DODGE TOWN AND COUNTRY 2004 Service Manual

(49) Install rear sun gear and #7 needle bearing
(Fig. 122).
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. 121). 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. 123).
(51) Install front sun gear assembly and #4 thrust
washer (Fig. 124).
Fig. 121 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 122 Install Rear Sun Gear and #7 Needle Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 123 Install Front Carrier and Rear AnnulusAssembly
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 124 Install Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
21s - 200 41TE AUTOMATIC TRANSAXLERS
41TE 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. 125). 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. 126), the input
clutch assembly is not seated properly.
(c) Remove oil pump o-ring (Fig. 127). 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. 128). (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. 125 Select Thinnest No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 126 View Through Input Speed Sensor Hole
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
Fig. 127 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 128 Measure Input Shaft End Play Using End Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
RS 41TE AUTOMATIC TRANSAXLE21s - 201
41TE 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. 129).
(54) Install #1 caged needle bearing (Fig. 130).
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. 131). (56) Install oil pump gasket (Fig. 132).
Fig. 129 Install Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 130 Install Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 131 Install Cooler Bypass Valve
1 - COOLER BYPASS VALVE
Fig. 132 Install Oil Pump Gasket
1 - PUMP GASKET
21s - 202 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(57) Install oil pump assembly (Fig. 133).
(58) Install oil pump-to-case bolts and torque to 27
N´m (20 ft. lbs.) (Fig. 134). (59) Install low/reverse accumulator (Fig. 135).
(60) Install low/reverse accumulator plug (Fig.
136).
Fig. 133 Install Oil Pump
1 - OIL PUMP
2 - GASKET
Fig. 134 Install Pump-to-Case Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 135 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
Fig. 136 Install Low/Reverse Accumulator Plug (Cover)
1 - ADJUSTABLE PLIERS
2 - PLUG
RS 41TE AUTOMATIC TRANSAXLE21s - 203
41TE AUTOMATIC TRANSAXLE (Continued)

(61) Install low/reverse accumulator snap ring
(Fig. 137).
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
(Fig. 138). (63) Install valve body to transaxle (Fig. 139).
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. 140).
Fig. 137 Install Low/Reverse Accumulator Snap Ring
1 - SNAP RING
2 - PLUG
Fig. 138 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 139 Install Valve Body
1 - VALVE BODY
Fig. 140 Install Valve Body-to-Case Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
21s - 204 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(65) Install oil filter and new o-ring (Fig. 141).
(66) Apply an 1/8º bead of MopartATF RTV (MS-
GF41) to oil pan and immediately install to case (Fig.
142).
(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. 143). (69) Install and tighten solenoid/pressure switch
assembly-to-transaxle case bolts to 12 N´m (110 in.
lbs.) (Fig. 144). (70) Install and torque input and output speed
sensors to case to 27 N´m (20 ft. lbs.).
Fig. 141 Install Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 142 Install Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPAR TATF RTV (MS-GF41)
3 - OIL FILTER
Fig. 143 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 144 Solenoid Pack-to-Transaxle Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
RS 41TE AUTOMATIC TRANSAXLE21s - 205
41TE AUTOMATIC TRANSAXLE (Continued)

ACCUMULATOR
DESCRIPTION
The 4XTE underdrive, overdrive, low/reverse, and 2/4
clutch hydraulic circuits each contain an accumulator.
An accumulator typically consists of a piston, return
spring(s), and a cover or plug. The overdrive and under-
drive accumulators are located within the transaxle
case, and are retained by the valve body (Fig. 145).
The low reverse accumulator (Fig. 146) is also
located within the transaxle case, but the assembly is
retained by a cover and a snap-ring.
The 2/4 accumulator is located in the valve body. It is
retained by a cover and retaining screws (Fig. 147).
VALVE BODY
REMOVAL
NOTE: If valve body is replaced or reconditioned,
the TCM Quick Learn Procedure must be per-
formed. (Refer t o 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Disconnect battery negative cable.
(2) Disconnect gearshift cable from manual valve
lever. (3) Remove manual valve lever from manual shaft.
(4) Raise vehicle on hoist.
(5) Remove oil pan bolts (Fig. 148).
Fig. 145 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 146 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
Fig. 147 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
Fig. 148 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
21s - 206 41TE AUTOMATIC TRANSAXLERS

(6) Remove oil pan (Fig. 149).
(7) Remove oil filter (Fig. 150).(8) Remove the valve body-to-transaxle case bolts
(Fig. 151).
NOTE: To ease removal of the valve body, turn the
manual valve lever fully clockwise to low or first
gear.
(9) Remove park rod rollers from guide bracket
and remove valve body from transaxle (Fig. 152) (Fig.
153).
Fig. 149 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 150 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
Fig. 151 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 152 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
RS 41TE AUTOMATIC TRANSAXLE21s - 207
VALVE BODY (Continued)

CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
DISASSEMBLY
NOTE: If valve body assembly is being recondi-
tioned, the PCM/TCM Quick Learn Procedure must
be performed. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Remove manual shaft seal (Fig. 154). (2) Remove Transmission Range Sensor retaining
screw (Fig. 155).
(3) Remove Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 156).
Fig. 153 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 154 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 155 Remove Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
Fig. 156 Manual Shaft/Rooster Comb and Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
21s - 208 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(4) Remove 2/4 Accumulator Retaining Plate (Fig.
157).
(5) Remove 2/4 Accumulator components as shown
in (Fig. 158). (6) Remove Valve Body to Transfer Plate screws
(Fig. 159).
(7) Invert assembly and remove Transfer Plate
(Fig. 160). Beware of loose check balls.
Fig. 157 2/4 Accumulator Retaining Plate
1 - 2±4 ACCUMULATOR RETAINING PLATE
2 - DETENT SPRING
Fig. 158 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
Fig. 159 Remove Valve Body to Transfer Plate Screws
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
Fig. 160 Remove Transfer Plate
1 - TRANSFER PLATE
RS 41TE AUTOMATIC TRANSAXLE21s - 209
VALVE BODY (Continued)