DODGE TOWN AND COUNTRY 2004 Service Manual

(8) Remove oil screen (Fig. 161).
(9) Remove the overdrive clutch (#5) check valve
(Fig. 162) (10) Remove separator plate (Fig. 163).
(11) Remove thermal valve (Fig. 164).
Fig. 161 Remove Oil Screen
1 - OIL SCREEN
Fig. 162 Remove Overdrive Clutch (#5) Check Valve
1 - OVERDRIVE CLUTCH (#5) CHECK VALVE
Fig. 163 Remove Separator Plate
1 - SEPARATOR PLATE
2 - VALVE BODY
Fig. 164 Remove Thermal Valve
1 - THERMAL VALVE
21s - 210 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(12) Remove check balls (Fig. 165).
NOTE: Tag all valve/spring assemblies for reassem-
bly identification. (13) Remove dual retainer plate using Tool 6301
(Fig. 166).
Fig. 165 Ball Check Location
1 - (#4) BALL CHECK LOCATION
2 - (#2) BALL CHECK LOCATION
3 - RETAINER 4 - (#3) BALL CHECK LOCATION
5 - LOW/REVERSE SWITCH VALVE
6 - T/C LIMIT VALVE
Fig. 166 Remove Dual Retainer Plate using Tool 6301
1 - TOOL 6301
2 - RETAINER
RS
41TE AUTOMATIC TRANSAXLE21s - 211
VALVE BODY (Continued)

(14) Remove regulator valve spring retainer (Fig.
167).
(15) Remove remaining retainers as shown in (Fig.
168). (16) Remove valves and springs as shown in (Fig.
169).
NOTE: Refer to Valve Body Cleaning and Inspection
for cleaning procedures.
ASSEMBLY
NOTE: If valve body assembly is reconditioned, the
PCM/TCM Quick Learn Procedure must be per-
formed. (Refer t o 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Install valves and springs as shown in (Fig.
169). (2) Install regulator valve spring retainer (Fig.
170). (3) Install dual retainer plate using Tool 6301 (Fig.
171).
Fig. 167 Remove Regulator Valve Spring Retainer using Tool 6302
1 - TOOL 6302
2 - RETAINER
Fig. 168 Valve Retainer Location
1 - RETAINER
2 - RETAINER
21s - 212 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

Fig. 169 Springs and Valves Location
1 - VALVE BODY 5 - MANUAL VALVE
2 - T/C REGULATOR VALVE 6 - CONVERTER CLUTCH SWITCH VALVE
3 - L/R SWITCH VALVE 7 - SOLENOID SWITCH VALVE
4 - CONVERTER CLUTCH CONTROL VALVE 8 - REGULATOR VALVE
Fig. 170 Install Regulator Valve Spring Retainerusing Tool 6302
1 - TOOL 6302
2 - RETAINER
Fig. 171 Install Dual Retainer Plate using Tool 6301
1 - TOOL 6301
2 - RETAINER
RS 41TE AUTOMATIC TRANSAXLE21s - 213
VALVE BODY (Continued)

(4) Verify that all retainers are installed as shown
in (Fig. 172). Retainers should be flush or below
valve body surface. (5) Install check balls into position as shown in
(Fig. 173). If necessary, secure them with petrolatum
or transmission assembly gel for assembly ease.
Fig. 172 Valve Retainer Location
1 - RETAINER
2 - RETAINER
Fig. 173 Ball Check Location
1 - (#4) BALL CHECK LOCATION
2 - (#2) BALL CHECK LOCATION
3 - RETAINER 4 - (#3) BALL CHECK LOCATION
5 - LOW/REVERSE SWITCH VALVE
6 - T/C LIMIT VALVE
21s - 214 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(6) Install thermal valve into transfer plate (Fig.
174).
(7) Install separator plate to valve body (Fig. 175). (8) Install the overdrive clutch (#5) check valve to
separator plate (Fig. 176)
(9) Install oil screen to separator plate (Fig. 177).
Fig. 174 Install Thermal Valve
1 - THERMAL VALVE
Fig. 175 Install Separator Plate
1 - SEPARATOR PLATE
2 - VALVE BODY
Fig. 176 Install Overdrive Clutch (#5) Check Valve
1 - OVERDRIVE CLUTCH (#5) CHECK VALVE
Fig. 177 Install Oil Screen
1 - OIL SCREEN
RS 41TE AUTOMATIC TRANSAXLE21s - 215
VALVE BODY (Continued)

(10) Install transfer plate to valve body and sepa-
rator plate. Make sure oil screen and #5 check valve
do not bind (Fig. 178).
(11) Install twenty-four transfer plate to valve
body screws (Fig. 179) and torque to 5 N´m (45 in.
lbs.). (12) Install 2/4 Accumulator components as shown
in (Fig. 180).
(13) Torque 2/4 Accumulator retainer to 5 N´m (45
in. lbs.) (Fig. 181).
Fig. 178 Install Transfer Plate
1 - TRANSFER PLATE
Fig. 179 Install Valve Body to Transfer Plate Screws
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
Fig. 180 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
Fig. 181 2/4 Accumulator Retaining Plate
1 - 2±4 ACCUMULATOR RETAINING PLATE
2 - DETENT SPRING
21s - 216 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(14) Install Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 182).
(15) Make sure Manual Valve control pin is con-
tained within the rooster comb slot (Fig. 183). Install
Transmission Range Sensor retaining screw (Fig.
183) and torque to 5 N´m (45 in. lbs.). (16) Install manual shaft seal (Fig. 184).
INSTALLATION
NOTE: If valve body assembly is being replaced or
reconditioned, it is necessary to perform the TCM
Quick Learn Procedure. (Refer t
o 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install valve body assembly to transaxle (Fig.
185). Install and torque valve body-to-transaxle case
bolts (Fig. 186) to 12 N´m (105 in. lbs.).
Fig. 182 Install Manual Shaft/Rooster Comb and Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
Fig. 183 Install Transmission Range Sensor Retaining Screw
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
Fig. 184 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 185 Valve Body Removal/Installation
1 - VALVE BODY
RS 41TE AUTOMATIC TRANSAXLE21s - 217
VALVE BODY (Continued)

(2) Install transaxle oil filter (Fig. 187). Inspect
the o-ring and replace if necessary.
(3) Ensure the transaxle oil pan and transaxle
case sealing surfaces are clean and dry. Install an
1/8º bead of Mopar tSilicone Rubber Adhesive Seal-
ant to the oil pan and install (Fig. 188). Torque oil
pan-to-transaxle case bolts (Fig. 189) to 19 N´m (165
in. lbs.). (4) Lower vehicle.
(5) Connect transmission range sensor connector.
(6) Install manual valve lever to manual shaft.
(7) Install gearshift cable to manual valve lever.
(8) Connect battery negative cable.
(9) Fill transaxle with Mopar
tATF +4 Transmis-
sion fluid. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
Fig. 186 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 187 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
Fig. 188 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 189 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
21s - 218 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND
WHEEL VIBRATION.....................1
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE AND
WHEEL BALANCE......................5
STANDARD PROCEDURE - TIRE AND
WHEEL MATCH MOUNTING..............7
STANDARD PROCEDURE - TIRE AND
WHEEL ROTATION.....................7
REMOVAL
REMOVAL - TIRE AND WHEEL ASSEMBLY
(ALUMINUM WHEEL)....................7
REMOVAL - TIRE AND WHEEL ASSEMBLY
(STEEL WHEEL).......................8
INSTALLATION
INSTALLATION - TIRE AND WHEEL
ASSEMBLY (ALUMINUM WHEEL)..........8
INSTALLATION - TIRE AND WHEEL
ASSEMBLY (STEEL WHEEL)..............8
TIRE PRESSURE MONITORING
DESCRIPTION..........................9
OPERATION............................9
SENSOR - TPM
DESCRIPTION.........................10
OPERATION...........................10
CAUTION.............................10
DIAGNOSIS AND TESTING - TIRE PRESSURE
SENSOR............................10
STANDARD PROCEDURE - TIRE PRESSURE
SENSOR RETRAIN....................10
REMOVAL.............................11
INSTALLATION.........................12
TIRES
DESCRIPTION
DESCRIPTION - TIRE..................13
DESCRIPTION - RADIAL-PLY TIRES.......14DESCRIPTION - REPLACEMENT TIRES....14
DESCRIPTION - SPARE TIRE
(TEMPORARY).......................14
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - TIRE NOISE . . . 14
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD...............................14
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS..........................16
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS.........................16
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE INFLATION
PRESSURES.........................16
STANDARD PROCEDURE - TIRE
PRESSURE FOR HIGH SPEED
OPERATION.........................17
STANDARD PROCEDURE - TIRE LEAK
REPAIRING..........................17
CLEANING - TIRES.....................17
WHEELS
DESCRIPTION - WHEEL..................18
DIAGNOSIS AND TESTING - WHEEL
INSPECTION.........................18
CLEANING - ALUMINUM WHEEL CARE......18
SPECIFICATIONS
WHEEL.............................19
WHEEL COVER
DESCRIPTION.........................19
REMOVAL.............................19
INSTALLATION.........................19
WHEEL MOUNTING STUDS - FRONT
REMOVAL.............................20
INSTALLATION.........................21
WHEEL MOUNTING STUDS - REAR
REMOVAL.............................21
INSTALLATION.........................22
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND WHEEL
VIBRATION
Tire and wheel imbalance, runout and force varia-
tion can cause vehicles to exhibit steering wheel
vibration.
VISUAL INSPECTION
Visual inspection of the vehicle is recommended
prior to road testing or performing any other proce-
dure. Raise vehicle on a suitable hoist. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
Inspect for the following:
²Verify correct (OEM) wheel and tire, as well as
correct wheel weights. Aluminum wheels require
RSTIRES/WHEELS22-1