2002 CHRYSLER CARAVAN tow

(2) Gently tap on end cover ears to separate cover
from case (Fig. 31).
(3) Use special tool No. 6514 and remove the dif-
ferential bearing race located in the end cover (Fig.
32). The race must be removed to gain access to the
seal.(4) Use special tool No. 7794-A to remove seal (Fig.
33).
INSTALLATION
The power transfer unit input shaft cover seal is
the larger of the two seals located on the inside of
the end cover. The differential bearing cup must be
removed to service this seal.
(1) Clean and inspect seal area.
(2) Use special tool No. MD998803 and install seal
(Fig. 34). When installing seal the spring side of the
seal must face toward the special tool.
Fig. 31 End Cover Removal
1 - END COVER EARS
2 - HAMMER
3 - POWER TRANSFER UNIT
Fig. 32 Bearing Race Removal
1 - END COVER
2 - SPECIAL TOOL
No. 6514
Fig. 33 Seal Removal
1 - END COVER
2 - SPECIAL TOOL 7794±A
3 - SLIDE HAMMER
4 - SOFT JAW VICE
Fig. 34 Seal Installation
1 - SPECIAL TOOL No. MD998803
2 - HAMMER
3 - END COVER
21 - 14 POWER TRANSFER UNITRS
INPUT SHAFT COVER SEAL (Continued)
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INSTALLATION
The Power Transfer Unit must be removed from
the vehicle to service this seal. Refer to Power Trans-
fer Unit Removal in this section for procedures.
(1) Clean and inspect seal area.
(2) Lay housing on bench and install new seal with
seal driver C-4657 and handle C-4171 (Fig. 47). The
seal must be installed with the spring side facing
towards the ring gear. Drive the seal in until it bot-
toms against the case shoulder.
(3) Install input shaft.(4) Install oil trough.
Fig. 44 Oil Trough
1 - OIL TROUGH
2 - POWER TRANSFER UNIT
Fig. 45 Input Shaft and Ring Gear Removal
1 - POWER TRANSFER UNIT
2 - RING GEAR
Fig. 46 Seal Removal
1 - POWER TRANSFER UNIT
2 - SPECIAL TOOL 7794±A
Fig. 47 Seal Installation
1 - HAMMER
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL C-4657
4 - POWER TRANSFER UNIT
21 - 18 POWER TRANSFER UNITRS
INPUT SHAFT SEAL (Continued)
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(3) Remove kickdown piston return spring and pis-
ton (Fig. 199).
(4) Disassemble piston assembly as shown in (Fig.
200).CLEANING
Clean the servo piston components (Fig. 201) with
solvent and dry them with compressed air. Wipe the
band clean with lint free shop towels.
Replace the front band if distorted, lining is
burned, flaking off, or worn to the point where the
grooves in the lining material are no longer visible.
Replace any servo component if doubt exists about
condition. Do not reuse suspect parts.
Fig. 199 Kickdown Piston Return Spring and Piston
1 - RETURN SPRING
2 - KICKDOWN LEVER
3 - PISTON ROD
4 - KICKDOWN SERVO PISTON
Fig. 200 Controlled Load Kickdown Servo
1 - KICKDOWN PISTON
2 - O-RING
3 - SNAP RING
4 - PISTON ROD GUIDE
5 - SNAP RING
6 - O-RING
7 - PISTON RETURN SPRING
8 - PISTON ROD
9 - SEAL RINGS
Fig. 201 Front Servo Piston
1 - PISTON RINGS
2 - O-RING
3 - SNAP-RING
4 - SEAL RING
5 - PISTON ROD GUIDE
6 - SNAP-RING
7 - SERVO SPRING
8 - PISTON ROD
9 - SERVO PISTON
21 - 112 31TH AUTOMATIC TRANSAXLERS
SERVO - KICKDOWN (Continued)
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OPERATION
The converter impeller (Fig. 235) (driving member),
which is integral to the converter housing and bolted
to the engine drive plate, rotates at engine speed.
The converter turbine (driven member), which reacts
from fluid pressure generated by the impeller, rotates
and turns the transmission input shaft.
TURBINE
As the fluid that was put into motion by the impel-
ler blades strikes the blades of the turbine, some of
the energy and rotational force is transferred into the
turbine and the input shaft. This causes both of them
(turbine and input shaft) to rotate in a clockwise
direction following the impeller. As the fluid is leav-
ing the trailing edges of the turbine's blades it con-
tinues in a ªhinderingº direction back toward the
impeller. If the fluid is not redirected before it strikes
the impeller, it will strike the impeller in such a
direction that it would tend to slow it down.
Fig. 235 Torque Converter Fluid Operation
1 - APPLY PRESSURE 3 - RELEASE PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD
21 - 126 31TH AUTOMATIC TRANSAXLERS
TORQUE CONVERTER (Continued)
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(12) Remove shift/shuttle valves and springs as
shown in (Fig. 320).
CLEANING
Clean the valve body components in a parts clean-
ing solution only. Do not use gasoline, kerosene, or
any type of caustic solution. Dry the parts with com-
pressed air. Make sure all passages are clean and
free from obstructions.
NOTE: Do not use rags or shop towels to wipe off
valve body components. Lint from these materials
will adhere to the valve body components. Lint will
interfere with valve operation and may clog filters
and fluid passages.
Minor distortion of a valve body mating surface
may be corrected by smoothing the surface with cro-
cus cloth. The cloth should be in sheet form and bepositioned on a surface plate, sheet of plate glass, or
equally flat surface. However, if distortion is severe
or any surfaces are heavily scored, the valve body
will have to be replaced.
CAUTION: Many of the valve body valves and plugs
are made of coated aluminum. Aluminum compo-
nents can be identified by the dark color of the spe-
cial coating applied to the surface (or by testing
with a magnet). DO NOT polish or sand aluminum
valves or plugs with any type of material, or under
any circumstances. This practice might damage the
special coating and cause the valves and plugs to
stick and bind.
Aluminum valves and plugs should not be sanded
or polished under any circumstances. However, minor
burrs or scratches on steel valves and plugs can be
removed with crocus cloth but do not round off the
Fig. 320 Shift Valves and Shuttle Valve
1 - SHUTTLE VALVE E-CLIP 9 - BY-PASS VALVE SPRING
2 - SHUTTLE VALVE SECONDARY SPRING 10 - 1±2 SHIFT VALVE SPRING
3 - SHUTTLE VALVE 11 - 1±2 SHIFT VALVE
4 - 2±3 SHIFT VALVE 12 - BY-PASS VALVE
5 - SHUTTLE VALVE PRIMARY SPRING 13 - TORQUE CONVERTER CLUTCH SOLENOID
6 - 2±3 SHIFT VALVE SPRING 14 - VALVE BODY
7 - SHUTTLE VALVE PLUG 15 - SPRING GUIDES (2)
8 - SCREWS
21 - 154 31TH AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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(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.
(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).
Fig. 147 Install Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
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
RS41TE AUTOMATIC TRANSAXLE21 - 209
41TE AUTOMATIC TRANSAXLE (Continued)
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(19) Take average of four measurements and com-
pare with UD clutch pack clearance specification.
Underdrive clutch pack clearance must be 0.94-
1.50 mm (0.037-0.059 in.).
(20) If necessary, select the proper reaction plate
to achieve specifications:
UNDERDRIVE REACTION PLATE THICKNESS
4659939AB 5.837-5.937 mm (0.230-0.234 in.)
4659940AB 6.147-6.248 mm (0.242-0.246 in.)
4659941AB 6.457-6.557 mm (0.254-0.258 in.)
(21) Install the OD clutch pack (four frictions/three
steels) (Fig. 275).
(22) Install OD pressure plate waved snap ring
(Fig. 276).
(23) Install the OD/Reverse pressure plate with
large step down (towards OD clutch pack) (Fig. 277).
Fig. 274 Press Down on UD Clutch Pack and Zero
Dial Indicator
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
Fig. 275 Install OD Clutch Pack
1 - OVERDRIVE CLUTCH PACK
Fig. 276 Install Waved Snap Ring
1 - OVERDRIVE PRESSURE PLATE WAVED SNAP RING
2 - SCREWDRIVER
Fig. 277 OD/Reverse Pressure Plate
1 - OVERDRIVE/REVERSE PRESSURE PLATE
2 - (STEP SIDE DOWN)
21 - 268 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)
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(24) Install OD pressure plate flat snap ring (Fig.
278).
(25) Measure OD clutch pack clearance. Set up
dial indicator on top of the OD/Reverse pressure
plate as shown in (Fig. 279).(26) Zero dial indicator and apply 30 psi (206 kPa)
air pressure to the overdrive clutch hose on Tool
8391. Measure and record OD clutch pack measure-
ment in four (4) places, 90É apart.
(27) Take average of four measurements and com-
pare with OD clutch pack clearance specification.
The overdrive (OD) clutch pack clearance is
1.07-3.25 mm (0.042-0.128 in.).
If not within specifications, the clutch is not
assembled properly. There is no adjustment for the
OD clutch clearance.
(28) Install reverse clutch pack (two frictions/one
steel) (Fig. 280).
(29) Install reverse clutch reaction plate with the
flat side down towards reverse clutch (Fig. 281).
Fig. 278 Install Flat Snap Ring
1 - ARBOR PRESS RAM
2 - TOOL 5059A
3 - FLAT SNAP RING
Fig. 279 Measure OD Clutch Pack Clearance
1 - DIAL INDICATOR
2 - OD/REVERSE REACTION PLATE
Fig. 280 Install Reverse Clutch Pack
1 - REVERSE CLUTCH PLATE
2 - REVERSE CLUTCH DISCS
Fig. 281 Install Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)
RS41TE AUTOMATIC TRANSAXLE21 - 269
INPUT CLUTCH ASSEMBLY (Continued)
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