2002 CHRYSLER CARAVAN shaft

SOLENOID SWITCH VALVE
The solenoid switch valve controls line pressure
from the LR/CC solenoid. In one position, it allows
the low/reverse clutch to be pressurized. In the other,
it directs line pressure to the converter control and
converter clutch valves.
MANUAL VALVE
The manual valve is operated by the mechanical
shift linkage. Its primary responsibility is to send
line pressure to the appropriate hydraulic circuits
and solenoids. The valve has three operating ranges
or positions.
CONVERTER CLUTCH SWITCH VALVE
The main responsibility of the converter clutch switch
valve is to control hydraulic pressure applied to the front
(off) side of the converter clutch piston. Line pressure
from the regulator valve is fed to the torque converter
regulator valve, where it passes through the valve, and is
slightly regulated. The pressure is then directed to the
converter clutch switch valve and to the front side of the
converter clutch piston. This pressure pushes the piston
back and disengages the converter clutch.
CONVERTER CLUTCH CONTROL VALVE
The converter clutch control valve controls the
back (on) side of the torque converter clutch. When
the TCM energizes or modulates the LR/CC solenoid
to apply the converter clutch piston, both the con-
verter clutch control valve and the converter control
valve move, allowing pressure to be applied to the
back side of the clutch.
T/C REGULATOR VALVE
The torque converter regulator valve slightly regu-
lates the flow of fluid to the torque converter.
LOW/REVERSE SWITCH VALVE
The low/reverse clutch is applied from different
sources, depending on whether low (1st) gear or
reverse is selected. The low/reverse switch valve
alternates positions depending on from which direc-
tion fluid pressure is applied. By design, when the
valve is shifted by fluid pressure from one channel,
the opposing channel is blocked. The switch valve
alienates the possibility of a sticking ball check, thus
providing consistent application of the low/reverse
clutch under all operating conditions.
REMOVAL
REMOVAL
NOTE: If valve body is replaced or reconditioned,
the TCM Quick Learn Procedure must be per-formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Disconnect battery negative cable.
(2) Disconnect gearshift cable from manual valve
lever.
(3) Remove manual valve lever from manual shaft.
(4) Raise vehicle on hoist.
(5) Remove oil pan bolts (Fig. 341).
(6) Remove oil pan (Fig. 342).
Fig. 341 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 342 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
21 - 294 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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(7) Remove oil filter (Fig. 343).
(8) Remove the valve body-to-transaxle case bolts
(Fig. 344).
NOTE: To ease removal of the valve body, turn the
manual valve lever fully clockwise to low or first
gear.(9) Remove park rod rollers from guide bracket
and remove valve body from transaxle (Fig. 345) (Fig.
346).
CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
Fig. 343 Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 344 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 345 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
Fig. 346 Valve Body Removal/Installation
1 - VALVE BODY
RS41TE AUTOMATIC TRANSAXLE21 - 295
VALVE BODY (Continued)
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REMOVAL
NOTE: If valve body is replaced or reconditioned,
the TCM Quick Learn Procedure must be per-
formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Disconnect battery negative cable.
(2) Disconnect gearshift cable from manual valve
lever.
(3) Remove manual valve lever from manual shaft.
(4) Raise vehicle on hoist.
(5) Remove oil pan bolts (Fig. 347).
(6) Remove oil pan (Fig. 348).(7) Remove oil filter (Fig. 349).
(8) Remove the valve body-to-transaxle case bolts
(Fig. 350).
NOTE: To ease removal of the valve body, turn the
manual valve lever fully clockwise to low or first
gear.
Fig. 347 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 348 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 349 Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 350 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
21 - 296 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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(9) Remove park rod rollers from guide bracket
and remove valve body from transaxle (Fig. 351) (Fig.
352).
CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
DISASSEMBLY
NOTE: If valve body assembly is being recondi-
tioned, the TCM Quick Learn Procedure must be
performed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)(1) Remove manual shaft seal (Fig. 353).
(2) Remove Transmission Range Sensor retaining
screw (Fig. 354).
Fig. 351 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
Fig. 352 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 353 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 354 Remove Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
RS41TE AUTOMATIC TRANSAXLE21 - 297
VALVE BODY (Continued)
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(3) Remove Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 355).
(4) Remove 2/4 Accumulator Retaining Plate (Fig.
356).(5) Remove 2/4 Accumulator components as shown
in (Fig. 357).
(6) Remove Valve Body to Transfer Plate screws
(Fig. 358).
Fig. 355 Manual Shaft/Rooster Comb and
Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
Fig. 356 2/4 Accumulator Retaining Plate
1 - 2±4 ACCUMULATOR RETAINING PLATE
2 - DETENT SPRING
Fig. 357 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - SPRINGS
5 - SEALS
6 - PISTON
Fig. 358 Remove Valve Body to Transfer Plate
Screws
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
21 - 298 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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(14) Install Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 381).
(15) Make sure Manual Valve control pin is con-
tained within the rooster comb slot (Fig. 382). Install
Transmission Range Sensor retaining screw (Fig.
382) and torque to 5 N´m (45 in. lbs.).(16) Install manual shaft seal (Fig. 383).
INSTALLATION
NOTE: If valve body assembly is being replaced or
reconditioned, it is necessary to perform the TCM
Quick Learn Procedure. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install valve body assembly to transaxle (Fig.
384). Install and torque valve body-to-transaxle case
bolts (Fig. 385) to 12 N´m (105 in. lbs.).
Fig. 381 Install Manual Shaft/Rooster Comb and
Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
Fig. 382 Install Transmission Range Sensor
Retaining Screw
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
Fig. 383 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 384 Valve Body Removal/Installation
1 - VALVE BODY
21 - 306 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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(2) Install transaxle oil filter (Fig. 386). Inspect
the o-ring and replace if necessary.
(3) Ensure the transaxle oil pan and transaxle
case sealing surfaces are clean and dry. Install an
1/8º bead of MopartSilicone Rubber Adhesive Seal-ant to the oil pan and install (Fig. 387). Torque oil
pan-to-transaxle case bolts (Fig. 388) to 19 N´m (165
in. lbs.).
(4) Lower vehicle.
(5) Connect transmission range sensor connector.
(6) Install manual valve lever to manual shaft.
(7) Install gearshift cable to manual valve lever.
(8) Connect battery negative cable.
(9) Fill transaxle with MopartATF +4 Transmis-
sion fluid. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
Fig. 385 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 386 Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 387 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 388 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
RS41TE AUTOMATIC TRANSAXLE21 - 307
VALVE BODY (Continued)
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T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
T850 MANUAL TRANSAXLE
DESCRIPTION........................308
OPERATION..........................311
DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES...................318
REMOVAL............................318
DISASSEMBLY........................323
ASSEMBLY...........................329
INSTALLATION........................338
SPECIFICATIONS - T850 MANUAL
TRANSAXLE........................343
SPECIAL TOOLS - T850 TRANSAXLE.......345
AXLE SEALS
REMOVAL............................348
INSTALLATION........................348
BACK-UP LAMP SWITCH
REMOVAL............................349
INSTALLATION........................349
DIFFERENTIAL
DESCRIPTION........................349
OPERATION..........................349
DISASSEMBLY........................350
ASSEMBLY...........................353
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL TURNING
TORQUE...........................356
ADJUSTMENT - DIFFERENTIAL SIDE GEAR
ENDPLAY..........................358
FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK............................358
STANDARD PROCEDURE - FLUID DRAIN
AND FILL...........................359
GEARSHIFT BOOT
REMOVAL............................359
INSTALLATION........................360GEARSHIFT CABLE - CROSSOVER
REMOVAL............................360
INSTALLATION........................363
ADJUSTMENTS
ADJUSTMENT.......................366
GEARSHIFT CABLE - SELECTOR
REMOVAL............................368
INSTALLATION........................371
GEARSHIFT KNOB
REMOVAL............................374
INSTALLATION........................374
GEARSHIFT MECHANISM
REMOVAL............................375
INSTALLATION........................377
INPUT SHAFT
DESCRIPTION........................380
DISASSEMBLY........................380
ASSEMBLY...........................383
INTERMEDIATE SHAFT
DESCRIPTION........................387
DISASSEMBLY........................388
ASSEMBLY...........................395
SHIFT COVER
DESCRIPTION........................401
SHIFT FORK AND SHAFT
DESCRIPTION........................402
SYNCHRONIZER
DESCRIPTION........................402
DISASSEMBLY........................402
CLEANING
CLEAN............................402
INSPECTION
INSPECT...........................402
ASSEMBLY...........................403
VEHICLE SPEED SENSOR
REMOVAL............................403
INSTALLATION........................403
T850 MANUAL TRANSAXLE
DESCRIPTION
The NV T850 5-speed transaxle (Fig. 1) is a con-
stant-mesh manual transaxle that is synchronized in
all gear ranges, including reverse.
The transaxle consists of three major sub-assem-
blies: the input shaft, intermediate shaft, and differ-ential assembly. The transaxle shift system consists
of a mechanical shift cover, rails, forks, and cables.
The unique design of this shift system provides a
higher mechanical advantage, resulting in less fric-
tion and lower shift cable loads for smoother, more
positive operation.
21 - 308 T850 MANUAL TRANSAXLERS
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