DODGE TOWN AND COUNTRY 2004 Service Manual

(57) Install oil pump assembly (Fig. 147).
(58) Install oil pump-to-case bolts and torque to 27
N´m (20 ft. lbs.) (Fig. 148). (59) Install low/reverse accumulator (Fig. 149).
(60) Install low/reverse accumulator plug (Fig.
150).
Fig. 147 Install Oil Pump
1 - OIL PUMP
2 - GASKET
Fig. 148 Install Pump-to-Case Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 149 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
Fig. 150 Install Low/Reverse Accumulator Plug
1 - ADJUSTABLE PLIERS
2 - PLUG
21s - 70 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(61) Install low/reverse accumulator snap ring
(Fig. 151).
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
and springs (Fig. 152). (63) Install valve body to transaxle (Fig. 153).
Rotate manual valve shaft fully clockwise to ease
installation. Make sure park rod rollers are posi-
tioned within park guide bracket.
(64) Install and torque valve body-to-case bolts to
12 N´m (105 in. lbs.) (Fig. 154).
Fig. 151 Install Low/Reverse Accumulator Snap Ring
1 - SNAP RING
2 - PLUG
Fig. 152 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 153 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 154 Install Valve Body-to-Case Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
RS 40TE AUTOMATIC TRANSAXLE21s-71
40TE AUTOMATIC TRANSAXLE (Continued)

(65) Install oil filter and new o-ring (Fig. 155).
(66) Apply an 1/8º bead of MopartATF RTV (MS-
GF41) to oil pan and immediately install to case (Fig.
156).
(67) Install oil pan-to-case bolts and torque to 19
N´m (165 in. lbs.). (68) Install solenoid/pressure switch assembly and
gasket to case (Fig. 157). (69) Install and tighten solenoid/pressure switch
assembly-to-transaxle case bolts to 12 N´m (110 in.
lbs.) (Fig. 158).
(70) Install and torque input and output speed
sensors to case to 27 N´m (20 ft. lbs.).
Fig. 155 Install Oil Filter and O-Ring
1 - OIL FILTER
2 - O-RING
Fig. 156 Install Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPAR TATF RTV (MS-GF41)
3 - OIL FILTER
Fig. 157 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 158 Attaching Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
21s - 72 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is nec-
essary to perfrom the TCM Quick Learn procedure.
(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
bellhousing 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. 159). (3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 159). (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) Align and install rear mount bracket-to-case
bolts by hand (Fig. 160). Torque horizontal bolt to
102 N´m (75 ft. lbs.). (12) AWD models: Install power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - INSTALLATION)
Fig. 160 Rear Mount Bracket - Typical
1 - BOLT - VERTICAL 102 N´m (75 ft. lbs.)
2 - BRACKET - REAR MOUNT 3 - BOLT - HORIZONTAL 102 N´m (75 ft. lbs.)
Fig. 159 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
RS
40TE AUTOMATIC TRANSAXLE21s-73
40TE AUTOMATIC TRANSAXLE (Continued)

(13) Install left and right halfshaft assemblies.
(Refer t o 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION) (14) Install front wheel/tire assemblies.
(15) Lower vehicle.
(16) Torque remaining rear mount bracket-to-tran-
saxle vertical bolts (Fig. 160) to 102 N´m (75 ft. lbs.). (17) Install transaxle upper bellhousing-to-block
bolts and torque to 95 N´m (70 ft. lbs.). (18) Install and connect crank position sensor (if
equipped). (19) Connect gearshift cable to upper mount
bracket and transaxle manual valve lever (Fig. 161).
(20) Connect solenoid/pressure switch assembly
(Fig. 162). (21) Connect transmission range sensor connector
(Fig. 162). (22) Connect input and output speed sensor con-
nectors (Fig. 162). (23) Remove plugs and install transaxle oil cooler
line service splice kit. Refer to instructions included
with kit. (24) Remove plug and Install fluid level indicator/
tube assembly. (25) Install coolant recovery bottle (Fig. 163).
(26) Install battery shield.
(27) Connect battery cables.
(28) Fill transaxle with suitable amount of ATF+4
(Automatic Transmission FluidÐType 9602). (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE/FLUID - STANDARD PROCEDURE)
Fig. 161 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 162 Component Connector Location - Typical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 163 Coolant Recovery Bottle
1 - COOLANT RECOVERY CONTAINER
2 - HOSE
3 - BOLT
4 - SUB FRAME RAIL
21s - 74 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

SCHEMATICS AND DIAGRAMS
4XTE TRANSAXLE HYDRAULIC SCHEMATICS
Park/Neutral (Speed Under 8 MPH)
RS40TE AUTOMATIC TRANSAXLE21s-75
40TE AUTOMATIC TRANSAXLE (Continued)

Neutral (Speed Over 8 MPH)
21s - 76 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

Reverse
RS40TE AUTOMATIC TRANSAXLE21s-77
40TE AUTOMATIC TRANSAXLE (Continued)

Reverse Block (Shift to Reverse W/Speed Over 8 mph)
21s - 78 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

First Gear
RS40TE AUTOMATIC TRANSAXLE21s-79
40TE AUTOMATIC TRANSAXLE (Continued)