2001 CHRYSLER VOYAGER check transmission fluid

FLUID
STANDARD PROCEDURE - FLUID LEVEL AND
CONDITION CHECK
NOTE: The transmission and differential sump have
a common oil sump with a communicating opening
between the two.
FLUID LEVEL CHECK
The torque converter fills in both the P Park and N
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate.The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground. This will assure complete oil level sta-
bilization between differential and transmis-
sion.The fluid should be at normal operating
temperature (approximately 82 C. or 180 F.). The
fluid level is correct if it is in the HOT region (cross-
hatched area) on the fluid level indicator (Fig. 165).
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, the air bubbles can cause overheat-
ing, fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and servo operation.
Foaming can also result in fluid escaping from the
transaxle dipstick where it may be mistaken for a
leak.Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
If there is any doubt about its condition, drain out a
sample for a double check.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle recondition is needed.
Be sure to examine the fluid on the dipstick closely.
If there is any doubt about its condition, drain out a
sample for a double check.
Moparž ATF+4 (Automatic Transmission Fluid-
Type 9602) when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
the vehicle such as engine oil or antifreeze. The red
color is not permanent and is not an indicator of fluid
condition. As the vehicle is driven, the ATF will begin
to look darker in color and may eventually become
brown. This is normal. A dark brown/black fluid
accompanied with a burnt odor and/or deterioration
in shift quality may indicate fluid deterioration or
transmission component failure.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
STANDARD PROCEDURE - FLUID AND FILTER
CHANGE
NOTE: For the recommended maintenance (fluid/fil-
ter change) intervals for this transaxle, (Refer to
LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
NOTE: Only fluids of the type labeled Moparž
ATF+4 (Automatic Transmission Fluid) Type 9602
should be used. A filter change should be made at
the time of the transmission oil change. The magnet
(on the inside of the oil pan) should also be cleaned
with a clean, dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Place a drain con-
tainer with a large opening, under transaxle oil pan.
Fig. 165 Fluid Level Indicator Markings
1 - TRANSAXLE DIPSTICK
21 - 98 AUTOMATIC - 31THRS

(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) Remove oil filter-to-valve body screws (Fig.
166).
(4) Remove oil filter and gasket (Fig. 167).
(5) Install a new filter and gasket (Fig. 167).
(6) Clean the oil pan and magnet. Reinstall pan
using new Moparž Silicone Rubber Adhesive Sealant.
Torque oil pan bolts to 19 N´m (165 in. lbs.).(7) Pour four quarts of Moparž ATF+4 (Automatic
Transmission Fluid-Type 9602) through the dipstick
opening.
(8) 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.
(9) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ªADDº mark on the dip-
stick (Fig. 168).
(10) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/FLUID - STANDARD PROCEDURE)
(11) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
DIPSTICK TUBE FLUID SUCTION METHOD
(ALTERNATIVE)
(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 (VaculaŸ
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) Pour four quarts of Moparž ATF+4 (Automatic
Transmission FluidÐType 9602) through the dipstick
opening.
(7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
Fig. 166 Oil Filter Screws
1 - SCREWDRIVER HANDLE
2 - SPECIAL TOOL L-4553
3 - OIL FILTER SCREWS (2)
4 - OIL FILTER
Fig. 167 Oil Filter and Gasket
1 - OIL FILTER
2 - GASKET
3 - VALVE BODY
Fig. 168 Dipstick Markings
1 - TRANSAXLE DIPSTICK
RSAUTOMATIC - 31TH21-99
FLUID (Continued)

applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ªADDº mark on the dip-
stick (Fig. 168).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/FLUID - STANDARD PROCEDURE)
(10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
GEAR SHIFT CABLE
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect gear shift cable at manual valve
lever (Fig. 169).
(3) Disconnect gear shift cable from upper mount
bracket (Fig. 169).(4) Remove instrument panel lower silencer (Fig.
170).
(5) Remove knee bolster (Fig. 171).
(6) Disconnect PRNDL cable from gear shift lever
(Fig. 172).
(7) Disconnect gear shift cable from gear shift
lever (Fig. 173).
(8) Remove gear shift cable from column bracket
(Fig. 173).
(9) Disengage grommet from dash panel and
remove gear shift cable from inside vehicle (Fig. 174).
Fig. 169 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 170 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 171 Knee Bolster
1 - KNEE BOLSTER
21 - 100 AUTOMATIC - 31THRS
FLUID (Continued)

pressure. Generally governor pressure ranges from
0-100 psi from idle to maximum speed, and rises pro-
portionally with the increase in output shaft speed.
Governor pressure and throttle pressure are acting
upon the shift valves to determine when a shift will
occur. Governor pressure is a direct indication of road
speed, and throttle pressure is an indication of
engine load. When both parameters have been met
by the throttle and governor pressures, an upshift or
downshift will occur.
CLEANING
Thoroughly clean all the governor parts in a suit-
able cleaning solution but do not use any type of
caustic cleaning agents.
The governor weight components and the governor
valve, must slide freely in their bores when clean and
dry. Minor surface scratches and burrs can be
smoothed with crocus cloth.
INSPECTION
The aluminum governor valve and outer weight
have a hard coating on them. Check condition of this
coating carefully. Do not reuse either part if the coat-
ing is damaged.
Inspect the governor weight spring for distortion.
Replace the spring, if distorted, collapsed, or broken.
Clean the filter in solvent and dry it with compressedair. Replace the filter, if damaged. Inspect the park
gear for chipped or worn gear teeth or damaged ring
grooves. Replace the gear, if damaged.
Check the teeth on the park gear for wear or dam-
age. Replace the gear if necessary. Inspect the metal
seal rings on the park gear hub. Replace the rings
only if severely worn, or broken.
OIL PUMP
DESCRIPTION
The oil pump is located in the pump housing inside
the bell housing of the transmission case. The oil
pump consists of an inner and outer gear, a housing,
and a cover that also serves as the reaction shaft
support (Fig. 182).
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 suction
at 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.
Fig. 182 Oil Pump Assembly
1 - REACTION SHAFT SUPPORT
2 - INNER GEAR
3 - PUMP BODY4 - PUMP BUSHING
5 - OUTER GEAR
21 - 104 AUTOMATIC - 31THRS
GOVERNOR (Continued)

STANDARD PROCEDURE - OIL PUMP VOLUME
CHECK
Measuring the oil pump output volume will deter-
mine if sufficient oil flow to the transmission oil
cooler exists, and whether or not an internal trans-
mission failure is present.
Verify that the transmission fluid is at the proper
level. Refer to the Fluid Level Check procedure in
this section. If necessary, fill the transmission to the
proper level with Moparž ATF +4, type 9602, Auto-
matic Transmission Fluid.
(1) Using hose cutters or a suitable blade, cut the
To coolerline off flush with the cooler inlet fitting
and place a collecting 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) Run the engineat curb idle speed, with the
shift selector in neutral.
(3) If one quart of transmission fluid is collected in
the container in 20 seconds or less, oil pump flow vol-
ume is within acceptable limits. If fluid flow is inter-
mittent, or it takes more than 20 seconds to collect
one quart of fluid, (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 31TH - DIAGNOSIS
AND TESTING) for further diagnosis.
(4) Re-connect theTo coolerline to the transmis-
sion cooler inlet using a service splice kit. Refer to
instructions included with the kit.
(5) Refill the transmission to proper level. (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 31TH/FLUID - STANDARD PROCEDURE)
DISASSEMBLY
(1) Remove reaction shaft support-to-pump body
bolts.
(2) Remove reaction shaft support, and the inner
and outer pump gears (Fig. 183).
CLEANING
Clean pump and support components with solvent
and dry them with compressed air.
INSPECTION
(1) Check condition of the seal rings and thrust
washer on the reaction shaft support. The seal rings
do not need to be replaced unless cracked, broken, or
severely worn.
(2) Visually inspect the pump and support compo-
nents. Replace the pump assembly if the seal ring
grooves or machined surfaces are worn, scored, pit-
ted, or damaged. Replace the pump assembly if the
gears if pitted, worn chipped, or damaged.
(3) Inspect the pump bushing. Then check the
reaction shaft support bushing. Replace the pump
assembly if either bushing is heavily worn, scored or
damaged.
(4) Clearance between outer gear and reaction
shaft housing should be 0.010 to 0.063 mm (0.0004 to
0.0025 in.). Clearance between inner gear and reac-
tion shaft housing should be 0.010 to 0.063 mm
(0.0004 to 0.0025 in.). Both clearances can be mea-
sured at the same time by installing the gears in the
pump body and measure pump component clearances
as follows:
(5) Reinstall gears to pump body and measure
outer gear-to-pocket clearance with a feeler gauge
(Fig. 184).Outer gear-to-pocket clearance should
be within 0.045-0.141 mm (0.0018-0.0056 in.).
(6) Measure both inner and outer gear side clear-
ance with PlastigageŸ. If PlastigageŸ is not avail-
able, measure across the pump body with a straight
edge and feeler gauge.
(a) Position an appropriate piece of PlastigageŸ
across both gears.
(b) Align the plastigage to a flat area on the
reaction shaft housing.
(c) Install the reaction shaft support to the
pump housing and torque to 28 N´m (250 in. lbs.).
(d) Separate the reaction shaft housing from the
pump housing and measure the PlastigageŸ fol-
lowing the instructions supplied with it.Inner
and outer gear side clearance should be
within 0.020-0.046 mm (0.0008-0.0018 in.).
ASSEMBLY
(1) Install inner and outer gears to pump body
(Fig. 183). Lubricate gears with Moparž ATF+4
(Automatic Transmission Fluid-Type 9602).
(2) Install reaction shaft support to pump body
and align holes.
(3) Install and torque reaction shaft support-to-
pump body bolts to 28 N´m (250 in. lbs.).
RSAUTOMATIC - 31TH21 - 105
OIL PUMP (Continued)

TORQUE CONVERTER CLUTCH (TCC)
In a standard torque converter, the impeller and
turbine are rotating at about the same speed and the
stator is freewheeling, providing no torque multipli-
cation. By applying the turbine's piston to the front
cover's friction material, a total converter engage-
ment can be obtained. The result of this engagement
is a direct 1:1 mechanical link between the engine
and the transmission.
The engagement and disengagement of the TCC
are automatic and controlled by the Powertrain Con-
trol Module (PCM). The engagement cannot be acti-
vated in the lower gears because it eliminates the
torque multiplication effect of the torque converter
necessary for acceleration. Inputs that determine
clutch engagement are: coolant temperature, vehicle
speed and throttle position. The torque converter
clutch is engaged by the clutch solenoid on the valve
body. The clutch will engage at approximately 56
km/h (35 mph) with light throttle, after the shift to
third gear.
REMOVAL
(1) Remove transmission and torque converter
from vehicle. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 31TH - REMOVAL)
(2) Place a suitable drain pan under the converter
housing end of the transmission.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pull the torque converter forward until the cen-
ter hub clears the oil pump seal.
(4) Separate the torque converter from the trans-
mission.
INSTALLATION
Check converter hub and drive notches for sharp
edges, burrs, scratches, or nicks. Polish the hub and
notches with 320/400 grit paper or crocus cloth if nec-
essary. The hub must be smooth to avoid damaging
the pump seal at installation.(1) Lubricate converter hub and oil pump seal lip
with transmission fluid.
(2) Place torque converter in position on transmis-
sion.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
(3) Align torque converter to oil pump seal open-
ing.
(4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 237). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter is fully seated.
(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.
(8) Install the transmission in the vehicle. (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 31TH - INSTALLATION)
(9) Fill the transmission with the recommended
fluid.
Fig. 237 Checking Torque Converter Seating
1 - SCALE
2 - STRAIGHTEDGE
RSAUTOMATIC - 31TH21 - 125
TORQUE CONVERTER (Continued)

AUTOMATIC - 41TE
TABLE OF CONTENTS
page page
AUTOMATIC - 41TE
DESCRIPTION..........................159
OPERATION............................159
DIAGNOSIS AND TESTING................159
41TE TRANSAXLE GENERAL DIAGNOSIS . . . 159
ROAD TEST..........................161
HYDRAULIC PRESSURE TESTS..........162
CLUTCH AIR PRESSURE TESTS..........164
TORQUE CONVERTER HOUSING FLUID
LEAKAGE............................164
REMOVAL.............................165
DISASSEMBLY..........................169
ASSEMBLY............................186
INSTALLATION..........................209
SCHEMATICS AND DIAGRAMS.............212
SPECIFICATIONS........................225
SPECIAL TOOLS........................227
ACCUMULATOR
DESCRIPTION..........................232
OPERATION............................233
AUTOSTICK SWITCH
DESCRIPTION..........................233
OPERATION............................233
DRIVING CLUTCHES
DESCRIPTION..........................234
OPERATION............................234
FINAL DRIVE
DESCRIPTION..........................234
OPERATION............................234
DISASSEMBLY..........................235
ASSEMBLY............................240
ADJUSTMENTS.........................243
FLUID
STANDARD PROCEDURE.................246
FLUID LEVEL AND CONDITION CHECK.....246
FLUID AND FILTER SERVICE.............246
GEAR SHIFT CABLE
REMOVAL.............................248
INSTALLATION..........................250
ADJUSTMENTS.........................251
HOLDING CLUTCHES
DESCRIPTION..........................251
OPERATION............................251
INPUT CLUTCH ASSEMBLY
DISASSEMBLY..........................252
ASSEMBLY............................259
OIL PUMP
DESCRIPTION..........................269
OPERATION............................269STANDARD PROCEDURE.................269
OIL PUMP VOLUME CHECK..............269
DISASSEMBLY..........................270
ASSEMBLY............................271
PLANETARY GEARTRAIN
DESCRIPTION..........................271
OPERATION............................271
SEAL - OIL PUMP
REMOVAL.............................271
INSTALLATION..........................272
SHIFT INTERLOCK SOLENOID
DESCRIPTION..........................272
OPERATION............................273
DIAGNOSIS AND TESTING................274
BRAKE/TRANSMISSION SHIFT INTERLOCK
SOLENOID...........................274
REMOVAL.............................274
INSTALLATION..........................275
SOLENOID/PRESSURE SWITCH ASSEMBLY
DESCRIPTION..........................276
OPERATION............................276
REMOVAL.............................277
INSTALLATION..........................277
SPEED SENSOR - INPUT
DESCRIPTION..........................278
OPERATION............................278
REMOVAL.............................279
INSTALLATION..........................279
SPEED SENSOR - OUTPUT
DESCRIPTION..........................280
OPERATION............................280
REMOVAL.............................280
INSTALLATION..........................281
TORQUE CONVERTER
DESCRIPTION..........................281
OPERATION............................284
REMOVAL.............................286
INSTALLATION..........................286
TRANSMISSION CONTROL RELAY
DESCRIPTION..........................287
OPERATION............................287
TRANSMISSION RANGE SENSOR
DESCRIPTION..........................287
OPERATION............................287
REMOVAL.............................288
INSTALLATION..........................288
TORQUE REDUCTION LINK (TRD)
DESCRIPTION..........................289
OPERATION............................289
21 - 158 AUTOMATIC - 41TERS

VALVE BODY
DESCRIPTION..........................289
OPERATION............................290
REMOVAL.............................290DISASSEMBLY..........................292
ASSEMBLY............................296
INSTALLATION..........................301
AUTOMATIC - 41TE
TRANSAXLE IDENTIFICATION
DESCRIPTION
The 41TE (Fig. 1) is a four-speed transaxle that is
a conventional hydraulic/mechanical assembly with
an integral differential, and is controlled with adap-
tive electronic controls and monitors. The hydraulic
system of the transaxle consists of the transaxle
fluid, fluid passages, hydraulic valves, and various
line pressure control components. An input clutch
assembly which houses the underdrive, overdrive,
and reverse clutches is used. It also utilizes separate
holding clutches: 2nd/4th gear and Low/Reverse. The
primary mechanical components of the transaxle con-
sist of the following:
²Three multiple disc input clutches
²Two multiple disc holding clutches
²Four hydraulic accumulators
²Two planetary gear sets
²Hydraulic oil pump
²Valve body
²Solenoid/Pressure switch assembly
²Integral differential assembly
Control of the transaxle is accomplished by fully
adaptive electronics. Optimum shift scheduling is
accomplished through continuous real-time sensor
feedback information provided to the Transmission
Control Module (TCM).
The TCM is the heart of the electronic control sys-
tem and relies on information from various direct
and indirect inputs (sensors, switches, etc.) to deter-
mine driver demand and vehicle operating condi-
tions. With this information, the TCM can calculate
and perform timely and quality shifts through vari-
ous output or control devices (solenoid pack, trans-
mission control relay, etc.).
The TCM also performs certain self-diagnostic
functions and provides comprehensive information
(sensor data, DTC's, etc.) which is helpful in proper
diagnosis and repair. This information can be viewed
with the DRB scan tool.
The 41TE transaxle identification code is a series
of digits printed on a bar-code label that is fixed to
the transaxle case as shown in (Fig. 2).For example, the identification code K 821 1125
1316 can be broken down as follows:
²K = Kokomo Transmission Plant
²821 = Last three digits of the transaxle part
number
²1125 = Build date
²1316 = Build sequence number
If the tag is not legible or missing, the ªPKº num-
ber, which is stamped into the transaxle case behind
the transfer gear cover, can be referred to for identi-
fication. This number differs slightly in that it con-
tains the entire transaxle part number, rather than
the last three digits.
OPERATION
Transmission output is directed to an integral dif-
ferential by a transfer gear system in the following
input-to-output ratios:
First...............................2.84 : 1
Second.............................1.57 : 1
Third..............................1.00 : 1
Overdrive...........................0.69 : 1
Reverse............................2.21 : 1
DIAGNOSIS AND TESTING - 41TE TRANSAXLE
GENERAL DIAGNOSIS
NOTE: Before attempting any repair on a 41TE four-
speed automatic transaxle, check for diagnostic
trouble codes (DTC's) using the DRB scan tool.
Refer to the Transmission Diagnostic Procedures
Manual.
Transaxle malfunctions may be caused by these
general conditions:
²Poor engine performance
²Improper adjustments
²Hydraulic malfunctions
²Mechanical malfunctions
²Electronic malfunctions
Diagnosis of these problems should always begin
by checking the easily accessible variables: fluid level
and condition, gearshift cable adjustment. Then per-
form a road test to determine if the problem has been
corrected or that more diagnosis is necessary. If the
problem persists after the preliminary tests and cor-
rections are completed, hydraulic pressure checks
should be performed.
RSAUTOMATIC - 41TE21 - 159