1996 CHRYSLER VOYAGER oil filter

Remove neutral starting and back-up lamp switch.
Measuring input shaft end play before disassembly
will usually indicate if a thrust washer change isrequired. The thrust washer is located between input
and output shafts.
Fig. 11 Oil Filter Screws
Fig. 12 Oil Filter
Fig. 13 Remove Parking Rod E-Clip
Fig. 14 Parking Rod
Fig. 15 Valve Body Attaching Bolts
Fig. 16 Valve Body and Governor Tubes
21 - 22 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

31TH TORQUE SPECIFICATIONS
DESCRIPTION TORQUE DESCRIPTION TORQUE
Bell Housing Cover Bolts 12 N´m (106 in. lbs.) Output Shaft Nut 271 N´m (200 ft. lbs.)
Cooler Hose To Rad. Conn. 12 N´m (105 in. lbs.) Park/Neutral Switch 34 N´m (25 ft. lbs.)
Cooler Line Conn. 28 N´m (250 in. lbs.) Pressure Check Plug 5 N´m (45 in. lbs.)
Diff. Bear. Ret. To Case Bolt 28 N´m (250 in. lbs.) Pump To Case Bolts 31 N´m (275 in. lbs.)
Diff. Cover To Case Bolt 19 N´m (165 in. lbs.) Reaction Shaft Assembly Bolt 28 N´m (250 in. lbs.)
Exten. Hous. To Case Bolt 28 N´m (250 in. lbs.) Rear Cover To Case Screw 19 N´m (165 in. lbs.)
Flex Plate To Crankshaft Bolts 95 N´m (70 ft. lbs.) Reverse Band Adj. Lock Nut 14 N´m (125 in. lbs.)
Flex Plate To Torque Conv. Bolts 68 N´m (50 ft. lbs.) Reverse Band Shaft Plug 7 N´m (60 in. lbs.)
Fluid Filter Screw 5 N´m (45 in. lbs.) Ring Gear Screw 95 N´m (70 ft. lbs.)
Front Motor Mount Bolt 54 N´m (40 ft. lbs.) Speedo. To Ext. Hous. Screw 7 N´m (60 in. lbs.)
Governor Counterweight Screw 28 N´m (250 in. lbs.) Sprag Ret. To Transfer Case Bolt 28 N´m (250 in. lbs.)
Governor To Support Bolt 7 N´m (60 in. lbs.) Starter To Trans. Bell Bolts 54 N´m (40 ft. lbs.)
Kickdown Band Adj. Lock Nut 47 N´m (35 ft. lbs.) Throttle Cable To Trans. Case
Bolt12 N´m (105 in. lbs.)
Left Motor Mount Bolts 54 N´m (40 ft. lbs.) Throttle Lever To Trans. Shaft
Bolts12 N´m (105 in. lbs.)
Lower Bell Housing Cover Screw 41 N´m (30 ft. lbs.) Trans. To Cyl. Block Bolt 95 N´m (70 ft. lbs.)
Manual Cable To Trans. Case Bolt 28 N´m (250 in. lbs.) Transfer Shaft Nut 271 N´m (200 ft. lbs.)
Manual Control Lever Screw 12 N´m (105 i n. lbs.) Transfer Gear Strap Bolts 23 N´m (17 ft. lbs.)
Oil Pan To Trans. Case Screw 19 N´m (165 in. lbs.) Valve Body Assy. To Case Bolts 12 N´m (105 in. lbs.)
Output Gear Strap Bolts 23 N´m (17 ft. lbs.) Valve Body Screw 5 N´m (45 in. lbs.)
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 65
SPECIFICATIONS (Continued)

41TE AUTOMATIC TRANSAXLE
INDEX
page page
GENERAL INFORMATION
41TE FOUR SPEED AUTOMATIC TRANSAXLE . 71
FLUID LEVEL AND CONDITION............. 72
SELECTION OF LUBRICANT............... 72
SPECIAL ADDITIVES..................... 72
DESCRIPTION AND OPERATION
ADAPTIVE CONTROLS................... 73
CLUTCH AND GEAR..................... 72
ELECTRONICS......................... 73
GEARSHIFT AND PARKING LOCK CONTROLS . 74
HYDRAULICS........................... 73
ON-BOARD DIAGNOSTICS................ 74
SENSORS............................. 73
SHIFT POSITION INDICATOR.............. 74
SOLENOIDS............................ 73
TORQUE MANAGEMENT.................. 74
TRANSMISSION CONTROL MODULE........ 74
TRANSMISSION RANGE SENSOR........... 74
DIAGNOSIS AND TESTING
41TE TRANSAXLE GENERAL DIAGNOSIS..... 75
CLUTCH AIR PRESSURE TESTS............ 77
FLUID LEAKAGE-TORQUE CONVERTER
HOUSING AREA....................... 78
HYDRAULIC PRESSURE TESTS............ 75
ROAD TEST............................ 75
SHIFT POSITION INDICATOR.............. 78
SERVICE PROCEDURES
ALUMINUM THREAD REPAIR.............. 81
FLUID AND FILTER CHANGE............... 79
FLUID DRAIN AND REFILL................. 81
FLUSHING COOLERS AND TUBES.......... 81OIL PUMP VOLUME CHECK............... 82
PINION FACTOR PROCEDURE............. 83
TRANSAXLE QUICK LEARN PROCEDURE.... 82
REMOVAL AND INSTALLATION
GEARSHIFT CABLE...................... 83
MANUAL VALVE LEVER (SHIFT LEVER)...... 84
OIL PUMP SEAL......................... 92
SOLENOID ASSEMBLY-REPLACE........... 85
SPEED SENSOR-INPUT................... 86
SPEED SENSOR-OUTPUT................. 86
TRANSAXLE........................... 89
TRANSMISSION CONTROL MODULE........ 87
TRANSMISSION RANGE SENSOR........... 85
VALVE BODY........................... 88
DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL REPAIR.................. 139
INPUT CLUTCHES-RECONDITION.......... 110
TRANSAXLE ASSEMBLE................. 122
TRANSAXLE DISASSEMBLE............... 95
VALVE BODY RECONDITION............... 92
CLEANING AND INSPECTION
CLEANING VALVE BODY................. 144
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT......... 144
SCHEMATICS AND DIAGRAMS
41TE TRANSAXLE HYDRAULIC SCHEMATICS . 145
SPECIFICATIONS
41TE AUTOMATIC TRANSAXLE............ 158
41TE TORQUE SPECIFICATIONS.......... 158
SPECIAL TOOLS
41TE AUTOMATIC TRANSAXLE............ 159
GENERAL INFORMATION
41TE FOUR SPEED AUTOMATIC TRANSAXLE
The 41TE four-speed FWD transaxle uses fully-
adaptive controls. Adaptive controls are those which
perform their functions based on real-time feedback
sensor information. The transaxle uses hydraulically
applied clutches to shift a planetary gear train.
TRANSAXLE IDENTIFICATION
The 41TE transaxle identification code is printed
on a label. The label is located on the transaxle case
next to the solenoid assembly (Fig. 1).
Fig. 1 Identification Tag Location
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 71

(4) Reverse and LR clutch pressure should read
165 to 235 psi.
(5) This test checks the reverse clutch hydraulic
circuit.
TEST RESULT INDICATIONS
(1) If proper line pressure is found in any one test,
the pump and pressure regulator are working prop-
erly.
(2) Low pressure in all positions indicates a defec-
tive pump, a clogged filter, or a stuck pressure regu-
lator valve.
(3) Clutch circuit leaks are indicated if pressures
do not fall within the specified pressure range.
(4) If the overdrive clutch pressure is greater than
5 psi in Step 4 of Test Three, a worn reaction shaft
seal ring or a defective solenoid assembly is indi-
cated.
(5) If the underdrive clutch pressure is greater
than 5 psi in Step 4 of Test 2A, a defective solenoid
assembly or TCM is the cause.
CLUTCH AIR PRESSURE TESTS
Inoperative clutches can be located using a series
of tests by substituting air pressure for fluid pressure
(Fig. 3) (Fig. 4). The clutches may be tested by apply-
ing air pressure to their respective passages. The
valve body must be removed and Tool 6056 installed.
To make air pressure tests, proceed as follows:
NOTE: The compressed air supply must be free of
all dirt and moisture. Use a pressure of 30 psi.
Remove oil pan and valve body. See Valve body
removal.
OVERDRIVE CLUTCH
Apply air pressure to the overdrive clutch apply
passage and watch for the push/pull piston to move
forward. The piston should return to its starting
position when the air pressure is removed.
PRESSURE CHECK SPECIFICATIONS
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 77
DIAGNOSIS AND TESTING (Continued)

If a problem arises with the shifter position indica-
tor, consult the following chart for diagnostic infor-
mation. If the malfunction cannot be corrected using
the chart, consult the proper diagnostic manual.
To replace the shifter position indicator, refer to
Group 8E, Instrument Panel And Gauges.SERVICE PROCEDURES
FLUID AND FILTER CHANGE
When the factory fill fluid is changed, only fluids
labeled MOPARtATF PLUS 3 (Automatic Transmis-
sion fluid) Type 7176 should be used.
If the transaxle is disassembled for any reason, the
fluid and filter should be changed.
30,000 MILE TRANSAXLE OIL CHANGE
When a vehicle attains 30,000 miles on its odome-
ter it is recommended that the transaxle oil be
changed. To change the oil, use the procedure that
follows:
It is recommended that a transaxle fluid exchanger
(ATF 2000+ or equivalent) be used to replace the
used fluid in the transaxle. If a fluid exchanger is not
available use a fluid suction pump (Vaculayor equiv-
alent) to draw the fluid out of the dipstick tube. If a
fluid suction pump is not available remove the oil
pan and drain the fluid.
CAUTION: Chrysler Corporation does not recom-
mend using any fluid exchanger that introduces
additives into the transaxle.
TRANSAXLE FLUID EXCHANGER METHOD
(1) To perform the transaxle fluid exchange, the
transaxle must be at operating temperature. Drive
the vehicle till it reaches full operating temperature.
(2) Verify that the fill tank on the transaxle fluid
exchanger (ATF 2000+ or equivalent) is clean and
dry.
(3) Fill the tank to the recommended fill capacity
with Mopar ATF Plus 3 Type 7176.
(4) Hookup the vehicle to the machine following
the manufacturers instructions. Perform the
exchange procedure following the instructions pro-
vided with the machine.
(5) Once machine has completed the fluid
exchange. Check the fluid level and condition and fill
to proper level with Mopar ATF Plus 3 Type 7176.
NOTE: Verify that the transaxle cooler lines are
tightened to proper specifications. Cooler line
torque specification is 2 N´m (18 in. lbs.).
CONDITION POSSIBLE CAUSE
ALL PRND3L DISPLAY
LIGHTS9ON9IN P&N
GEAR POSITIONS1.Check wiring and
connectors
2. Faulty trans. range
sensor
3. Faulty manual lever
ALL DISPLAY LIGHTS
9ON9IN ALL GEAR
POSITIONS1. Check wiring &
connectors
2. Faulty trans. range
sensor
3. Faulty manual lever
4. CCD communication
malfunction
5. Check oil level
ALL DISPLAY LIGHTS
9OFF91. Normal transient
condition between P&R
and R&N gear positions
2. Check shift lever
linkage
3. Body controller
malfunction
4. Check wiring and
connectors
5. Faulty cluster
ALL DISPLAY LIGHTS
9OFF9ACCOMPANIED
BY A9NO BUS9
MESSAGE1. CCD communication
malfunction
DISPLAY LIGHTS OUT
OF SEQUENCE WITH
SHIFT LEVER1. Check wiring and
connectors
2. Faulty trans. range
sensor
3. Faulty manual lever
4. CCD communication
malfunction
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 79
DIAGNOSIS AND TESTING (Continued)

DIPSTICK TUBE FLUID SUCTION METHOD
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (Vaculay
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Add 4 Quarts of Mopar ATF Plus 3 Type 7176
transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be in
the HOT range.
TRANSAXLE OIL PAN DROP METHOD
This procedure involves removing the transaxle oil
pan to drain the transaxle fluid.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N²m (165 in. lbs.).
(6) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid levelto 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be in
the HOT range. Drive the vehicle a minimum of 10
miles.
(10) Raise the vehicle on the hoist.
(11) Check for leaks around the transaxle oil pan
sealing surfaces.
(12) Recheck the fluid level. The level should be in
the HOT range.
SEVERE USAGE SERVICE
If the vehicle exhibits any of the following symp-
toms, it is recommended that the transaxle oil and
filter be replaced.
²Transaxle oil discolored
²Transaxle oil has high mileage
²Oil feels grimy when rubbed between fingertips
²Poor shift quality
²Delayed gear engagement
²Vehicle shudder between shifts
TRANSAXLE OIL AND FILTER REPLACEMENT
This procedure involves changing the transaxle
fluid and filter, driving the vehicle for 10 miles and
changing the transaxle fluid a second time.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Separate the filter and O-ring from the valve
body. Inspect the O-ring for cuts or improper instal-
lation. This could lead to delayed garage shifts.
(6) Install a new filter. Replace the O-ring as nec-
essary.
(7) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N´m (165 in. lbs.).
(8) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(9) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(10) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
21 - 80 TRANSAXLE AND POWER TRANSFER UNITNS
SERVICE PROCEDURES (Continued)

(11) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range. Drive the vehicle a minimum of
10 miles.
(12) Raise the vehicle on the hoist.
(13) Remove the pan and clean all sealant from
the pan and transaxle mating surfaces. Clean the
magnet and the inside of the pan.
(14) Separate the filter from the valve body to
allow additional fluid to drain from the transaxle.
Inspect the filter O-ring for any damage and replace
as necessary.
(15) After the transaxle has stopped draining,
reinstall the filter and O-ring.
(16) Apply a 1/8 inch bead of Mopar RTV Sealant
to the mounting flange of the transaxle oil pan.
Apply RTV Sealant to the underside of the attaching
bolts. Attach the oil pan to the transaxle. Tighten the
bolts to 19 N´m (165 in. lbs.).
(17) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(18) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(19) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(20) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range.
FLUID DRAIN AND REFILL
(1) Raise vehicle on a hoist (See Group 0, Lubrica-
tion). Place a drain container with a large opening,
under transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and O-ring on bottom of the
valve body.
(4) Clean the oil pan and magnet. Reinstall pan
using new MOPARtRTV sealant. Tighten oil pan
bolts to 19 N´m (165 in. lbs.).
(5) Pour four quarts of MOPARtATF PLUS 3
(Automatic Transmission Fluid) Type 7176 through
the fill tube.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.(7) Add sufficient fluid to bring level to 1/8 inch
below the ADD mark.
CAUTION: Do not overfill transaxle. Do not add oil
if level is between: Lower holes for warm oil
(100ÉF). Upper holes for hot oil (180ÉF).
(8) Recheck fluid level after transaxle is at normal
operating temperature. The level should be in the
HOT region (Fig. 5).
(9) To prevent dirt from entering transaxle, make
certain that dipstick is seated into the dipstick fill
tube.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum tran-
saxle case and valve body can be repaired by the use
of Heli-Coils, or equivalent. This repair consists of
drilling out the worn-out damaged threads. Then tap
the hole with a special Heli-Coil tap, or equivalent,
and installing a Heli-Coil insert, or equivalent, into
the hole. This brings the hole back to its original
thread size.
Heli-Coil, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
FLUSHING COOLERS AND TUBES
When a transaxle failure has contaminated the
fluid, the oil cooler(s) must be flushed. The cooler
bypass valve in the transaxle must be replaced also.
The torque converter must also be replaced with an
exchange unit. This will insure that metal particles
or sludged oil are not later transferred back into the
reconditioned (or replaced) transaxle.
The recommended procedure for flushing the tran-
saxle cooler is to use Tool 6906A Cooler Flusher.
Fig. 5 Oil Level Indicator
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 81
SERVICE PROCEDURES (Continued)

SOLENOID ASSEMBLY-REPLACE
To install solenoid assembly, reverse removal pro-
cedure. Tighten screws to 12 N´m (105 in. lbs.).
TRANSMISSION RANGE SENSOR
The transmission range sensor is located within
the transaxle. To remove the TRS the transaxle oil
pan and valve body must be removed.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove engine air cleaner and tube.
(3) Remove gearshift cable (Fig. 17).
(4) Remove manual valve lever.
(5) Disconnect transmission range sensor connec-
tor.
(6) Hoist vehicle.
(7) Carefully remove transaxle oil pan and drain
fluid.
(8) Remove transaxle oil filter. Let transaxle oil
drain fully.
(9) Remove valve body retaining bolts.
(10) Extract park rod from guide bracket and
remove valve body from transaxle.
(11) Place valve body on workbench (Fig. 18).
(12) Remove TRS retaining screw (Fig. 19).
Fig. 12 Manual Valve Lever (Shift Lever)
Fig. 13 Remove Input Speed Sensor
Fig. 14 Remove Sound Cover
Fig. 15 Remove Attaching Screws
Fig. 16 Remove Solenoid Assembly
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 85
REMOVAL AND INSTALLATION (Continued)