2002 CHRYSLER CARAVAN oil pressure

41TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
41TE AUTOMATIC TRANSAXLE
DESCRIPTION........................162
OPERATION..........................164
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - 41TE
TRANSAXLE GENERAL DIAGNOSIS......164
DIAGNOSIS AND TESTING - ROAD TEST . . 165
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS...................165
DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS...................168
DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE . . 168
REMOVAL............................169
DISASSEMBLY........................171
ASSEMBLY...........................190
INSTALLATION........................213
SCHEMATICS AND DIAGRAMS
41TE TRANSAXLE HYDRAULIC
SCHEMATICS.......................216
SPECIFICATIONS - 41TE TRANSAXLE......228
SPECIAL TOOLS
41TE AUTOMATIC TRANSAXLE.........230
ACCUMULATOR
DESCRIPTION........................236
OPERATION..........................236
AUTOSTICK SWITCH
DESCRIPTION........................237
OPERATION..........................237
DRIVING CLUTCHES
DESCRIPTION........................237
OPERATION..........................238
FINAL DRIVE
DISASSEMBLY........................238
ASSEMBLY...........................243
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL BEARING
PRELOAD..........................246
FLUID
STANDARD PROCEDURE
FLUID LEVEL AND CONDITION CHECK . . . 249
STANDARD PROCEDURE - FLUID AND
FILTER SERVICE.....................250
GEAR SHIFT CABLE
REMOVAL............................251
INSTALLATION........................253
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT.......254
HOLDING CLUTCHES
DESCRIPTION........................255OPERATION..........................255
INPUT CLUTCH ASSEMBLY
DISASSEMBLY........................255
ASSEMBLY...........................263
OIL PUMP
DESCRIPTION........................272
OPERATION..........................272
STANDARD PROCEDURE - OIL PUMP
VOLUME CHECK.....................272
DISASSEMBLY........................273
ASSEMBLY...........................274
PLANETARY GEARTRAIN
DESCRIPTION........................274
OPERATION..........................274
SEAL - OIL PUMP
REMOVAL............................275
INSTALLATION........................275
SHIFT INTERLOCK SOLENOID
DESCRIPTION........................275
OPERATION..........................276
DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK
SOLENOID..........................277
REMOVAL............................277
INSTALLATION........................278
SOLENOID/PRESSURE SWITCH ASSY
DESCRIPTION........................279
OPERATION..........................280
REMOVAL............................280
INSTALLATION........................281
SPEED SENSOR - INPUT
DESCRIPTION........................281
OPERATION..........................282
REMOVAL............................282
INSTALLATION........................283
SPEED SENSOR - OUTPUT
DESCRIPTION........................283
OPERATION..........................283
REMOVAL............................284
INSTALLATION........................284
TORQUE CONVERTER
DESCRIPTION........................285
OPERATION..........................289
REMOVAL............................290
INSTALLATION........................290
TRANSMISSION CONTROL RELAY
DESCRIPTION........................291
OPERATION..........................291
TRANSMISSION RANGE SENSOR
DESCRIPTION........................291
RS41TE AUTOMATIC TRANSAXLE21 - 161
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OPERATION..........................292
REMOVAL............................292
INSTALLATION........................292
TRD LINK
DESCRIPTION........................292
OPERATION..........................292
VALVE BODY
DESCRIPTION........................293OPERATION..........................293
REMOVAL
REMOVAL..........................294
REMOVAL..........................296
DISASSEMBLY........................297
ASSEMBLY...........................301
INSTALLATION........................306
41TE AUTOMATIC
TRANSAXLE
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 pump²Valve 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.
21 - 162 41TE AUTOMATIC TRANSAXLERS
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DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS
Inoperative clutches can be located using a series
of tests by substituting air pressure for fluid pressure
(Fig. 5) (Fig. 6). The clutches may be tested by apply-
ing air pressure to their respective passages. The
valve body must be removed and Tool 6056 installed.
To make air pressure tests, proceed as follows:
NOTE: The compressed air supply must be free of
all dirt and moisture. Use a pressure of 30 psi.
Remove oil pan and valve body. See Valve body
removal.
OVERDRIVE CLUTCH
Apply air pressure to the overdrive clutch apply
passage and watch for the push/pull piston to move
forward. The piston should return to its starting
position when the air pressure is removed.
REVERSE CLUTCH
Apply air pressure to the reverse clutch apply pas-
sage and watch for the push/pull piston to move rear-
ward. The piston should return to its starting
position when the air pressure is removed.
2/4 CLUTCH
Apply air pressure to the feed hole located on the
2/4 clutch retainer. Look in the area where the 2/4
piston contacts the first separator plate and watch
carefully for the 2/4 piston to move rearward. The
piston should return to its original position after the
air pressure is removed.
LOW/REVERSE CLUTCH
Apply air pressure to the low/reverse clutch feed
hole (rear of case, between 2 bolt holes). Then, look
in the area where the low/reverse piston contacts the
first separator plate. Watch carefully for the piston to
move forward. The piston should return to its origi-
nal position after the air pressure is removed.
UNDERDRIVE CLUTCH
Because this clutch piston cannot be seen, its oper-
ation is checked by function. Air pressure is applied
to the low/reverse and the 2/4 clutches. This locks the
output shaft. Use a piece of rubber hose wrapped
around the input shaft and a pair of clamp-on pliers
to turn the input shaft. Next apply air pressure to
the underdrive clutch. The input shaft should not
rotate with hand torque. Release the air pressure
and confirm that the input shaft will rotate.
DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE
When diagnosing converter housing fluid leaks,
three actions must be taken before repair:
(1) Verify proper transmission fluid level.
(2) Verify that the leak originates from the con-
verter housing area and is transmission fluid.
(3) Determine the true source of the leak.
Fluid leakage at or around the torque converter
area may originate from an engine oil leak (Fig. 7).
The area should be examined closely. Factory fill
fluid is red and, therefore, can be distinguished from
engine oil.
Some suspected converter housing fluid leaks may
not be leaks at all. They may only be the result of
residual fluid in the converter housing, or excess
fluid spilled during factory fill, or fill after repair.
Fig. 5 Air Pressure Test Plate
1 - TOOL 6056
2 - ACCUMULATORS
Fig. 6 Testing Reverse Clutch
1 - TOOL 6056
2 - AIR NOZZLE
21 - 168 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(3) Remove coolant recovery bottle (Fig. 10).
(4) Remove fluid level indicator/tube assembly.
Plug opening to prevent debris from entering trans-
axle.
(5) Using a blade or suitable hose cutter, cut trans-
axle oil cooler lines off flush with fittings. Plug lines
and fittings to prevent debris from entering transaxle
or cooler circuit. A service splice kit will be installed
upon reassembly.
(6) Disconnect input and output shaft speed sensor
connectors (Fig. 11).
(7) Disconnect transmission range sensor (TRS)
connector (Fig. 11).
(8) Disconnect solenoid/pressure switch assembly
connector (Fig. 11).
(9) Disconnect gear shift cable from manual valve
lever and upper mount bracket (Fig. 12).
(10) Disconnect crankshaft position sensor (if
equipped). Remove sensor from bellhousing.
(11) Reposition leak detection pump harness and
hoses.
(12) Remove rear mount bracket-to-transaxle case
bolts (Fig. 13).
(13) Remove transaxle upper bellhousing-to-block
bolts.
(14) Raise vehicle on hoist.
(15) Remove transaxle oil pan and drain fluid into
suitable container.
(16) Remove front wheel/tire assemblies.
(17) Remove left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - REMOVAL)
Fig. 10 Coolant Recovery Bottle
1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL
Fig. 11 Component Connector LocationÐTypical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 12 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 170 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(18) AWD models: Remove power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - REMOVAL)
(19) Remove rear mount bracket-to-transaxle case
lower (horizontal) bolt (Fig. 13).
(20) Remove front mount/bracket assembly.
(21) Remove starter motor.
(22) Remove lateral bending brace.
(23) Remove inspection cover.
(24) Remove torque converter-to-drive plate bolts.
(25) Support engine/transaxle assembly at engine
oil pan with screw jack and wood block.
(26) Partially remove left wheelhouse splash shield
to gain access to and remove upper mount thru-bolt
(Fig. 14).
(27) Lower engine/transaxle assembly with screw
jack.
(28) Obtain helper and/or transmission jack.
Secure transmission jack to transaxle assembly.
(29) Remove upper mount bracket from transaxle
(Fig. 14).
(30) Remove remaining transaxle bellhousing-to-
engine bolts.
(31) Remove transaxle assembly from vehicle.DISASSEMBLY
CAUTION: If transaxle failure has occurred, it is
necessary to flush the transaxle oil cooler and lines
to remove debris and particles that could contami-
nate and/or fail a new or rebuilt unit. (Refer to 7 -
COOLING/TRANSMISSION - STANDARD PROCE-
DURE)
NOTE: If transaxle is being overhauled (clutch
and/or seal replacement) or replaced, it is neces-
sary to perform the TCM Quick Learn Procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
NOTE: This procedure does not include final drive
(differential) disassembly.
(1) Remove input and output speed sensors.
(2) Remove three (3) solenoid/pressure switch
assembly-to-case bolts.
Fig. 13 Rear Mount Bracket - Typical
1 - BOLT - VERTICAL
2 - BRACKET - REAR MOUNT3 - BOLT - HORIZONTAL
RS41TE AUTOMATIC TRANSAXLE21 - 171
41TE AUTOMATIC TRANSAXLE (Continued)
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(3) Remove solenoid/pressure switch assembly and
gasket (Fig. 15).(4) Remove oil pan-to-case bolts (Fig. 16).
(5) Remove oil pan (Fig. 17).
Fig. 14 Left Mount-to-Bracket
1 - BOLT - BRACKET TO FRAME RAIL
2 - BOLT - MOUNT TO RAIL THROUGH
3 - BOLT - LEFT MOUNT TO TRANSAXLE
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
Fig. 15 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 16 Remove Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 17 Remove Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPARTATF RTV (MS-GF41)
3 - OIL FILTER
21 - 172 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(64) Install and torque valve body-to-case bolts to
12 N´m (105 in. lbs.) (Fig. 159).
(65) Install oil filter and new o-ring (Fig. 160).(66) Apply an 1/8º bead of MopartATF RTV (MS-
GF41) to oil pan and immediately install to case (Fig.
161).
(67) Install oil pan-to-case bolts and torque to 19
N´m (165 in. lbs.).
(68) Install solenoid/pressure switch assembly and
gasket to case (Fig. 162).
Fig. 159 Install Valve Body-to-Case Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 160 Install Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 161 Install Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPARTATF RTV (MS-GF41)
3 - OIL FILTER
Fig. 162 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
21 - 212 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(20) Connect solenoid/pressure switch assembly
(Fig. 167).
(21) Connect transmission range sensor connector
(Fig. 167).
(22) Connect input and output speed sensor con-
nectors (Fig. 167).(23) Remove plugs and install transaxle oil cooler
line service splice kit. Refer to instructions included
with kit.
(24) Remove plug and Install fluid level indicator/
tube assembly.
(25) Install coolant recovery bottle (Fig. 168).
(26) Install battery shield.
(27) Connect battery cables.
(28) Fill transaxle with suitable amount of ATF+4
(Automatic Transmission FluidÐType 9602). (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE/FLUID - STANDARD PROCEDURE)
Fig. 167 Component Connector Location - Typical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 168 Coolant Recovery Bottle
1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL
RS41TE AUTOMATIC TRANSAXLE21 - 215
41TE AUTOMATIC TRANSAXLE (Continued)
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