1996 CHRYSLER VOYAGER torque

CAUTION: Always use new retaining bolt, old
retaining bolt may not be reused.
(9) Install the new retaining bolt and washer (Fig.
226). Tighten to 271 N´m (200 ft. lbs.) (Fig. 227).
(10) Using an inch-pound torque wrench, check the
turning torque (Fig. 228).The torque should be
between 3 and 8 inch-pounds.
If the turning torque is too high, install a .04 mm
(.0016 inch) thicker shim. If the turning torque is too
low, install a .04 mm (.0016 inch) thinner shim.
Repeat until the proper turning torque is 3 to 8 inch
pounds.
NOTE: Install output gear stirrup and strap bolts.
All transaxles utilize a stirrup and retaining strap
that is attached to the output gear. The stirrup pre-
vents the output gear retaining bolt from turning
and backing out of the rear carrier. The strap is used
to hold the stirrup to the output gear and prevent
the stirrup retaining bolts from backing out.
Fig. 226 Install Output Gear Bolt and Washer
Fig. 227 Tighten Output Gear to 271 N´m
(200 ft. lbs.)
Fig. 228 Check Output Gear Bearings Turning
Torque
Fig. 229 Output Gear Retaining Bolt Stirrup
(Serration Side Out)
Fig. 230 Stirrup Strap (Align Strap Holes With
Tapped Gear Holes)
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 127
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Screw Tool 5049-A onto transfer shaft.
Install transfer shaft.
TRANSFER SHAFT BEARING
(1) Install a 4.66 mm (.184 inch) gauging shim on
the transfer shaft.
(2) Install transfer shaft gear and bearing assem-
bly and torque the nut to 271 N´m (200 ft. lbs.).
To measure bearing end play:
²Attach Tool L-4432 to the transfer gear.
²Mount a steel ball with grease into the end of
the transfer shaft.
²Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
²Using a dial indicator, measure transfer shaft
end play.
(3) Refer to the Transfer Bearing Shim Chart for
the required shim combination to obtain the proper
bearing setting.
(4) Use Tool 6259 to remove the retaining nut and
washer. Remove the transfer shaft gear using Tool
L-4407.
Fig. 237 Install Transfer Shaft
Fig. 238 Install Transfer Shaft Bearing Snap Ring
Fig. 239 Install Transfer Shaft Bearing Cup Into
Retainer
Fig. 240 Install Bearing Cup Retainer
Fig. 241 Install Transfer Gear Bearing Cone
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 129
DISASSEMBLY AND ASSEMBLY (Continued)

(5) Remove the gauging shim and install the cor-
rect shim (Fig. 242). Install the transfer gear and
bearing assembly (Fig. 243).
CAUTION: Original retaining nut may not be
reused. Always use a new retaining nut when reas-
sembling.
(6) Install the new retaining nut and washer and
torque to 271 N´m (200 ft. lbs.) (Fig. 244).Measure
transfer shaft end play, end play should be .05
to .10 mm (.002 to .004 inch).
(7) Measure bearing end play as outlined in . End
play should be between .05 mm and .10 mm (.002 to
.004 inch).
NOTE: If end play is too high, install a .04 mm
(.0016 inch) thinner shim. If end play is too low,
install a .04 mm (.0016 inch) thicker shim combina-
tion. Repeat until .05 to .10 mm (.002 to .004 inch)
end play is obtained.NOTE: Install the low/reverse reaction plate
stepped side up.
Fig. 242 Transfer Shaft Gear and (Select) Shim
Fig. 243 Install Transfer Shaft Gear
Fig. 244 Tighten Nut to 271 N´m (200 ft. lbs.)
Fig. 245 Install Rear Cover
Fig. 246 Install Rear Cover Bolts
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 131
DISASSEMBLY AND ASSEMBLY (Continued)

(1) Install transaxle solenoid pack (Fig. 284).
(2) Install input and output speed sensors.
This concludes the assembly of the transaxle cen-
terline.
DIFFERENTIAL REPAIR
NOTE: The differential is serviced as an assembly.
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
any other part fails within the differential, you must
replace the differential assembly along with the
transfer shaft.
DISASSEMBLE
The transfer shaft should be removed for differen-
tial repair and bearing turning torque checking.
(1) Remove the differential cover and bolts (Fig.
285) (Fig. 286).
(2) Remove the differential bearing retainer and
bolts (Fig. 287) (Fig. 288).(3) Using a plastic hammer, remove extension
housing/adapter plate on the right side of the tran-
saxle.
Fig. 283 Install Pan Bolts
Fig. 284 Install Solenoid Pack
Fig. 285 Differential Cover Bolts
Fig. 286 Remove Differential Cover
Fig. 287 Differential Retainer Bolts
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 139
DISASSEMBLY AND ASSEMBLY (Continued)

(2) Using Miller Special Tool 5052 and C-4171,
install differential bearing to differential (bearing
retainer side).
(3) Using Miller Special Tool 6061 and C-4171,
install differential bearing race to bearing retainer
(Fig. 297).
(4) Using Miller Special Tool L±4520 and C-4171,
install differential bearing to extension housing.
DIFFERENTIAL BEARING PRELOAD
ADJUSTMENT
NOTE: Perform all differential bearing preload mea-
surements with the transfer shaft and gear
removed.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING
EXISTING SHIM
(1) Position the transaxle assembly vertically on
the support stand, differential bearing retainer side
up.
(2) Install Tool L-4436A into the differential and
onto the pinion mate shaft (Fig. 298).
(3) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.
(4) Using Tool L-4436A and an inch-pound torque
wrench, check the turning torque of the differential
(Fig. 299).The turning torque should be
between 5 and 18 inch-pounds.
(5) If the turning torque is within specifications,
remove tools. Setup is complete.
(6) If turning torque is not within specifications
proceed with the following steps.
(a) Remove differential bearing retainer from
the transaxle case.
(b) Remove the bearing cup from the differential
bearing retainer using Tool 6062A.(c) Remove the existing shim from under the
cup.
(d) Measure the existing shim.
NOTE: If the turning torque was too high when
measured, install a .05 mm (.002 inch) thinner shim.
If the turning torque is was too low, install a .05 mm
(.002 inch) thicker shim. Repeat until 5 to 18 inch-
pounds turning torque is obtained.
Oil Baffle is not required to be installed when
making shim selection.
(e) Install the proper shim under the bearing
cup. Make sure the oil baffle is installed properly
in the bearing retainer, below the bearing shim
and cup.
(f) Install the differential bearing retainer using
Tool 5052 and C-4171. Seal the retainer to the
housing with MOPARtAdhesive Sealant and
torque bolts to 28 N´m (250 in. lbs.).
Fig. 297 Differential Bearing Retainer
Fig. 298 Tool L-4436 and Torque Wrench
Fig. 299 Checking Differential Bearings Turning
Torque
21 - 142 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

(7) Using Tool L-4436A and an inch-pound torque
wrench, recheck the turning torque of the differential
(Fig. 299).The turning torque should be
between 5 and 18 inch-pounds.
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Differential carrier
²Differential bearing retainer
²Extension housing
²Differential bearing cups and cones
PRELOAD ADJUSTMENT W/O SHIM
(1) Remove the bearing cup from the differential
bearing retainer using Miller special Tool 6062A.
(2) Remove existing shim from under bearing cup.
(3) Reinstall the bearing cup into the retainer
using Miller Special Tool 6061, and C-4171.
NOTE: Oil baffle is not required when making the
shim calculation.
(4) Install the bearing retainer into the case.
Torque bolts to 28 N´m (250 in. lbs.).(5) Position the transaxle assembly vertically on
the support stand and install Miller Special Tool
L-4436-A into the bearing retainer.
(6) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.
(7) Attach a dial indicator to the case and zero the
dial. Place the tip on the end of Special Tool
L-4436-A.
(8) Place a large screwdriver to each side of the
ring gear and lift. Check the dial indicator for the
amount of end play.
CAUTION: Do not damage the transaxle case
and/or differential retainer sealing surface.
(9) Using the end play measurement that was
determined, add .18mm (.007 inch). This should give
you between 5 and 18 inch pounds of bearing pre-
load. Refer to the Differential Bearing Shim Chart to
determine which shim to use.
(10) Remove the differential bearing retainer.
Remove the bearing cup.
DIFFERENTIAL BEARING SHIM CHART
PART NUMBER SHIM THICKNESS
MM INCH
4659257 .980 0.0386
4659258 1.02 0.0402
4659259 1.06 0.0418
4659260 1.10 0.0434
4659261 1.14 0.0449
4659262 1.18 0.0465
4659263 1.22 0.0481
4659264 1.26 0.0497
4659265 1.30 0.0512
4659266 1.34 0.0528
4659267 1.38 0.0544
4659268 1.42 0.0560
4659269 1.46 0.0575
4659270 1.50 0.0591
4659271 1.54 0.0607
4659272 1.58 0.0623
4659273 1.62 0.0638
4659274 1.66 0.0654
4659275 1.70 0.0670
4659283 2.02 0.0796
4659284 2.06 0.0812
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 143
DISASSEMBLY AND ASSEMBLY (Continued)

(11) Install the oil baffle. Install the proper shim
combination under the bearing cup.
(12) Install the differential bearing retainer. Seal
the retainer to the housing with MopartSilicone
Rubber Adhesive Sealant. Torque bolts to 28 N´m
(250 in. lbs.).
(13) Using Miller Special Tool L-4436-A and an
inch-pound torque wrench, check the turning torque
of the differential (Fig. 299). The turning torque
should be between 5-18 inch-pounds.
NOTE: If turning torque is too high install a .05mm
(.002 inch) thicker shim. If the turning torque is too
low, install a .05mm (.002 inch) thinner shim. Repeat
until 5-18 inch-pounds of turning torque is
obtained.
CLEANING AND INSPECTION
CLEANING VALVE BODY
Prior to removing any transaxle parts, plug all
openings and clean unit, preferably by steam. Clean-
liness through entire disassembly and assembly can-
not be overemphasized. When disassembling, each
part should be washed in a suitable solvent, then
dried by compressed air.Do not wipe parts with
shop towels.All mating surfaces in the transaxles
are accurately machined; therefore, careful handling
of all parts must be exercised to avoid nicks or burrs.
NOTE: Tag all springs, as they are removed, for
reassembly identification.
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT
Lift and rotate the gearshift hand lever into the
park (P) gate position and remove the ignition key.This confirms the shift lever is in the gated park (P)
position.
After confirming the park gate position, turn the
ignition switch. If the starter will operate, the park
gate position is correct. Move the shift lever into the
neutral (N) position. If the starter will operate in this
position, the linkage is properly adjusted. If the
starter fails to operate in either position, linkage
adjustment is required.
(1) Park the vehicle on level ground and set the
parking brake.
(2) Place the gearshift lever in park (P) gate posi-
tion and remove key.
(3) Loosen the cable adjustment screw at the tran-
saxle operating lever (Fig. 300).
(4) Pull the transaxle operating lever fully forward
to the park detent position.
(5) Release the park brake, then rock the vehicle
to assure it is in park lock. Reset the park brake.
(6) Tighten the cable adjustment screw to 8 N´m
(70 in. lbs.). Gearshift cable should now be properly
adjusted.
(7) Check adjustment by using the preceding pro-
cedure.
Fig. 300 Gearshift Cable Adjustment
21 - 144 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

SPECIFICATIONS
41TE AUTOMATIC TRANSAXLE
Type..........................Fully adaptive,
electronically controlled,
four speed automatic with
torque converter
and integral differential
Torque Converter Diameter........241 millimeters
(9.48 in.)
Oil Capacity........................8.6 Liters
(18.25 pints)
OilType...........MopartATF PLUS 3Type 7176
Cooling Method...........Water Heat Exchanger
and/or air to oil
heat exchanger
Lubrication......Pump (internal-external gear-type
Gear Ratios
Transmission Portion
First Gear..............................2.84
Second Gear.............................1.57
Direct Gear.............................1.00
Overdrive Gear..........................0.69
Reverse Gear............................2.21
Overall Top Gear Ratio
3.8 Liter................................2.38
3.3 Liter................................2.49
2.4 Liter................................2.69
Pump Clearances
Outer Gear To Pocket.............0.045-0.141mm
(0.0018-0.0056 in.)
Outer Gear Side Clearance.........0.020-0.046mm
(0.0008-0.0018 in.)
Inner Gear Side Clearance.........0.020-0.046mm
(0.0008-0.0018 in.)
Tapered Roller Bearing Settings
Differential Assembly . . .5 to 18 in. lbs. Drag Torque
Output Hub............3to8in.lbs. Drag Torque
Transfer Shaft.........0.002 to 0.004 in. End Play
Overall Drag At Output Hub........3to16in.lbs.
Drag Torque
Clutch Pack Clearances
Low/Rev Clutch
(Select Reaction Plate)............0.89-1.04mm
(0.035-0.042 in.)
Two/Four Clutch
(No Selection)...................0.76-2.64mm
(0.030-0.104 in.)Reverse Clutch (Select Snap Ring).....0.76-1.24mm
(0.030-0.049 in.)
Overdrive Clutch
(No Selection)...................0.96-2.26mm
(0.038-0.089 in.)
Underdrive Clutch
Select Pressure Plate)............0.91-1.47mm
(0.036-0.058 in.)
Transmission End Play.............0.12-0.63mm
(0.005-0.025 in.)
41TE TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Cooler Line Fittings..........12N´m(105 in. lbs.)
Differential Cover............19N´m(165 in. lbs.)
Differential Ring Gear.........95N´m(70ft.lbs.)
Differential Bearing Ret........28N´m(21ft.lbs.)
Driveplate To Crank. Bolts......95N´m(70ft.lbs.)
Driveplate To Torque Conv.......75N´m(55ft.lbs.)
Eight Way Solenoid Conn........4N´m(35in.lbs.)
Extension Housing............28N´m(21ft.lbs.)
Input Speed Sensor............27N´m(20ft.lbs.)
L/R Clutch Retainer............5N´m(45in.lbs.)
Oil Pan To Trans. Case........19N´m(165 in. lbs.)
Output Gear Bolt...........271 N´m (200 ft. lbs.)
Output Gear Stirrup Ret........23N´m(17ft.lbs.)
Output Speed Sensor..........27N´m(20ft.lbs.)
Pressure Taps................5N´m(45in.lbs.)
Pump To Case Bolts...........27N´m(20ft.lbs.)
Reaction Shaft Bolts...........27N´m(20ft.lbs.)
Rear End Cover..............19N´m(14ft.lbs.)
Sixty-Way Connector...........4N´m(35in.lbs.)
Solenoid Assembly To Case.....12N´m(105 in. lbs.)
Transmission Range Sensor......5N´m(45in.lbs.)
Transfer Gear Nut..........271 N´m (200 ft. lbs.)
Transfer Plate To Case........12N´m(105 in. lbs.)
Valve Body To Case Bolts......12N´m(105 in. lbs.)
Valve Body Bolts..............5N´m(45in.lbs.)
Vent Assembly..............12N´m(105 in. lbs.)
21 - 158 TRANSAXLE AND POWER TRANSFER UNITNS