2002 CHRYSLER CARAVAN shaft

(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)
ProCarManuals.com

(12) Remove low/reverse accumulator plug (Fig.
26).
(13) Remove low/reverse accumulator piston using
petrolatum and a suitable tool (Fig. 27).
(14) Remove low/reverse accumulator (Fig. 28).
(15) Measure input shaft end play. Place transaxle
so input shaft is vertical. Set up end play set and
dial indicator as shown in (Fig. 29).Input shaft end
play should be within 0.13-0.64 mm (0.005-0.025
in.)If outside of this range, a #4 thrust plate change
is required. Record indicator reading for referenceupon reassembly.
Fig. 26 Remove Low/Reverse Accumulator Plug
(Cover)
1 - ADJUSTABLE PLIERS
2 - PLUG
Fig. 27 Remove Low/Reverse Accumulator Piston
1 - SEAL RINGS
2 - PISTON
3 - PISTON
4 - PETROLATUM
5 - SUITABLE TOOL
Fig. 28 Remove Low/Reverse Accumulator
1 - ACCUMULATOR PISTON
2 - SEAL RINGS
3 - RETURN SPRINGS
4 - (NOTE NOTCH)
Fig. 29 Measure Input Shaft End Play Using End
Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
RS41TE AUTOMATIC TRANSAXLE21 - 175
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(16) Remove oil pump-to-case bolts (Fig. 30).
CAUTION: Be sure input speed sensor is removed
before removing oil pump.
(17) Install pullers Tool C-3752 as shown in (Fig.
31).(18) Remove oil pump assembly (Fig. 32) (Fig. 33).
Fig. 33 Oil Pump Removed
1 - OIL PUMP
2 - GASKET
Fig. 30 Remove Pump Attaching Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 31 Install Tool C-3752
1 - PULLERS TOOL C-3752
2 - PUMP
Fig. 32 Remove Oil Pump
1 - ªPUSH INº ON INPUT SHAFT WHILE REMOVING PUMP
21 - 176 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(23) Remove #4 thrust plate (Fig. 38).
(24) Remove front sun gear assembly and #4
thrust washer (Fig. 39).(25) Remove front carrier/rear annulus assembly
and #6 needle bearing (Fig. 40).
(26) Remove rear sun gear and #7 needle bearing
(Fig. 41).
NOTE: The number 7 needle bearing has three anti-
reversal tabs and is common with the number five
and number two position. The orientation should
allow the bearing to seat flat against the rear sun
gear (Fig. 42). A small amount of petrolatum can be
used to hold the bearing to the rear sun gear.
Fig. 38 No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 39 Remove Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
Fig. 40 Remove 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. 41 Remove Rear Sun Gear
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
21 - 178 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(38) Using Tool 6259, remove transfer shaft gear-
to-shaft nut and coned washer (Fig. 54) (Fig. 55).(39) Using tool L-4407A, remove transfer shaft
gear (Fig. 56).
(40) Remove transfer gear shim (select) (Fig. 57).
Fig. 54 Remove Transfer Shaft Gear Nut
1 - TRANSFER SHAFT GEAR
2 - OUTPUT GEAR
3 - SPECIAL TOOL 6259
Fig. 55 Transfer Shaft Gear Nut and Coned Washer
1 - TRANSFER SHAFT
2 - LOCK WASHER
3 - NUT
Fig. 56 Remove Transfer Shaft Gear
1 - SPECIAL TOOL L4407-6
2 - TRANSFER SHAFT GEAR
3 - SPECIAL TOOL L4407A
Fig. 57 Remove Transfer Shaft Gear and (Select)
Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM (SELECT)
21 - 182 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(41) Remove bearing cup retainer (Fig. 58).
(42) Remove transfer gear bearing cone using
setup shown in (Fig. 59).(43) Remove transfer shaft bearing cup from
retainer using Tool 6062 (Fig. 60).
(44) Using Tool 6051, remove transfer shaft bear-
ing snap ring (Fig. 61).
Fig. 58 Remove Bearing Cup Retainer
1 - ALIGN INDEXING TAB TO SLOT
2 - BEARING CUP RETAINER
Fig. 59 Remove Transfer Gear Bearing Cone
1 - WRENCHES
2 - TOOL 5048 WITH JAWS TOOL 5048±4 AND BUTTON TOOL
L-4539±2
3 - TRANSFER SHAFT GEAR
Fig. 60 Remove Transfer Shaft Bearing Cup
1 - WRENCHES
2 - TOOL 6062
3 - TRANSFER SHAFT BEARING CUP RETAINER
Fig. 61 Remove Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS TOOL 6051
2 - TRANSFER SHAFT BEARING SNAP RING
3 - TRANSFER SHAFT
RS41TE AUTOMATIC TRANSAXLE21 - 183
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(45) Using tool 5049A, remove transfer shaft from
transaxle (Fig. 62).
(46) Slip bearing cup retainer and oil baffle off of
shaft (Fig. 63).(47) Using tool P-334, press transfer shaft bearing
cone off of shaft (Fig. 64).
(48) Bend output gear retaining strap ears flat to
allow bolt removal.
(49) Remove output shaft stirrup strap bolts (Fig.
65).
Fig. 62 Remove Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
Fig. 63 Bearing Cup Removed
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
Fig. 64 Remove Transfer Shaft Bearing Cone
1 - ARBOR PRESS RAM
2 - TRANSFER SHAFT
3 - TOOL P-334
4 - BEARING CONE
Fig. 65 Remove Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
21 - 184 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(50) Remove stirrup and strap (Fig. 66).
(51) Using Tool 6259 (Fig. 67), remove output shaft
gear-to-shaft bolt and washer (Fig. 68).(52) Using Tool L4407A, and button 6055, remove
output gear from shaft (Fig. 69).
Fig. 66 Remove Stirrup Strap
1 - OUTPUT GEARBOLT
2 - RETAINING STRAP
3 - STIRRUP
Fig. 67 Remove Output Gear Bolt
1 - OUTPUT GEAR
2 - TOOL 6259
Fig. 68 Output Gear Bolt and Washer
1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
Fig. 69 Remove Output Gear
1 - OUTPUT GEAR
2 - BUTTON TOOL 6055
3 - WRENCHES
4 - TOOL L4407A
5 - BOLTS TOOL L4407±6
RS41TE AUTOMATIC TRANSAXLE21 - 185
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com