2001 CHRYSLER VOYAGER engine oil

STATOR
The stator assembly (Fig. 334) is mounted on a sta-
tionary shaft which is an integral part of the oil
pump. The stator is located between the impeller and
turbine within the torque converter case (Fig. 335).
The stator contains an over-running clutch, which
allows the stator to rotate only in a clockwise direc-
tion. When the stator is locked against the over-run-
ning clutch, the torque multiplication feature of the
torque converter is operational.
TORQUE CONVERTER CLUTCH (TCC)
The TCC (Fig. 336) was installed to improve the
efficiency of the torque converter that is lost to the
slippage of the fluid coupling. Although the fluid cou-
pling provides smooth, shock±free power transfer, it
is natural for all fluid couplings to slip. If the impel-
ler and turbine were mechanically locked together, a
zero slippage condition could be obtained. A hydraulic
piston was added to the turbine, and a friction mate-
rial was added to the inside of the front cover to pro-
vide this mechanical lock-up.
Fig. 333 Turbine
1 - TURBINE VANE
2 - ENGINE ROTATION
3 - INPUT SHAFT
4 - PORTION OF TORQUE CONVERTER COVER5 - ENGINE ROTATION
6 - OIL FLOW WITHIN TURBINE SECTION
RSAUTOMATIC - 41TE21 - 283
TORQUE CONVERTER (Continued)

STATOR
Torque multiplication is achieved by locking the
stator's over-running clutch to its shaft (Fig. 338).
Under stall conditions (the turbine is stationary), the
oil leaving the turbine blades strikes the face of the
stator blades and tries to rotate them in a counter-
clockwise direction. When this happens the over±run-
ning clutch of the stator locks and holds the stator
from rotating. With the stator locked, the oil strikes
the stator blades and is redirected into a ªhelpingº
direction before it enters the impeller. This circula-
tion of oil from impeller to turbine, turbine to stator,
and stator to impeller, can produce a maximum
torque multiplication of about 2.4:1. As the turbine
begins to match the speed of the impeller, the fluid
that was hitting the stator in such as way as to
cause it to lock±up is no longer doing so. In this con-
dition of operation, the stator begins to free wheel
and the converter acts as a fluid coupling.
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.
Fig. 337 Torque Converter Fluid Operation
1 - APPLY PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD3 - RELEASE PRESSURE
4 - THE PISTON MOVES SLIGHTLY REARWARD
Fig. 338 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
RSAUTOMATIC - 41TE21 - 285
TORQUE CONVERTER (Continued)

Since there are four switches, there are 16 possible
combinations of open and closed switches (codes).
Seven of these codes are related to gear position and
three are recognized as ªbetween gearº codes. This
results in six codes which should never occur. These
are called ªinvalidº codes. An invalid code will result
in a DTC, and the TCM will then determine the shift
lever position based on pressure switch data. This
allows reasonably normal transmission operation
with a TRS failure.
TRS SWITCH STATES
SLP T42 T41 T3 T1
PCL CL CL OP
RCL OP OP OP
NCL CL OP CL
ODOP OP OP CL
3OP OP CL OP
LCL OP CL CL
TRANSMISSION TEMPERATURE SENSOR
The TRS has an integrated thermistor (Fig. 342)
that the TCM uses to monitor the transmission's
sump temperature. Since fluid temperature can
affect transmission shift quality and convertor lock
up, the TCM requires this information to determine
which shift schedule to operate in. The PCM also
monitors this temperature data so it can energize the
vehicle cooling fan(s) when a transmission ªoverheatº
condition exists. If the thermistor circuit fails, the
TCM will revert to calculated oil temperature usage.
CALCULATED TEMPERATURE
A failure in the temperature sensor or circuit will
result in calculated temperature being substituted for
actual temperature. Calculated temperature is a pre-
dicted fluid temperature which is calculated from a
combination of inputs:
²Battery (ambient) temperature
²Engine coolant temperature
²In-gear run time since start-up
REMOVAL
(1) Remove valve body assembly from transaxle.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/VALVE BODY - REMOVAL)
(2) Remove transmission range sensor retaining
screw and remove sensor from valve body (Fig. 343).
(3) Remove TRS from manual shaft.
INSTALLATION
(1) Install transmission range sensor (TRS) to the
valve body and torque retaining screw (Fig. 343) to 5
N´m (45 in. lbs.).
(2) Install valve body to transaxle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
41TE/VALVE BODY - INSTALLATION)
Fig. 342 Transmission Temperature Sensor
1 - TRANSMISSION RANGE SENSOR
2 - TEMPERATURE SENSOR
Fig. 343 Remove Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
21 - 288 AUTOMATIC - 41TERS
TRANSMISSION RANGE SENSOR (Continued)

DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES
The majority of transaxle malfunctions are a result
of:
²Insufficient lubrication
²Incorrect lubricant
²Misassembled or damaged internal components
²Improper operation
HARD SHIFTING
Hard shifting may be caused by a misadjusted
crossover cable. If hard shifting is accompanied by
gear clash, synchronizer clutch and stop rings or gear
teeth may be worn or damaged.
Hard shifting may also be caused by a binding or
broken shift cover mechanism. Remove shift cover
and verify smooth operation. Replace as necessary.
Misassembled synchronizer components also cause
shifting problems. Incorrectly installed synchronizer
sleeves, keys, balls, or springs can cause shift prob-
lems.
NOISY OPERATION
Transaxle noise is most often a result of worn or
damaged components. Chipped, broken gear or syn-
chronizer teeth, and brinnelled, spalled bearings all
cause noise.
Abnormal wear and damage to the internal compo-
nents is frequently the end result of insufficient
lubricant.
SLIPS OUT OF GEAR
Transaxle disengagement may be caused by mis-
aligned or damaged shift components, or worn teeth
on the drive gears or synchronizer components. Incor-
rect assembly also causes gear disengagement. Check
for missing snap rings.
LOW LUBRICANT LEVEL
Insufficient transaxle lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method. Leakage is evident by the presence of oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill.
If air±powered lubrication equipment is used to fill
a transaxle, be sure the equipment is properly cali-
brated. Equipment out of calibration can lead to an
underfill condition.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash, and noise.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
REMOVAL
REMOVAL - 2.4L GAS
(1) Raise hood.
(2) Disconnect gearshift cables from shift levers/
cover assembly (Fig. 10).
(3) Remove gearshift cable retaining clips from
mounting bracket (Fig. 10). Remove cables and
secure out of way.
(4) Remove three (3) right engine mount bracket-
to-transaxle bolts (Fig. 11).
(5) Raise vehicle on hoist.
(6) Remove front wheel/tires and halfshafts.
(7) Drain transaxle fluid into suitable container.
(8) Remove cradle plate.
(9) Remove front harness retainer and secure har-
ness out of way.
(10) Remove clutch release access cover.
(11)RHD Models:Using Tool 6638A, disconnect
clutch hydraulic circuit quick connect (located on
slave cylinder tube). Remove clutch slave cylinder by
depressing towards case and rotating counter-clock-
wise 60É, while lifting anti-rotation tab out of case
slot with screwdriver (Fig. 12).LHD Models:
Remove clutch release cable by pulling outward on
cable housing, then forward to allow cable core to
pass through case slot (Fig. 13). Disengage T-end
from release lever and secure cable out of way.
(12) Remove engine left mount bracket.
(13) Remove starter motor (Fig. 14).
Fig. 10 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
RGT850 MANUAL TRANSAXLE21a-11
T850 MANUAL TRANSAXLE (Continued)

(14) Disconnect back-up lamp switch connector.
(15) Remove structural collar.
(16) Remove modular clutch assembly-to-drive
plate bolts.
(17) Position screw jack and wood block to engine
oil pan.
(18) Remove transmission upper mount through-
bolt from left frame rail.
(19) Lower engine/transaxle assembly on screw
jack.
(20) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 15).
(21) Obtain helper and transmission jack. Secure
transaxle to transmission jack and remove transaxle-
to-engine bolts.
(22) Remove transaxle from engine.
(23) Inspect modular clutch assembly, clutch
release components, and engine drive plate.
Fig. 11 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 12 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 13 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
21a - 12 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)

(11) Raise vehicle on hoist.
(12) Remove front wheel/tires and halfshafts.
(13) Remove underbody splash shield.
(14) Drain transaxle fluid into suitable container.
(15) Remove cradle plate.
(16) Remove front harness retainer and secure
harness out of way.
(17) Remove clutch release access cover.
(18)RHD Models:Using Tool 6638A, disconnect
clutch hydraulic circuit quick connect (located on
slave cylinder tube). Remove clutch slave cylinder by
depressing towards case and rotating counter-clock-
wise 60É, while lifting anti-rotation tab out of case
slot with screwdriver (Fig. 22).LHD Models:
Remove clutch release cable by pulling outward on
cable housing, then forward to allow cable core to
pass through case slot (Fig. 23). Disengage T-end
from release lever and secure cable out of way.
(19) Remove engine left mount bracket (Fig. 24).
(20) Remove starter motor (Fig. 25).
(21) Disconnect back-up lamp switch connector.
(22) Position screw jack and wood block to engine
oil pan.
(23) Remove transmission upper mount through-
bolt from left frame rail.
(24) Lower engine/transaxle assembly on screw
jack.(25) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 26).
(26) Obtain helper and transmission jack. Secure
transaxle to transmission jack and remove transaxle-
to-engine bolts.
(27) Remove transaxle from engine (Fig. 27).
(28) Inspect clutch, clutch release components, and
flywheel.
Fig. 22 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 23 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
Fig. 24 Left Mount Bracket Removal/Installation
1 - BOLT (2)
2 - MOUNT BRACKET
3 - BOLT (2)
RGT850 MANUAL TRANSAXLE21a-15
T850 MANUAL TRANSAXLE (Continued)

(21) Install battery thermal shield and clutch cable
eyelet (LHD only) (Fig. 99). Verify proper clutch cable
routing (LHD models). Cable should be routed over
guide, through eyelet, and around coolant bottle and
wiring harness.
(22) Connect battery cables.
(23) Check transaxle fluid and engine coolant lev-
els. Adjust if necessary. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/FLUID - STANDARD
PROCEDURE)
SPECIFICATIONS
SPECIFICATIONS - T850 MANUAL TRANSAXLE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Transaxle TypeConstant-mesh, fully synchronized 5-speed with integral
differential
Lubrication MethodSplash oil collected in case passage and oil trough and
distributed to mainshafts via gravity
Fluid Type ATF+4 (Automatic Transmission FluidÐType 9602)
GEAR RATIOS
GEAR RATIO (2.4L Gas) RATIO (2.5L TD)
1st 3.65 3.46
2nd 2.07 2.05
3rd 1.39 1.37
4th 1.03 0.97
5th 0.83 0.76
Reverse 3.47 3.47
Final Drive Ratio 3.77 3.53
Overall Top Gear 3.12 2.66
Fig. 99 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
RGT850 MANUAL TRANSAXLE21a-37
T850 MANUAL TRANSAXLE (Continued)

LUBRICANT USAGE
COMPONENT SERVICE INTERVAL LUBRICANT
Door Hinges - Hinge Pin and Pivot
Contact AreasAs Required Engine Oil
Hood Hingers - Pivot Points As Required Engine Oil
Lifgate Hinges As Required Engine Oil
Door Check Straps As Required Spray white lube (3)
Door Latches As Required Multi-Purpose Grease (Water
Resistant) (1)
Lifgate Latches As Required Spray white lube (3)
Lifgate Prop Pivots As Required Spray white lube (3)
Ash Receiver As Required Spray white lube (3)
Fuel Filler Door Remote Control
Latch MechanismAs Required Spray white lube (3)
Parking Brake Mechanism As Required Spray white lube (3)
Sliding Seat Tracks As Required Spray white lube (3)
All Other Hood Mechanisms As Required Multipurpose Grease (2)
Door Lock Cylinders As Required Lock Cylinder Lubricant (4)
Lifgate Lock Cylinder As Required Lock Cylinder Lubricant (4)
Sliding Door Upper Track As Required Multi-Purpose Grease NLGI Grade
2 EP (2)
Sliding Door Center Track Leading
EdgeAs Required Multi-Purpose Grease NLGI Grade
2 EP (2)
Sliding Door Lower Track Leading
EdgeAs Required Multi-Purpose Grease NLGI Grade
2 EP (2)
Window System Components
(Regulators, tracks, links, channel
areas Ð except glass run
weatherstrips and felt lubricator, if
equipped.)As Required Spray white lube (3)
1 MOPARž Wheel Bearing Grease (High Temperature)
2 MOPARž Multi-Mileage Lubricant or equivalent
3 MOPARž Spray white lube or equivalent
4 MOPARž Lock Cylinder Lubricant or equivalent
23 - 10 BODYRS
BODY (Continued)