DODGE TOWN AND COUNTRY 2004 Service Manual

(15) Install the output gear and bearing assembly
using Tool 6261 (Fig. 88).
(16) Install NEW output gear retaining bolt and
washer (Fig. 89). Using Tool 6259, torque output gear
retaining bolt to 271 N´m (200 ft. lbs.) (Fig. 90). (17) Using an inch pound torque wrench (Fig. 91),
check output shaft turning torque. Output shaft
turning torque should be within 3-8 in. lbs. If
the turning torque is too high, install a 0.04 mm
(0.0016 in.) thicker shim. If the turning torque is too
low, install a 0.04 mm (0.0016 in.) thinner shim.
Repeat until the proper turning torque of 3-8 in. lbs.
is obtained.
Fig. 88 Install Output Gear
1 - WRENCHES
2 - TOOL 6261 WITH STUD
3 - OUTPUT GEAR
Fig. 89 Output Gear Bolt and Washer
1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
Fig. 90 Tighten Output Gear to 271 N²m (200 ft.
lbs.)
1 - OUTPUT GEAR
2 - TORQUE WRENCH
3 - 200 FT. LBS.
4 - TOOL 6259
Fig. 91 Check Output Gear Bearings Turning Torque
1 - INCH-POUND TORQUE WRENCH
2 - OUTPUT GEAR
21s - 190 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(18) Install output gear stirrup with serrated side
out (Fig. 92).
(19) Install retaining strap.
(20) Install strap bolts but do not tighten at this
time (Fig. 93). (21) Rotate stirrup clockwise against flats of
retaining bolt (Fig. 94).
(22) Torque stirrup strap bolts to 23 N´m (200 in.
lbs.) (Fig. 95).
Fig. 92 Install Stirrup
1 - STIRRUP
2 - OUTPUT GEAR RETAINING BOLT
Fig. 93 Install Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
Fig. 94 Turn Stirrup Clockwise Against Bolt Flats
1 - RETAINING STRAP
2 - STIRRUP
Fig. 95 Tighten Stirrup Strap Bolts To 23 N´m (200 in.) lbs.)
1 - RETAINING STRAP
2 - STIRRUP
RS 41TE AUTOMATIC TRANSAXLE21s - 191
41TE AUTOMATIC TRANSAXLE (Continued)

(23) Bend tabs on strap up against flats of bolts
(Fig. 96).
(24) Install transfer shaft bearing cone using Tool
6052 (Fig. 97). (25) Install bearing cup and oil baffle to transfer
shaft (Fig. 98).
(26) Using Tool 5049A, install transfer shaft (Fig.
99).
Fig. 96 Bend Tabs On Strap Up Against Flats Of Bolts
1 - RETAINING STRAP TABS
2 - RETAINING STRAP
3 - STIRRUP
Fig. 97 Install Transfer Shaft Bearing Cone
1 - TOOL 6052
2 - NEW BEARING CONE
3 - TRANSFER SHAFT
4 - ARBOR PRESS RAM
Fig. 98 Install Bearing Cup to Shaft
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
Fig. 99 Install Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
21s - 192 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(27) Using Tool 6051, install transfer shaft bearing
snap ring (Fig. 100).
(28) Install transfer shaft bearing cup into retainer
using Tool 6061 (Fig. 101). (29) Install bearing cup retainer to transaxle (Fig.
102).
(30) Install transfer gear bearing cone to transfer
gear using Tool 5052 (Fig. 103).
Fig. 100 Install Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS TOOL 6051
2 - TRANSFER SHAFT BEARING SNAP RING
3 - TRANSFER SHAFT
Fig. 101 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. 102 Remove Bearing Cup Retainer
1 - ALIGN INDEXING TAB TO SLOT
2 - BEARING CUP RETAINER
Fig. 103 Install Transfer Gear Bearing Cone
1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - NEW BEARING CONE
4 - TRANSFER SHAFT GEAR
5 - TOOL 5052
RS 41TE AUTOMATIC TRANSAXLE21s - 193
41TE 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. 104). (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. 104) 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. 104 Install Transfer Shaft Gear and (Select)
Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM (SELECT)
21s - 194 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.) 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
RS
41TE AUTOMATIC TRANSAXLE21s - 195
41TE AUTOMATIC TRANSAXLE (Continued)

(32) Install the transfer shaft gear using Tool 6261
(Fig. 105).
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. 106). (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. 107).
(37) Install transfer gear cover-to-case bolts and
torque to 20 N´m (175 in. lbs.) torque (Fig. 108).
Fig. 105 Install Transfer Shaft Gear
1 - WRENCHES
2 - SPECIAL TOOL 6261
3 - OUTPUT GEAR
4 - TRANSFER SHAFT GEAR
Fig. 106 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. 107 Install Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPAR TATF RTV (MS-GF41) AS SHOWN
Fig. 108 Install Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
21s - 196 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(38) Install low/reverse clutch pack (Fig. 109).
Leave uppermost disc out until snap ring is installed.
(39) Install low/reverse reaction plate flat snap
ring (Fig. 110). (40) Install remaining low/reverse clutch disc (Fig.
111).
(41) Install low/reverse reaction plate with flat
side up (Fig. 112).
Fig. 109 Install Low/Reverse Clutch Pack
1 - CLUTCH PLATES (5)
2 - CLUTCH DISCS (5)
Fig. 110 Install Low/Reverse Reaction Plate Snap Ring
1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
Fig. 111 Install One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
Fig. 112 Install Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
RS 41TE AUTOMATIC TRANSAXLE21s - 197
41TE AUTOMATIC TRANSAXLE (Continued)

(42) Install tapered snap ring (with tapered side
up) as shown in (Fig. 113) (Fig. 114).
(43) Set up dial indicator as shown in (Fig. 115) 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. 116).
NOTE: The 2/4 Clutch Piston has bonded seals
which are not individually serviceable. Seal replace-
ment requires replacement of the piston assembly.
Fig. 113 Tapered Snap Ring Instructions
Fig. 114 Snap Ring Installed
1 - SCREWDRIVER
2 - TAPERED SNAP RING (INSTALL AS SHOWN)
Fig. 115 Check Low/Reverse Clutch Clearance
1 - DIAL INDICATOR
2 - DIAL INDICATOR TIP TOOL 6268
3 - HOOK TOOL
Fig. 116 Install 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
21s - 198 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(45) Orient 2/4 clutch return spring to retainer as
shown in (Fig. 117), and install to transaxle (Fig.
118). (46) Using tool 5058, compress 2/4 clutch return
spring just enough to install snap ring (Fig. 119).
(47) Install snap ring.
(48) Set up dial indicator as shown in (Fig. 120)
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. 117 Proper Orientation of 2/4 Clutch Retainer and Spring
1 - NOTE POSITION
2 - RETURN SPRING
3 - 2/4 CLUTCH RETAINER
Fig. 118 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 119 Install 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
Fig. 120 Check 2/4 Clutch Clearance
1 - DIAL INDICATOR
2 - HOOK TOOL
3 - DIAL INDICATOR TIP TOOL 6268
RS 41TE AUTOMATIC TRANSAXLE21s - 199
41TE AUTOMATIC TRANSAXLE (Continued)