2002 CHRYSLER VOYAGER speed sensor

ASSEMBLY...........................115
SHIFT INTERLOCK SOLENOID
DESCRIPTION........................115
OPERATION..........................115
DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK
SOLENOID..........................117
REMOVAL............................117
INSTALLATION........................118
SOLENOID - TCC
DESCRIPTION........................119
OPERATION..........................119
REMOVAL............................119
INSTALLATION........................120
THROTTLE VALVE CABLE
REMOVAL............................120
INSTALLATION........................121
ADJUSTMENTS
THROTTLE VALVE LINKAGE
ADJUSTMENT.......................122
TORQUE CONVERTER
DESCRIPTION........................122
OPERATION..........................126
REMOVAL............................127
INSTALLATION........................127
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/
BEARING
REMOVAL............................128INSTALLATION........................131
ADJUSTMENTS
ADJUSTMENT - OUTPUT SHAFT BEARING . 135
TRANSFER SYSTEM - TRANSFER SHAFT/
GEAR/BEARING
REMOVAL............................137
INSTALLATION........................141
ADJUSTMENTS
ADJUSTMENT - TRANSFER SHAFT
BEARING...........................145
VALVE BODY
REMOVAL............................146
DISASSEMBLY........................148
CLEANING...........................154
INSPECTION.........................155
ASSEMBLY...........................155
INSTALLATION........................158
ADJUSTMENTS
HYDRAULIC CONTROL PRESSURE
ADJUSTMENTS......................160
VEHICLE SPEED SENSOR/PINION GEAR
REMOVAL............................160
INSTALLATION........................160
31TH AUTOMATIC
TRANSAXLE
DESCRIPTION
This transaxle combines torque converter, three
speed transmission, final drive gearing, and differen-
tial into a front wheel drive system.
Within this transaxle, there are three primary
areas:
(1) Main center line plus valve body.
(2) Transfer shaft center line (includes governor
and parking sprag).
(3) Differential center line.
Center distances between the main rotating parts
in these three areas are held precise to maintain a
low noise level.
The torque converter, transaxle area, and differen-
tial are housed in an integral aluminum die casting.
The differential oil sump is common with the
transaxle sump. Separate filling of the differen-
tial is NOT necessary.
The torque converter is attached to the crankshaft
through a flexible driving plate. Cooling of the con-
verter is accomplished by circulating the transaxle
fluid through a remote cooler. There are two types of
coolers used. An oil-to-water type cooler located in
the radiator side tank and/or an oil-to-air heatexchanger. The torque converter assembly is a sealed
unit that cannot be disassembled.
The transaxle fluid is filtered by an internal filter
attached to the lower side of the valve body assembly.
Engine torque is transmitted to the torque con-
verter and then through the input shaft to multiple-
disc clutches in the transaxle. The power flow
depends on the application of the clutches and bands.
Refer to Elements in Use Chart in Diagnosis and
Tests section.
The transaxle consists of:
²Two multiple-disc clutches
²An overrunning clutch
²Two servos
²A hydraulic accumulator
²Two bands
²Two planetary gear sets
This provides three forward ratios and a reverse
ratio. The common sun gear of the planetary gear
sets is connected to the front clutch by a driving
shell. The driving shell is splined to the sun gear and
front clutch retainer. The hydraulic system consists
of an oil pump and a single valve body which con-
tains all of the valves except the governor valves.
The transaxle sump and differential sump are both
vented through the dipstick. Output torque from the
main center line is delivered through helical gears to
the transfer shaft. This gear set is a factor in the
transaxle final drive (axle) ratio. The shaft also car-
21 - 22 31TH AUTOMATIC TRANSAXLERS
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(12) Remove front mount and bracket (Fig. 11).
(13) Cut transaxle oil cooler lines flush with fit-
tings. a service kit will be installed upon reintalla-
tion. Plug lines and fittings to prevent debris
intrusion.
(14) Remove structural collar (Fig. 12).
(15) Disconnect vehicle speed sensor connector.
(16) Remove rear mount shield (Fig. 13).
(17) Remove rear mount thru-bolt.
(18) Support engine with screw jack and wood
block.
(19) Remove torque converter-to-drive plate bolts.
(20) Remove left wheel splash shield.
Fig. 11 Front Mount and Bracket
1 - BRACKET - FRONT MOUNT
2 - NUT
3 - BOLT
4 - MOUNT - FRONT INSULATOR
5 - BOLT
6 - BOLT
7 - FRONT CROSSMEMBER
Fig. 12 Structural Collar
1 - BOLT - COLLAR TO OIL PAN
2 - BOLT - COLLAR TO TRANSAXLE
3 - STRUCTURAL COLLAR
4 - OIL PAN
Fig. 13 Rear Mount Heat Shield
1 - BOLT - HEAT SHIELD
2 - HEAT SHIELD
3 - CLIP
4 - REAR MOUNT
RS31TH AUTOMATIC TRANSAXLE21-39
31TH AUTOMATIC TRANSAXLE (Continued)
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INSTALLATION
(1) Install transaxle assembly to engine using a
transmission jack and helper.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.).
(3) Using screw jack and wood block, raise engine/
transaxle assembly into position and install left
upper mount thru-bolt (Fig. 97). Torque bolt to 75
N´m (55 ft. lbs.).
(4) Install left wheel splash shield.
(5) Install torque converter-to-drive plate bolts and
torque to 88 N´m (65 ft. lbs.).
(6) Install rear mount bracket to transaxle (Fig.
98). Install bolts by hand but do not tighten at this
time.
(7) Align rear mount bracket to mount and install
thru-bolt. Do not tighten at this time.
(8) Connect vehicle speed sensor connector.
Fig. 97 Left Mount-to-Rail
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
Fig. 98 Rear Mount Bracket
1 - BOLT - VERTICAL
2 - BRACKET - REAR MOUNT3 - BOLT - HORIZONTAL
RS31TH AUTOMATIC TRANSAXLE21-61
31TH AUTOMATIC TRANSAXLE (Continued)
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(8) Install and torque oil pan-to-transaxle bolts
(Fig. 339) to 19 N´m (165 in. lbs.).
(9) Lower vehicle.
(10) Connect torque converter clutch solenoid.
(11) Connect gearshift cable to manual valve lever.
(12) Connect throttle valve cable to throttle valve
lever at transaxle.
(13) Connect battery negative cable.
ADJUSTMENTS
HYDRAULIC CONTROL PRESSURE
ADJUSTMENTS
LINE PRESSURE
An incorrect throttle pressure setting will cause incor-
rect line pressure readings even though line pressure
adjustment is correct. Always inspect and correct throttle
pressure adjustment before adjusting the line pressure.
The approximate adjustment for line pressure is 1-5/16
inches, measured from valve body to inner edge of adjust-
ing nut. However, due to manufacturing tolerances, the
adjustment can be varied to obtain specified line pres-
sure.
The adjusting screw may be turned with an Allen
wrench. One complete turn of adjusting screw
changes closed throttle line pressure approximately
1-2/3 psi. Turning adjusting screw counterclockwise
increases pressure, and clockwise decreases pressure.
THROTTLE PRESSURE
Throttle pressures cannot be tested accurately;
therefore, the adjustment should be measured if a
malfunction is evident.
(1) Insert gauge pin of Tool C-3763 between the
throttle lever cam and kickdown valve.(2) By pushing in on tool, compress kickdown
valve against its spring so throttle valve is com-
pletely bottomed inside the valve body.
(3) While compressing spring, turn throttle lever
stop screw with adapter C-4553. Turn until head of
screw touches throttle lever tang, with throttle lever
cam touching tool and throttle valve bottomed. Be
sure adjustment is made with spring fully com-
pressed and valve bottomed in the valve body.
VEHICLE SPEED SENSOR/
PINION GEAR
REMOVAL
(1)Remove harness connector from sensor (Fig. 340).
Be sure weather seal stays on harness connector.
(2) Remove bolt securing the sensor in the exten-
sion housing (Fig. 340) .
(3) Carefully pull sensor and pinion gear assembly
out of extension housing.
(4) Remove pinion gear from sensor (Fig. 340) .
(5) Inspect pinion gear for damage (missing teeth,
etc.) and replace as necessary.
NOTE: When removing vehicle speed sensor for
any reason, a new o-ring MUST be used.
INSTALLATION
(1) Install vehicle speed sensor and pinion gear to
extension housing with new o-ring (Fig. 340).
(2) Install bolt and torque to 7 N´m (60 in. lbs.).
(3) Connect connector.
(4) Lower vehicle.
Fig. 339 Transaxle Oil Pan Bolts
1 - TRANSAXLE OIL PAN
2 - OIL PAN BOLTS
Fig. 340 Vehicle Speed Sensor Removal/Installation
1 - CONNECTOR
2 - SPEEDO PINION
3 - O-RING
4 - SENSOR
21 - 160 31TH AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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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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Fig. 1 41TE Transaxle
1 - CASE 7 - LOW/REVERSE CLUTCH 13 - DIFFERENTIAL
2 - INPUT SPEED SENSOR 8 - OUTPUT SPEED SENSOR 14 - OIL PUMP
3 - UNDERDRIVE CLUTCH 9 - PLANETARY GEAR SET 15 - TORQUE CONVERTER
4 - OVERDRIVE CLUTCH 10 - OUTPUT SHAFT GEAR 16 - TORQUE CONVERTER CLUTCH
5 - REVERSE CLUTCH 11 - TRANSFER SHAFT
6 - 2/4 CLUTCH 12 - TRANSFER SHAFT GEAR
RS41TE AUTOMATIC TRANSAXLE21 - 163
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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