2002 CHRYSLER VOYAGER clutch

(2) Install rear planetary annulus gear bearing
cone using tool C-4637 and cup from Tool L-4518
(Fig. 252).
(3) Using a press and a
1¤2º socket to protect the
shaft, install output shaft into rear planetary annu-
lus gear (Fig. 253).(4) Using Tool L-4429-3, install both output shaft
bearing cups to transaxle case (Fig. 254) (Fig. 255).
(5) Determine output shaft bearing shim thick-
ness. Shim thickness need be determined only if any
of the following parts are replaced:
²Transaxle case
²Output shaft
²Rear planetary annulus gear
²Output shaft gear
²Rear annulus and output shaft gear bearing
cones
²Overrunning clutch race cups
To determine proper shim thickness, Refer to Output
Shaft Bearing Adjustment.Check output shaft
bearing turning torque, using an inch-pound
torque wrench. If turning torque is 3-8 in. lbs.,
the proper shim has been installed.
Fig. 252 Install Rear Planetary Annulus Gear
Bearing Cone
1 - ARBOR PRESS RAM
2 - SPECIAL TOOL C-4637
3 - REAR PLANETARY ANNULUS GEAR
4 - CUP FROM TOOL L-4518
5 - BEARING CONE
Fig. 253 Install Output Shaft into Rear Planetary
Annulus Gear
1 - PRESS
2 - 1/2 INCH SOCKET
3 - OUTPUT SHAFT
4 - REAR ANNULUS GEAR
5 - SPACER
Fig. 254 Install Output Shaft Gear Bearing Cup
1 - OUTPUT SHAFT GEAR BEARING CUP
2 - SPECIAL TOOL L-4429-3
Fig. 255 Install Rear Planetary Annulus Gear
Bearing Cup
1 - SPECIAL TOOL L-4429-3
21 - 132 31TH AUTOMATIC TRANSAXLERS
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)
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VALVE BODY
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect throttle valve cable from throttle
valve lever at transaxle.
(3) Disconnect gearshift cable from gearshift lever
at transaxle.
(4) Disconnect torque converter clutch solenoid
connector.
(5) Raise vehicle on hoist.
(6) Remove transaxle oil pan bolts (Fig. 297).
(7) Separate oil pan from case and drain fluid into
suitable container (Fig. 298).(8) Remove oil filter-to-valve body screws (Fig.
299).
(9) Remove oil filter and gasket (Fig. 300).
Fig. 297 Transaxle Oil Pan Bolts
1 - TRANSAXLE OIL PAN
2 - OIL PAN BOLTS
Fig. 298 Transaxle Oil Pan
1 - TRANSAXLE OIL PAN
2 - OIL FILTER
Fig. 299 Oil Filter Screws
1 - SCREWDRIVER HANDLE
2 - SPECIAL TOOL L-4553
3 - OIL FILTER SCREWS (2)
4 - OIL FILTER
Fig. 300 Oil Filter and Gasket
1 - OIL FILTER
2 - GASKET
3 - VALVE BODY
21 - 146 31TH AUTOMATIC TRANSAXLERS
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(11) Remove torque converter clutch solenoid,
spring, and plug as shown in (Fig. 319).
Fig. 319 Torque Converter Clutch Solenoid and Regulator/Control Valves
1 - CONVERTER PRESSURE CONTROL
VA LV E3 - SCREW (3) 5 - REGULATOR VALVE THROTTLE
PRESSURE PLUG
2 - END COVER4 - REGULATOR VALVE THROTTLE
PRESSURE PLUG SPRING 6 - SWITCH VALVE
RS31TH AUTOMATIC TRANSAXLE21 - 153
VALVE BODY (Continued)
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(12) Remove shift/shuttle valves and springs as
shown in (Fig. 320).
CLEANING
Clean the valve body components in a parts clean-
ing solution only. Do not use gasoline, kerosene, or
any type of caustic solution. Dry the parts with com-
pressed air. Make sure all passages are clean and
free from obstructions.
NOTE: Do not use rags or shop towels to wipe off
valve body components. Lint from these materials
will adhere to the valve body components. Lint will
interfere with valve operation and may clog filters
and fluid passages.
Minor distortion of a valve body mating surface
may be corrected by smoothing the surface with cro-
cus cloth. The cloth should be in sheet form and bepositioned on a surface plate, sheet of plate glass, or
equally flat surface. However, if distortion is severe
or any surfaces are heavily scored, the valve body
will have to be replaced.
CAUTION: Many of the valve body valves and plugs
are made of coated aluminum. Aluminum compo-
nents can be identified by the dark color of the spe-
cial coating applied to the surface (or by testing
with a magnet). DO NOT polish or sand aluminum
valves or plugs with any type of material, or under
any circumstances. This practice might damage the
special coating and cause the valves and plugs to
stick and bind.
Aluminum valves and plugs should not be sanded
or polished under any circumstances. However, minor
burrs or scratches on steel valves and plugs can be
removed with crocus cloth but do not round off the
Fig. 320 Shift Valves and Shuttle Valve
1 - SHUTTLE VALVE E-CLIP 9 - BY-PASS VALVE SPRING
2 - SHUTTLE VALVE SECONDARY SPRING 10 - 1±2 SHIFT VALVE SPRING
3 - SHUTTLE VALVE 11 - 1±2 SHIFT VALVE
4 - 2±3 SHIFT VALVE 12 - BY-PASS VALVE
5 - SHUTTLE VALVE PRIMARY SPRING 13 - TORQUE CONVERTER CLUTCH SOLENOID
6 - 2±3 SHIFT VALVE SPRING 14 - VALVE BODY
7 - SHUTTLE VALVE PLUG 15 - SPRING GUIDES (2)
8 - SCREWS
21 - 154 31TH AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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valve or plug edges. Squareness of these edges is
vitally important. These edges prevent foreign matter
from lodging between the valves, plugs and bore.
INSPECTION
Inspect the throttle and manual valve levers and
shafts. Do not attempt to straighten a bent shaft or
correct a loose lever. Replace these components if
worn, bent, loose or damaged in any way.
Inspect all of the valve body mating surfaces for
scratches, nicks, burrs, or distortion. Use a straight-
edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light
pressure.
Inspect the valves and plugs for scratches, burrs,
nicks, or scores. Also inspect the coating on the alu-
minum valves and plugs. If the coating is damaged
or worn through, the valve (or valve body) should be
replaced.
Inspect all the valve and plug bores in the valve
body. Use a penlight to view the bore interiors.
Replace the valve body if any bores are distorted or
scored. Inspect all of the valve body springs. The
springs must be free of distortion, warpage or broken
coils.
Trial fit each valve and plug in its bore to check
freedom of operation. When clean and dry, the valves
and plugs should drop freely into the bores. Valve
body bores do not change dimensionally with use. If
the valve body functioned correctly when new, it will
continue to operate properly after cleaning and
inspection. It should not be necessary to replace a
valve body assembly unless it is damaged in han-
dling.
ASSEMBLY
(1) Install shift/shuttle valves and springs as
shown in (Fig. 320).
(2) Install torque converter clutch solenoid, spring,
and plug as shown in (Fig. 319).
(3) Install governor plugs as shown in (Fig. 318).
(4) Install pressure regulator and manual control
springs and valves as shown in (Fig. 317).
(5) Install pressure regulator spring retainer/ad-
justing screw bracket (Fig. 321).
(6) Install manual valve from valve body (Fig.
322).
Fig. 321 Pressure Regulator and Adjusting Screw
Bracket
1 - SCREWDRIVER HANDLE
2 - PRESSURE REGULATOR SPRING RETAINER AND
ADJUSTING SCREW BRACKET
3 - VALVE BODY
4 - SCREWS
Fig. 322 Install Manual Valve
1 - MANUAL VALVE
2 - VALVE BODY
RS31TH AUTOMATIC TRANSAXLE21 - 155
VALVE BODY (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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