2001 CHRYSLER VOYAGER ABS

(48) Set up dial indicator as shown in (Fig. 138)
and measure 2/4 clutch clearance. Press down on
clutch pack with finger and zero dial indicator.2/4
clutch pack clearance is 0.76-2.64 mm
(0.030-0.104 in.).If clearance is outside this range,
the clutch is assembled improperly.There is no
adjustment for 2/4 clutch clearance.
(49) Install rear sun gear and #7 needle bearing
(Fig. 139).(50) Install front carrier/rear annulus assembly
and #6 needle bearing (Fig. 140).
(51) Install front sun gear assembly and #4 thrust
washer (Fig. 141).
Fig. 138 Check 2/4 Clutch Clearance
1 - DIAL INDICATOR
2 - HOOK TOOL
3 - DIAL INDICATOR TIP TOOL 6268
Fig. 139 Install Rear Sun Gear
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 140 Install Front Carrier and Rear Annulus
Assembly
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 141 Install Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
21 - 202 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (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. 142). 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.
143), the input clutch assembly is not seated prop-
erly.
(c) Remove oil pump o-ring (Fig. 144).Be sure
to reinstall oil pump o-ring after selecting the
proper #4 thrust plate.
(d) Set up input shaft for measurement with
Indicator Set C3339 and End Play Set 8266 as
shown in (Fig. 145).
(e) Measure the input shaft end play with the
transaxle in the vertical position.Input shaft end
play must within 0.005 to 0.025 inch.For exam-
ple, 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 reading of
0.020 inch which is within specifications.
(f) Refer to the No. 4 thrust plate chart to select
the proper No. 4 thrust plate:
Fig. 142 Select Thinnest No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 143 View Through Input Speed Sensor Hole
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
Fig. 144 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
RSAUTOMATIC - 41TE21 - 203
AUTOMATIC - 41TE (Continued)

ASSEMBLY
NOTE: The differential is serviced as an assembly.
Differential service is limited to bearing cups and
cones. Any other differential component failure
must be remedied by differential assembly and
transfer shaft replacement.
(1) Install side gear thrust washer to differential
case (Fig. 197).
(2) Install side gear to differential case (Fig. 198).(3) Install both pinion gears and washers to case,
while orientating washer tabs to notch in case (Fig.
199).
(4) Install pinion shaft (Fig. 200).
Fig. 197 Thrust Washer Installation
1 - THRUST WASHER
Fig. 198 Side Gear Installation
1 - DIFFERENTIAL SIDE GEAR
Fig. 199 Pinion Gear and Washer Installation
1 - PINION GEAR
2 - TABBED WASHER
3 - LOCATING TAB
4 - NOTCH
Fig. 200 Pinion Shaft Installation
1 - PINION SHAFT
21 - 240 AUTOMATIC - 41TERS
FINAL DRIVE (Continued)

(10) Remove and inspect #3 & #4 thrust washers
(Fig. 240) .
(11) Remove the underdrive shaft assembly (Fig.
241) .(12) Remove the #2 needle bearing (Fig. 242) .
(13) Remove the OD/UD reaction plate tapered
snap ring (Fig. 243) .
NOTE: The OD/UD clutch reaction plate has a step
on both sides. Install the OD/UD clutches reaction
plate tapered step side up.
Fig. 240 #3&4 Thrust Washers
1 - #3 THRUST PLATE (3 TABS)
2 - OD SHAFT ASSEMBLY
3 - #4 THRUST PLATE (3 SLOTS)
Fig. 241 Underdrive Shaft Assembly
1 - #3 THRUST WASHER (5 TABS)
2 - UNDERDRIVE SHAFT ASSEMBLY
Fig. 242 No. 2 Needle Bearing
1 - #2 NEEDLE BEARING (NOTE 3 TABS)
Fig. 243 OD/UD Reaction Plate Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
RSAUTOMATIC - 41TE21 - 255
INPUT CLUTCH ASSEMBLY (Continued)

(18) Using Tool 5059A and an arbor press, com-
press UD clutch piston enough to remove snap ring
(Fig. 248) (Fig. 249) .
(19) Remove spring retainer (Fig. 249) .(20) Remove UD clutch piston (Fig. 250) .
(21) Remove input hub tapered snap ring (Fig.
251) .
Fig. 248 UD Spring Retainer Snap Ring
1 - SNAP RING PLIERS
2 - ARBOR PRESS RAM
3 - SNAP RING
4 - SPECIAL TOOL 5059A
Fig. 249 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 250 Underdrive Clutch Piston
1 - PISTON
Fig. 251 Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
RSAUTOMATIC - 41TE21 - 257
INPUT CLUTCH ASSEMBLY (Continued)

(5) Install the input hub/shaft assy. to the OD/Re-
verse piston/clutch retainer assy. (Fig. 264).
(6) Install input hub tapered snap ring (Fig. 265).(7) Install UD clutch piston (Fig. 266).
(8) Install UD piston return spring and Tool 5067
as shown in (Fig. 267).
(9) Using Tool 5059A and an arbor press, Install
the UD spring retainer and snap ring. (Fig. 268) (Fig.
269)Compress just enough to install snap ring.
CAUTION: Compress return spring just enough to
install snap ring.
Fig. 264 Install Input Shaft Hub Assembly
1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY
(ROTATE TO ALIGN SPLINES)
2 - OD/REV. PISTON
Fig. 265 Install Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
Fig. 266 Underdrive Clutch Piston
1 - PISTON
Fig. 267 Seal Compressor Special Tool 5067
1 - PISTON RETURN SPRING
2 - SPECIAL TOOL 5067
3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY
RSAUTOMATIC - 41TE21 - 261
INPUT CLUTCH ASSEMBLY (Continued)

(35) Take average of four measurements and com-
pare with reverse clutch pack clearance specification.
The reverse clutch pack clearance is 0.89-1.37
mm (0.035-0.054 in.).Select the proper reverse
clutch snap ring to achieve specifications:
REVERSE CLUTCH SNAP RING THICKNESS
4377195 1.53-1.58 mm (0.060-0.062 in.)
4412871 1.77-1.83 mm (0.070-0.072 in.)
4412872 2.02-2.07 mm (0.080-0.082 in.)
4412873 2.27-2.32 mm (0.090-0.091 in.)
(36) To complete the assembly, reverse clutch and
overdrive clutch must be removed .
(37) Install the #2 needle bearing (Fig. 290).
(38) Install the underdrive shaft assembly (Fig.
291).
(39) Install the #3 thrust washer to the underdrive
shaft assembly. Be sure five tabs are seated properly
(Fig. 292).
(40) Install the #3 thrust plate to the bottom of the
overdrive shaft assembly. Retain with petrolatum or
transmission assembly gel (Fig. 293).(41) Install the overdrive shaft assembly (Fig.
294).
(42) Reinstall overdrive and reverse clutch as
shown.Rechecking these clutch clearances is
not necessary.
Fig. 290 Install No. 2 Needle Bearing
1 - #2 NEEDLE BEARING (NOTE 3 SMALL TABS)
2 - TABS UP
Fig. 291 Install Underdrive Shaft Assembly
1 - UNDERDRIVE SHAFT ASSEMBLY
2 - #2 NEEDLE BEARING
Fig. 292 Install No. 3 Thrust Washer
1 - #3 THRUST WASHER (NOTE 5 TABS)
2 - UNDERDRIVE SHAFT ASSEMBLY
21 - 268 AUTOMATIC - 41TERS
INPUT CLUTCH ASSEMBLY (Continued)

OIL PUMP
DESCRIPTION
The oil pump is located in the pump housing inside
the bell housing of the transaxle case (Fig. 295). The
oil pump consists of an inner and outer gear, a hous-
ing, and a cover that also serves as the reaction shaft
support.
OPERATION
As the torque converter rotates, the converter hub
rotates the inner and outer gears. As the gears
rotate, the clearance between the gear teeth
increases in the crescent area, and creates a suctionat the inlet side of the pump. This suction draws
fluid through the pump inlet from the oil pan. As the
clearance between the gear teeth in the crescent area
decreases, it forces pressurized fluid into the pump
outlet and to the valve body.
STANDARD PROCEDURE - OIL PUMP VOLUME
CHECK
Measuring oil pump output volume will determine
if sufficient flow to the transmission oil cooler exists,
and whether or not an internal transmission failure
is present.
Verify that transmission fluid is at the proper
level. If adding fluid is necessary, fill to the proper
level with Moparž ATF+4 (Automatic Transmission
Fluid±Type 9602). The following procedure is to
check oil pump output volume:
(1) Using hose cutters or a suitable blade, cut the
ªto coolerº (Fig. 296) line off flush with the cooler
inlet fitting and place a collection container under
the open line .
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Start engine and runat curb idle speed, with
the shift selector in neutral.
Fig. 293 Install No. 3 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - DABS OF PETROLATUM (FOR RETENTION)
3 - #3 THRUST PLATE (NOTE 3 TABS)
Fig. 294 Install Overdrive Shaft Assembly
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #3 THRUST PLATE
3 - #3 THRUST WASHER
Fig. 295 Oil Pump Assembly
1 - PUMP HOUSING
2 - OUTER PUMP GEAR
3 - INNER PUMP GEAR
4 - REACTION SHAFT SUPPORT
5 - SEAL RINGS (4)
6 - REACTION SHAFT
7 - CRESCENT
RSAUTOMATIC - 41TE21 - 269
INPUT CLUTCH ASSEMBLY (Continued)