2002 CHRYSLER CARAVAN shaft

(14) Remove pinion shaft (Fig. 189).
(15) Remove pinion gears and tabbed washers
(Fig. 190).(16) Remove differential side gear (Fig. 191).
(17) Remove side gear thrust washer (Fig. 192).
(18) Inspect all components for excessive wear.
Fig. 189 Pinion Shaft Removal
1 - PINION SHAFT
Fig. 190 Pinion Gear and Washer Removal
1 - PINION GEAR
2 - TABBED WASHER
3 - LOCATING TAB
4 - NOTCH
Fig. 191 Side Gear Removal
1 - DIFFERENTIAL SIDE GEAR
Fig. 192 Side Gear Thrust Washer Removal
1 - THRUST WASHER
21 - 242 41TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)
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ASSEMBLY
NOTE: The differential is serviced as an assembly.
Differential service is limited to bearing cups and
cones. Any other differential component failure
must be remedied by differential assembly and
transfer shaft replacement.
(1) Install side gear thrust washer to differential
case (Fig. 193).
(2) Install side gear to differential case (Fig. 194).(3) Install both pinion gears and washers to case,
while orientating washer tabs to notch in case (Fig.
195).
(4) Install pinion shaft (Fig. 196).
Fig. 193 Thrust Washer Installation
1 - THRUST WASHER
Fig. 194 Side Gear Installation
1 - DIFFERENTIAL SIDE GEAR
Fig. 195 Pinion Gear and Washer Installation
1 - PINION GEAR
2 - TABBED WASHER
3 - LOCATING TAB
4 - NOTCH
Fig. 196 Pinion Shaft Installation
1 - PINION SHAFT
RS41TE AUTOMATIC TRANSAXLE21 - 243
FINAL DRIVE (Continued)
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(9) Install ring gear-to-case bolts, with pinion shaft
retainers (Fig. 201), and torque bolts to 95 N´m (70
ft. lbs.).
(10) Using Miller Special Tool L-4410, and C-4171,
install differential bearing to differential (extension
housing side) (Fig. 202).
(11) Using Miller Special Tool 5052 and C-4171,
install differential bearing to differential (bearing
retainer side).(12) Using Miller Special Tool 6061 and C-4171,
install differential bearing race to bearing retainer
(Fig. 203).
(13) Using Miller Special Tool L±4520 and C-4171,
install differential bearing to extension housing.
NOTE: Use MoparTSilicone Rubber Adhesive Seal-
ant, or equivalent, on retainer and extension hous-
ing/adapter plate to seal to case.
(14) Install differential assembly into transaxle
case. Install differential bearing retainer (Fig.
204)and torque retainer-to-case bolts (Fig. 205)to 28
N´m (21 ft. lbs.).
Fig. 201 Ring Gear-to-Case Bolts
1 - DIFFERENTIAL CASE
2 - PINION SHAFT RETAINER
3 - RING GEAR
4 - RING GEAR-TO-CASE BOLT
Fig. 202 Position Bearing Cone Onto DifferentialÐ
Typical
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL BEARING
Fig. 203 Differential Bearing Retainer
1 - DIFFERENTIAL BEARING CUP
2 - DIFFERENTIAL BEARING RETAINER
Fig. 204 Differential Bearing Retainer
1 - DIFFERENTIAL BEARING CUP
2 - DIFFERENTIAL BEARING RETAINER
RS41TE AUTOMATIC TRANSAXLE21 - 245
FINAL DRIVE (Continued)
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(15) Apply a bead of MopartSilicone Rubber
Adhesive Sealant to extension housing/adapter plate
and install into position. Install and torque bolts to
28 N´m (21 ft. lbs.).
(16)
Measure and adjust differential bearing preload.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/FINAL DRIVE - ADJUSTMENTS)
(17) Apply a bead of MopartSilicone Rubber
Adhesive Sealant to differential cover and install to
case (Fig. 206).
(18) Install and torque cover-to-case bolts to 19
N´m (165 in. lbs.) (Fig. 207).
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL BEARING
PRELOAD
NOTE: Perform all differential bearing preload mea-
surements with the transfer shaft and gear removed.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT
USING EXISTING SHIM
(1)Position the transaxle assembly vertically on the
support stand, differential bearing retainer side up.
(2) Install Tool L-4436A into the differential and
onto the pinion mate shaft (Fig. 208).
Fig. 205 Differential Retainer Bolts
1 - DIFFERENTIAL RETAINER BOLTS
Fig. 206 Install Differential Cover
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL COVER
Fig. 207 Differential Cover Bolts
1 - DIFFERENTIAL COVER BOLTS
2 - DIFFERENTIAL COVER
Fig. 208 Tool L-4436 and Torque Wrench
1 - SPECIAL TOOL L-4436±A
2 - TORQUE WRENCH
3 - DIFFERENTIAL BEARING RETAINER
21 - 246 41TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)
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HOLDING CLUTCHES
DESCRIPTION
Two hydraulically applied multi-disc clutches are
used to hold planetary geartrain components station-
ary while the input clutches drive others. The 2/4
and Low/Reverse clutches are considered holding
clutches and are contained at the rear of the trans-
axle case. (Fig. 225) .
OPERATION
NOTE: Refer to the ªElements In Useº chart in Diag-
nosis and Testing for a collective view of which
clutch elements are applied at each position of the
selector lever.
2/4 CLUTCH
The 2/4 clutch is hydraulically applied in second
and fourth gears by pressurized fluid against the 2/4
clutch piston. When the 2/4 clutch is applied, the
front sun gear assembly is held or grounded to the
transaxle case.
LOW/REVERSE CLUTCH
The Low/Reverse clutch is hydraulically applied in
park, reverse, neutral, and first gears by pressurized
fluid against the Low/Reverse clutch piston. When
the Low/Reverse clutch is applied, the front planet
carrier/rear annulus assembly is held or grounded to
the transaxle case.
INPUT CLUTCH ASSEMBLY
DISASSEMBLY
(1) Mount input clutch assembly to Input Clutch
Pressure Fixture (Tool 8391).
(2) Tap down reverse clutch reaction plate to
release pressure from snap ring (Fig. 226).
Fig. 225 2/4 and Low/Reverse Clutches
1 - FRONT PLANET CARRIER/REAR ANNULUS
2 - 2/4 CLUTCH
3 - L/R CLUTCH
4 - REAR PLANET CARRIER/FRONT ANNULUS
5 - REAR SUN GEAR
6 - FRONT SUN GEAR ASSEMBLY
Fig. 226 Tapping Reaction Plate
1 - #4 THRUST PLATE (SELECT)
2 - TAP DOWN REVERSE CLUTCH REACTION PLATE TO
REMOVE OR INSTALL SNAP RING
3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY
4 - REVERSE CLUTCH REACTION PLATE
RS41TE AUTOMATIC TRANSAXLE21 - 255
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(6) Remove the OD/Reverse pressure plate snap
ring (Fig. 231).
(7) Remove OD/Reverse pressure plate (Fig. 232).(8) Remove OD/Reverse pressure plate wave snap
ring (Fig. 233).
(9) Remove OD shaft/hub and OD clutch pack (Fig.
234) (Fig. 235).
NOTE: Tag overdrive clutch pack for reassembly
identification.
Fig. 231 OD/Reverse Pressure Plate Snap Ring
1 - OD/REVERSE PRESSURE PLATE
2 - SCREWDRIVER
3 - OD/REVERSE PRESSURE PLATE SNAP RING
Fig. 232 OD/Reverse Pressure Plate
1 - OD/REVERSE PRESSURE PLATE (STEP SIDE DOWN)
2 - (STEP SIDE DOWN)
Fig. 233 Waved Snap Ring
1 - OVERDRIVE SHAFT ASSEMBLY
2 - OD/REVERSE CLUTCH WAVED SNAP RING
3 - SCREWDRIVER
Fig. 234 Remove OD Clutch Pack
1 - OVERDRIVE SHAFT ASSEMBLY AND OD CLUTCH PACK
2 - #3 THRUST PLATE
3 - #3 THRUST WASHER
4 - UNDERDRIVE SHAFT ASSEMBLY
RS41TE AUTOMATIC TRANSAXLE21 - 257
INPUT CLUTCH ASSEMBLY (Continued)
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(10) Remove and inspect #3 & #4 thrust washers
(Fig. 236).(11) Remove the underdrive shaft assembly (Fig.
237).
(12) Remove the #2 needle bearing (Fig. 238).
Fig. 235 Overdrive Clutch Pack
1 - OVERDRIVE CLUTCH PLATE
2 - OVERDRIVE SHAFT ASSEMBLY
3 - OVERDRIVE CLUTCH DISC
Fig. 236 #3&4 Thrust Washers
1 - #3 THRUST PLATE (3 TABS)
2 - OD SHAFT ASSEMBLY
3 - #4 THRUST PLATE (3 SLOTS)
Fig. 237 Underdrive Shaft Assembly
1 - #3 THRUST WASHER (5 TABS)
2 - UNDERDRIVE SHAFT ASSEMBLY
Fig. 238 No. 2 Needle Bearing
1 - #2 NEEDLE BEARING (NOTE 3 TABS)
21 - 258 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)
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(21) Remove input hub tapered snap ring (Fig.
247).
(22) Tap on input hub with soft faced hammer and
separate input hub from OD/Reverse piston and
clutch retainer (Fig. 248) (Fig. 249).(23) Separate clutch retainer from OD/Reverse pis-
ton (Fig. 250).
Fig. 247 Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
Fig. 248 Tap on Input Hub
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - PLASTIC HAMMER
Fig. 249 Input Hub Removed
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - INPUT CLUTCHES RETAINER
3 - O-RING
4 - SEAL
5 - OVERDRIVE/REVERSE PISTON
Fig. 250 Pull Retainer from Piston
1 - OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
RS41TE AUTOMATIC TRANSAXLE21 - 261
INPUT CLUTCH ASSEMBLY (Continued)
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