Page 1697 of 2321

(42) Install tapered snap ring (with tapered side
out) as shown in (Fig. 130) (Fig. 131).
(43) Set up dial indicator as shown in (Fig. 132) to
measure low/reverse clutch clearance. Press down on
clutch pack with finger and zero dial indicator. Low/
Reverse clutch pack clearance is 0.89-1.47 mm
(0.035-0.058 in.). Select the proper low/reverse reac-
tion plate to achieve specifications:
LOW/REVERSE REACTION PLATE CHART
PART NUMBER THICKNESS
4799846AA 5.88 mm (0.232 in.)
4799847AA 6.14 mm (0.242 in.)
4799848AA 6.40 mm (0.252 in.)
4799849AA 6.66 mm (0.262 in.)
4799855AA 6.92 mm (0.273 in.)
(44) Install 2/4 clutch pack (Fig. 133), staggering
clutch plate pads as shown in (Fig. 134).
Fig. 130 Tapered Snap Ring Instructions
Fig. 131 Snap Ring Installed
1 - SCREWDRIVER
2 - TAPERED SNAP RING (INSTALL AS SHOWN)
Fig. 132 Check Low/Reverse Clutch Clearance
1 - DIAL INDICATOR
2 - DIAL INDICATOR TIP TOOL 6268
3 - HOOK TOOL
Fig. 133 Install 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
21 - 200 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)
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Page 1698 of 2321
(45) Orient 2/4 clutch return spring to retainer as
shown in (Fig. 135), and install to transaxle (Fig.
136).(46) Using tool 5058, compress 2/4 clutch return
spring just enough to install snap ring (Fig. 137).
(47) Install snap ring.
Fig. 134 Stagger 2/4 Clutch Plate Pads
1 - PILOT PADS
2 - LUGS
Fig. 135 Proper Orientation of 2/4 Clutch Retainer
and Spring
1 - NOTE POSITION
2 - RETURN SPRING
3 - 2/4 CLUTCH RETAINER
Fig. 136 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 137 Install 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
RSAUTOMATIC - 41TE21 - 201
AUTOMATIC - 41TE (Continued)
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Page 1699 of 2321

(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)
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Page 1700 of 2321

(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)
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Page 1701 of 2321

NO. 4 THRUST PLATE CHART
PART NUMBER THICKNESS
4431662 0.91mm (0.036 in.)
4431663 1.14mm (0.045 in.)
4431664 1.37mm (0.054 in.)
4431665 1.60mm (0.063 in.)
3836237 1.73mm (0.068 in.)
4431666 1.80mm (0.071 in.)
3836238 1.96mm (0.077 in.)
4431667 2.03mm (0.080 in.)
3836239 2.16mm (0.085 in.)
4431668 2.24mm (0.088 in.)
3836240 2.39mm (0.094 in.)
4431669 2.46mm (0.097 in.)
3836241 2.62mm (0.103 in.)
4446670 2.67mm (0.105 in.)
4446671 2.90mm (0.114 in.)
4446672 3.15mm (0.124 in.)
4446601 3.38mm (0.133 in.)(53) Install input clutch assembly (Fig. 146).
(54) Install #1 caged needle bearing (Fig. 147).
CAUTION: The cooler bypass valve must be
replaced if transaxle failure has occurred. Do not
attempt to reuse or clean old valve.
Fig. 145 Measure Input Shaft End Play Using End
Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
Fig. 146 Install Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 147 Install Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
21 - 204 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)
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Page 1702 of 2321
(55) Install cooler bypass valve with o-ring end
towards rear of case (Fig. 148).
(56) Install oil pump gasket (Fig. 149).(57) Install oil pump assembly (Fig. 150).
(58) Install oil pump-to-case bolts and torque to 27
N´m (20 ft. lbs.) (Fig. 151).
Fig. 148 Install Cooler Bypass Valve
1 - COOLER BYPASS VALVE
Fig. 149 Install Oil Pump Gasket
1 - PUMP GASKET
Fig. 150 Install Oil Pump
1 - OIL PUMP
2 - GASKET
Fig. 151 Install Pump-to-Case Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
RSAUTOMATIC - 41TE21 - 205
AUTOMATIC - 41TE (Continued)
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(59) Install low/reverse accumulator (Fig. 152).
(60) Install low/reverse accumulator plug (Fig.
153).(61) Install low/reverse accumulator snap ring
(Fig. 154).
NOTE: Depending on engine application, some
accumulators will have two springs, and others will
have one spring. The springs are color-coded for
application and year.
(62) Install underdrive and overdrive accumulators
(Fig. 155) (Fig. 156) (Fig. 157).
Fig. 152 Install Low/Reverse Accumulator
1 - ACCUMULATOR PISTON
2 - SEAL RINGS
3 - RETURN SPRINGS
4 - (NOTE NOTCH)
Fig. 153 Install Low/Reverse Accumulator Plug
(Cover)
1 - ADJUSTABLE PLIERS
2 - PLUG
Fig. 154 Install Low/Reverse Accumulator Snap
Ring
1 - SNAP RING
2 - PLUG
Fig. 155 Accumulator (Underdrive)
1 - ACCUMULATOR PISTON (UNDERDRIVE)
2 - RETURN SPRINGS
3 - SEAL RING
4 - SEAL RING
21 - 206 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)
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Page 1704 of 2321
(63) Install valve body to transaxle (Fig. 158).
Rotate manual valve shaft fully clockwise to ease
installation. Make sure park rod rollers are posi-
tioned within park guide bracket.
(64) Install and torque valve body-to-case bolts to
12 N´m (105 in. lbs.) (Fig. 159).
Fig. 156 Accumulator (Overdrive)
1 - ACCUMULATOR PISTON (OVERDRIVE)
2 - RETURN SPRING
3 - SEAL RING
4 - SEAL RING
Fig. 157 Install Underdrive and Overdrive
Accumulators
1 - RETURN SPRING
2 - UNDERDRIVE CLUTCH ACCUMULATOR
3 - SEAL RING (2)
4 - OVERDRIVE CLUTCH ACCUMULATOR
Fig. 158 Install Valve Body
1 - VALVE BODY
Fig. 159 Install Valve Body-to-Case Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
RSAUTOMATIC - 41TE21 - 207
AUTOMATIC - 41TE (Continued)
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