1996 CHRYSLER VOYAGER sensor

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

A±598 MANUAL TRANSAXLE
CONTENTS
page page
GENERAL INFORMATION
A-598 MANUAL TRANSAXLE............... 2
A-558 MANUAL TRANSAXLEÐRHD
VEHICLES............................ 2
GEAR RATIOS........................... 3
GEAR RATIOSÐRHD VEHICLES............ 3
GEARSHIFT PATTERN..................... 3
GEARSHIFT PATTERNÐRHD VEHICLES...... 3
SELECTION OF LUBRICANT................ 2
SELECTION OF LUBRICANTÐRHD VEHICLES . 2
SPECIAL ADDITIVES..................... 2
SPECIAL ADDITIVESÐRHD VEHICLES....... 3
TRANSAXLE IDENTIFICATION INFORMATION . . 2
TRANSAXLE IDENTIFICATION
INFORMATIONÐRHD VEHICLES.......... 2
DESCRIPTION AND OPERATION
AXLE SEALS............................ 3
GEARSHIFT LEVERS...................... 3
DIAGNOSIS AND TESTING
CLUTCH PROBLEMS..................... 4
COMMON PROBLEM CAUSES.............. 3
HARD SHIFTING......................... 4
LOW LUBRICANT LEVEL.................. 4
NOISY OPERATION....................... 4
SLIPS OUT OF GEAR..................... 4
SERVICE PROCEDURES
FLUID DRAIN AND FILL................... 4
FLUID DRAIN AND FILLÐRHD VEHICLES.... 4
REMOVAL AND INSTALLATION
A-558 TRANSAXLE ASSEMBLYÐRHD
VEHICLES........................... 16
AXLE SEALS........................... 11
BACK-UP LAMP SWITCH.................. 9
CRANKSHAFT POSITION SENSOR Ð
2.5L VM DIESEL...................... 10
CROSSOVER LEVER..................... 11
GEARSHIFT BOOT....................... 5GEARSHIFT BOOT....................... 5
GEARSHIFT CABLES...................... 5
GEARSHIFT CABLESÐRHD VEHICLES....... 7
GEARSHIFT KNOB....................... 5
GEARSHIFT MECHANISM REPLACEMENT..... 7
GEARSHIFT MECHANISM REPLACEMENTÐ
RHD VEHICLES........................ 8
INPUT SHAFT FRONT BEARING RETAINER . . . 15
INPUT SHAFT SEAL..................... 16
SELECTOR LEVER...................... 11
SHIFT SHAFT SEALS.................... 12
TRANSAXLE........................... 12
VEHICLE SPEED SENSOR DRIVE GEAR...... 9
DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL......................... 39
INPUT SHAFT.......................... 32
INTERMEDIATE SHAFT................... 33
SHIFT COVER.......................... 45
SYNCHRONIZER........................ 43
TRANSAXLE........................... 20
TRANSAXLE CASE...................... 48
CLEANING AND INSPECTION
SYNCHRONIZER........................ 52
TRANSAXLE........................... 52
ADJUSTMENTS
BEARING ADJUSTMENT PROCEDURE....... 56
GEARSHIFT CROSSOVER CABLE........... 52
GEARSHIFT CROSSOVER CABLE........... 55
INTERMEDIATE SHAFT BEARING PRELOAD . . 57
SPECIFICATIONS
A-558 MANUAL TRANSAXLEÐRHD
VEHICLES........................... 59
A-598 (T-750) MANUAL TRANSAXLE....... 59
SPECIAL TOOLS
A-558 MANUAL TRANSAXLEÐRHD
VEHICLES........................... 60
A-598 (T-750) MANUAL TRANSAXLE....... 60
NS/GSA±598 MANUAL TRANSAXLE 21 - 1

(3) Remove gearshift cables. Refer to Gearshift
Cable Removal in this section.
(4) Remove retaining nuts at the base of the gear-
shift mechanism. Remove shifter.
INSTALLATION
(1) For installation, reverse removal procedure.
VEHICLE SPEED SENSOR DRIVE GEAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove wiring connector from speed sensor.
CAUTION: Clean area around speed sensor before
removing. This will prevent the possibility of dirt
from entering the transaxle during speed sensor
removal.
(3) Remove speed sensor retaining bolt.
(4) Remove speed sensor from transaxle extension
housing (Fig. 23).
CAUTION: Carefully remove vehicle speed sensor
so that sensor drive gear does not fall into tran-
saxle. Should sensor drive gear fall into the tran-
saxle during sensor removal, drive gear must be
reattached to sensor.
(5) Remove speed sensor drive gear from speed
sensor.
INSTALLATION
(1) To install, reverse removal procedure.
(2) Confirm vehicle speedometer is functioning
properly following installation.
BACK-UP LAMP SWITCH
The back-up lamp switch is located on the gear-
shift housing on top of the transaxle case.
REMOVAL
(1) From top side of vehicle, remove wiring connec-
tor from switch (Fig. 24).
(2) Unscrew switch from transaxle.
Fig. 18 Cable Retaining Clip
Fig. 19 Gearshift Console
Fig. 20 Selector Cable Clip
Fig. 21 Crossover Cable Clip
NS/GSA±598 MANUAL TRANSAXLE 21 - 9
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) To install, reverse removal procedure. Teflon
tape or equivalent must be used on switch threads.
CAUTION: Do not overtighten switch.
(2) Confirm back-up lamps are functioning prop-
erly following installation.
CRANKSHAFT POSITION SENSOR Ð 2.5L VM
DIESEL
The crankshaft position sensor is located on the
transaxle bellhousing. The sensor measures the posi-
tion of the crankshaft and relays that information to
the Powertrain Control Module.
Fig. 22 Gearshift Cables
Fig. 23 Vehicle Speed SensorFig. 24 Back-Up Lamp Switch Location
21 - 10 A±598 MANUAL TRANSAXLENS/GS
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) Remove electrical connector at crankshaft posi-
tion sensor (Fig. 25).
(2) Remove screw retaining the crankshaft position
sensor to the bellhousing.
(3) Remove the crankshaft position sensor.
INSTALLATION
(1) For installation, reverse removal procedure.
CROSSOVER LEVER
REMOVAL
(1) Remove crossover cable. Refer to Gearshift
Cable removal.
(2) Using a pin punch, remove the crossover roll
pin from lever.
(3) Pull up and remove the crossover lever from
the transaxle crossover shaft.
INSTALLATION
(1) For installation, reverse removal procedure.
Replace the roll pin that was removed with a new
one.
SELECTOR LEVER
REMOVAL
(1) Remove the selector cable. Refer to Gearshift
Cable removal.
(2) Using a pin punch, remove the roll pin from
the lever.
(3) Remove the selector lever from the transaxle
selector shaft
INSTALLATION
(1) For installation, reverse removal procedure.
Replace the roll pin with a new one.
AXLE SEALS
The axle shaft seals are identical for both sides of
the differential and will interchange.
EXTENSION HOUSING AXLE SEAL
REMOVAL
(1) Remove axle shaft. Refer to Group 2, Suspen-
sion and Driveshafts for service procedures.
(2) Insert a flat±blade pry tool into the axle seal
bore (Fig. 26).
(3) Using the pry tool, carefully pop out the seal
taking care not to nick the seal bore.
INSTALLATION
(1) Clean axle shaft seal bore of any excess seal-
ant.
(2) Align axle shaft seal with axle shaft seal bore.
(3) Position axle seal at extension housing.
(4) Using Tool L-4520 and Tool C-4171, tap seal
into position (Fig. 27).
Fig. 25 Crankshaft Position Sensor
Fig. 26 Extension Housing Axle Seal
Fig. 27 Install Seal
NS/GSA±598 MANUAL TRANSAXLE 21 - 11
REMOVAL AND INSTALLATION (Continued)

DIFFERENTIAL BEARING RETAINER AXLE
SEAL
REMOVAL
(1) Remove axle shaft. Refer to Group 2, Suspen-
sion and Driveshafts for service procedures.
(2) Insert a flat±blade pry tool into the axle seal
bore.
(3) Using the pry tool, carefully pop out the seal
taking care not to nick the seal bore.
INSTALLATION
(1) Clean axle shaft seal bore of any excess seal-
ant.
(2) Align axle shaft seal with axle shaft seal bore.
(3) Position axle seal at extension housing.
(4) Using Tool L-4520 and Tool C-4171, tap seal
into position.
SHIFT SHAFT SEALS
It isnotnecessary to remove the shift shaft cover
from the transaxle to service the shift shaft seals.
REMOVAL
(1) Remove the shift lever from the seal that is to
be serviced. Refer to shift lever removal for service
procedure.
(2) Using a pick tool, pry up on the shift shaft seal
and remove seal from bore.
INSTALLATION
(1) Position new shift shaft seal in bore.
(2) Install shift shaft seal into bore using an
appropriate size deep±well socket.
TRANSAXLE
The following items can be serviced without remov-
ing the transaxle from the vehicle:
²Gearshift housing
²5th speed synchronizer
²5th speed gear
²Roller detents and springs
²Speedometer pinion
²Vehicle speed sensor
²Bearing retainer plate.
²All external covers
²Shift shaft seals
²Axle shaft seals
To service any other component of the A-598 tran-
saxle you must remove it from the vehicle.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove air intake hose. Disconnect air mass
meter connector.
(3) Remove intercooler hose.(4) Remove connectors for back-up lamp (Fig. 28)
and crank position sensor (Fig. 29).
(5) Remove crank position sensor (2.5L VM Diesel
only).
(6) Remove wiring harness bracket at transaxle
(Fig. 30).
(7) Remove crossover and shift selector cables (Fig.
31).
(8) Remove the two top bolts at the rear engine
mount bracket.
(9) Remove bolts securing the coolant reservoir to
the top of the engine. Move the coolant reservoir out
of the way.
(10) Install an engine support chain to the cylinder
head assembly (Fig. 32).
Fig. 28 Back-up Lamp Connector
Fig. 29 Crankshaft Position Sensor
21 - 12 A±598 MANUAL TRANSAXLENS/GS
REMOVAL AND INSTALLATION (Continued)

(11) Remove three upper bellhousing bolts (Fig.
33).
(12) Install engine bridge fixture to chain and sup-
port engine (Fig. 34).(13) Hoist the vehicle.
(14) Remove front wheels.
(15) Remove axle shaft hub nuts.
(16) Remove steering knuckle steering stop studs.
(17) Remove lower control arm pinch bolts (Fig.
35).
(18) Using a pry bar, unseat lower control arm
from steering knuckle (Fig. 36).
(19) Remove drain plug and drain transaxle fluid
(Fig. 37).
(20) Remove right and left axle shaft assemblies
(21) Remove vehicle speed sensor wiring connector
(Fig. 38).
(22) Remove clutch cable retaining clip (Fig. 39).
Remove clutch cable from transaxle housing.
(23) Remove adapter plate and front engine mount
bolts (Fig. 40) (Fig. 41).
(24) Remove two remaining rear engine mount
bolts.
CAUTION: Always use a safety chain when remov-
ing or installing transaxle assembly.
Fig. 30 Wiring Harness Bracket
Fig. 31 Shift Cables
Fig. 32 Engine Support Chain
Fig. 33 Upper Bellhousing Bolts
Fig. 34 Engine Bridge Fixture
NS/GSA±598 MANUAL TRANSAXLE 21 - 13
REMOVAL AND INSTALLATION (Continued)

(25) Install transmission jack under transaxle
assembly.
(26) Remove left fender splash shield.
(27) Remove (4) left mount bolts (Fig. 42).(28) Remove lower bellhousing bolts.
(29) Lower transaxle and remove.
INSTALLATION
(1) For installation, reverse removal procedure.
NOTE: Lower control arm pinch bolts must be
installed with the bolt heads to the rear of the ball
joints.
(2) Fill transaxle to the proper level with the spec-
ified lubricant.
(3) While the vehicle is elevated slightly, run the
transaxle through all the forward gears. Apply
brakes and shift into reverse. Run the transaxle
through reverse gear.
Fig. 35 Lower Control Arm Pinch Bolt
Fig. 36 Unseat Control Arm
Fig. 37 Transaxle Drain Plug
Fig. 38 Vehicle Speed Sensor
Fig. 39 Clutch Cable Clip
21 - 14 A±598 MANUAL TRANSAXLENS/GS
REMOVAL AND INSTALLATION (Continued)