2002 CHRYSLER VOYAGER clutch

(19) Remove oil pump gasket (Fig. 34).
CAUTION: If transaxle failure has occurred, the
cooler bypass valve must be replaced. Do not
re-use or attempt to clean valve.
(20) Remove cooler bypass valve (Fig. 35).(21) Remove #1 needle bearing (Fig. 36).
(22) Remove input clutch assembly (Fig. 37).
Fig. 34 Remove Oil Pump Gasket
1 - PUMP GASKET
Fig. 35 Remove Bypass Valve
1 - COOLER BYPASS VALVE
Fig. 36 Remove Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 37 Remove Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
RS41TE AUTOMATIC TRANSAXLE21 - 177
41TE AUTOMATIC TRANSAXLE (Continued)
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(27) Setup tool 5058 as shown in (Fig. 43). Com-
press 2/4 clutch return spring (just enough to remove
snap ring) and remove snap ring.
NOTE: Verify that Tool 5058 is centered properly
over the 2/4 clutch retainer before compressing. If
necessary, fasten the 5058 bar to the bellhousing
flange with any combination of locking pliers and
bolts to center the tool properly.(28) Remove 2/4 clutch retainer (Fig. 44).
(29) Remove 2/4 clutch return spring (Fig. 45).
Fig. 42 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 43 Remove 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
Fig. 44 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 45 Remove 2/4 Clutch Return Spring
1 - 2/4 CLUTCH RETURN SPRING
RS41TE AUTOMATIC TRANSAXLE21 - 179
41TE AUTOMATIC TRANSAXLE (Continued)
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(30) Remove 2/4 clutch pack (Fig. 46).Tag 2/4
clutch pack for reassembly identification.
(31) Remove tapered snap ring (Fig. 47).(32) Remove low/reverse reaction plate (Fig. 48).
(33) Remove one low/reverse clutch disc (Fig. 49).
Fig. 46 Remove 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
Fig. 47 Remove Tapered Snap Ring
1 - LOW/REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)
4 - OIL PAN FACE
5 - LONG TAB
Fig. 48 Remove Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Fig. 49 Remove One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
21 - 180 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(34) Remove low/reverse reaction plate snap ring
(Fig. 50).
(35) Remove low/reverse clutch pack (Fig. 51).(36) Remove transfer gear cover-to-case bolts (Fig.
52).
(37) Remove transfer gear cover (Fig. 53).
Fig. 50 Remove Low/Reverse Reaction Plate Snap
Ring
1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
Fig. 51 Remove Low/Reverse Clutch Pack
1 - CLUTCH PLATES (5)
2 - CLUTCH DISCS (5)
Fig. 52 Remove Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
Fig. 53 Remove Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPARTATF RTV (MS-GF41) AS
SHOWN
RS41TE AUTOMATIC TRANSAXLE21 - 181
41TE AUTOMATIC TRANSAXLE (Continued)
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(57) Install low/reverse spring compressor tool as
shown in (Fig. 74) (Fig. 75).(58) Compress low/reverse piston return spring
and remove snap ring (Fig. 76).
(59) Remove low/reverse spring compressor tool
and low reverse piston return spring (Fig. 77).
Fig. 74 Low/Reverse Spring Compressor Tool
1 - TOOL 6057
2 - TOOL 5059
3 - TOOL 5058±3
Fig. 75 Compressor Tool in Use
1 - LOW/REVERSE CLUTCH RETURN SPRING
2 - SNAP RING (INSTALL AS SHOWN)
3 - TOOL 6057
4 - TOOL 5059
5 - TOOL 5058±3
Fig. 76 Remove Snap Ring
1 - SNAP RING OPENING MUST BE BETWEEN SPRING
LEVERS (AS SHOWN)
2 - SNAP RING PLIERS
3 - TOOL 6057
Fig. 77 Low/Reverse Piston Return Spring
1 - LOW/REVERSE PISTON RETURN SPRING
2 - PISTON
RS41TE AUTOMATIC TRANSAXLE21 - 187
41TE AUTOMATIC TRANSAXLE (Continued)
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(60) Using a suitable punch , drive out park guide
bracket pivot shaft plug (Fig. 78).
(61) Using ordinary pliers, remove pivot shaft and
guide bracket assembly (Fig. 79).(62) Inspect guide bracket components for exces-
sive wear and replace if necessary (Fig. 80).
(63) Remove low/reverse clutch piston (Fig. 81).
Fig. 78 Remove Anchor Shaft and Plug
1 - GUIDE BRACKET ANCHOR SHAFT
2 - PIVOT SHAFT
3 - ANCHOR SHAFT PLUG
Fig. 79 Pivot Shaft and Guide Bracket
1 - ANTIRACHET SPRING
2 - GUIDE BRACKET
3 - PIVOT SHAFT
4-PAWL
Fig. 80 Guide Bracket Disassembled
1 - ANTIRATCHET SPRING
2 - GUIDE BRACKET
3 - SPLIT SLEEVE
4 - SPACER
5-PAWL
6 - STEPPED SPACER
Fig. 81 Remove Low/Reverse Clutch Piston
1 - LOW/REVERSE CLUTCH PISTON
2 - D-RING SEAL
3 - D-RING SEAL
21 - 188 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(64) Remove low/reverse piston retainer-to-case
screws (Fig. 82).
(65) Remove low/reverse piston retainer (Fig. 83).(66) Remove low/reverse piston retainer-to-case
gasket (Fig. 84).
(67) Using a hammer and suitable drift, drive out
inner output bearing cup (Fig. 85).
Fig. 82 Remove Piston Retainer Attaching Screws
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - SCREWDRIVER
3 - TORX-LOC SCREWS
Fig. 83 Remove Piston Retainer
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - GASKET
Fig. 84 Remove Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Fig. 85 Remove Output Bearing Inner Cup
1 - OUTPUT BEARING CUPS (REPLACE IN PAIRS)
2 - HAMMER
3 - BRASS DRIFT
RS41TE AUTOMATIC TRANSAXLE21 - 189
41TE AUTOMATIC TRANSAXLE (Continued)
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(68) Using tool 6062, remove outer output bearing
cup (Fig. 86).
ASSEMBLY
CAUTION: If transaxle failure has occurred, it is
necessary to flush the transaxle oil cooler and lines
to remove debris and particles that could contami-
nate and/or fail a new or rebuilt unit. (Refer to 7 -
COOLING/TRANSMISSION - STANDARD PROCE-
DURE)
CAUTION: The cooler bypass valve must be
replaced if transaxle failure has occurred. Do not
attempt to reuse or clean old valve.
NOTE: If transaxle is being overhauled (clutch
and/or seal replacement), the TCM Quick Learn pro-
cedure must be performed. (Refer to 8 - ELECTRI-
CAL/ELECTRONIC CONTROL MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
(1) Install both output bearing cups using Tool
5050 (Fig. 87).
(2) Install low/reverse piston retainer gasket (Fig.
88). Make sure gasket holes line up with case.
Fig. 86 Remove Output Bearing Outer Cup
1 - TOOL 6062
Fig. 87 Install Both Output Bearing Cups
1 - OUTPUT BEARING CUPS
2 - WRENCHES
3 - TOOL 5050
Fig. 88 Install Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
21 - 190 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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