) 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. 130).
Fig. 127 Tapered Snap Ring Instructions
Fig. 128 Snap Ring Installed
1 - SCREWDRIVER
2 - TAPERED SNAP RING (INSTALL AS SHOWN)
Fig. 129 Check Low/Reverse Clutch Clearance
1 - DIAL INDICATOR
2 - DIAL INDICATOR TIP TOOL 6268
3 - HOOK TOOL
Fig. 130 Install 2/4 Clutch
1 - CLUTCH DISC
2 - CLUTCH PLATE
RS 40TE AUTOMATIC TRANSAXLE21s-65
40TE AUTOMATIC TRANSAXLE (Continued)

NOTE: The 2/4 Clutch Piston has bonded seals
which are not individually serviceable. Seal replace-
ment requires replacement of the piston assembly.(45) Orient 2/4 clutch return spring to retainer as
shown in (Fig. 131), and install to transaxle (Fig.
132).
(46) Using tool 5058, compress 2/4 clutch return
spring just enough to install snap ring (Fig. 133). (47) Install snap ring. (48) Set up dial indicator as shown in (Fig. 134)
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. 131 Proper Orientation of 2/4 Clutch Retainer and Spring
1 - NOTE POSITION
2 - RETURN SPRING
3 - 2/4 CLUTCH RETAINER
Fig. 132 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 133 Install 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
Fig. 134 Check 2/4 Clutch Clearance
1 - DIAL INDICATOR
2 - HOOK TOOL
3 - DIAL INDICATOR TIP TOOL 6268
21s - 66 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(49) Install rear sun gear and #7 needle bearing
(Fig. 136).
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. 135). 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. 137).
(51) Install front sun gear assembly and #4 thrust
washer (Fig. 138).
Fig. 135 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 136 Install Rear Sun Gear and #7 Needle Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 137 Install Front Carrier/Rear AnnulusAssembly
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 138 Install Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
RS 40TE AUTOMATIC TRANSAXLE21s-67
40TE AUTOMATIC TRANSAXLE (Continued)

(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. 139). 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. 140), the input
clutch assembly is not seated properly.
(c) Remove oil pump o-ring (Fig. 141). Be sure
to reinstall oil pump o-ring after selecting the
proper #4 thrust plate. (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. 142). (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. 139 Select Thinnest No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 140 View Through Input Speed Sensor Hole
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
Fig. 141 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 142 Measure Input Shaft End Play Using Tool 8266ÐTypical
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
21s - 68 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

NO. 4 THRUST PLATE CHART
PART NUMBER THICKNESS4431665AB 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. 143).
(54) Install #1 caged needle bearing (Fig. 144).
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. 145). (56) Install oil pump gasket (Fig. 146).
Fig. 143 Install Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 144 Install No. 1 Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 145 Install Cooler Bypass Valve
1 - COOLER BYPASS VALVE
Fig. 146 Install Oil Pump Gasket
1 - PUMP GASKET
RS 40TE AUTOMATIC TRANSAXLE21s-69
40TE AUTOMATIC TRANSAXLE (Continued)