2002 CHRYSLER VOYAGER clutch

(6) Adjust transmission fluid level shown on the
indicator according to the chart.
(7) Check transmission for leaks.
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transaxle vent where it may be mistaken
for a leak.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle recondition is proba-
bly required. Be sure to examine the fluid on the dip-
stick closely. If there is any doubt about its condition,
drain out a sample for a double check.
MopartATF+4 (Automatic Transmission Fluid-
Type 9602) when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
the vehicle such as engine oil or antifreeze. The red
color is not permanent and is not an indicator of fluid
condition. As the vehicle is driven, the ATF will begin
to look darker in color and may eventually become
brown.This is normal.ATF+4 also has a unique
odor that may change with age. Consequently,odor
and color cannot be used to indicate the fluid
condition or the need for a fluid change.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
STANDARD PROCEDURE - FLUID AND FILTER
SERVICE
NOTE: Refer to the maintenance schedules in
LUBRICATION and MAINTENANCE, or the vehicle
owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
NOTE: Only fluids of the type labeled MoparTATF+4
(Automatic Transmission Fluid) Type 9602 should
be used. A filter change should be made at the time
of the transmission oil change. The magnet (on the
inside of the oil pan) should also be cleaned with a
clean, dry cloth.NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Refer to LUBRICA-
TION and MAINTENANCE for proper procedures.
Place a drain container with a large opening, under
transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and o-ring on bottom of the
valve body (Fig. 212).
(4) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.).
(5) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick
opening.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
Fig. 212 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
21 - 250 41TE AUTOMATIC TRANSAXLERS
FLUID (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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(3) Remove reverse clutch snap ring (Fig. 227).
(4) Pry up and remove reverse clutch reaction
plate (Fig. 228) (Fig. 229).(5) Remove the reverse clutch pack (two frictions/
one steel) (Fig. 230).
NOTE: Tag reverse clutch pack for reassembly iden-
tification.
Fig. 227 Reverse Clutch Snap Ring
1 - REACTION PLATE
2 - SCREWDRIVER
3 - REVERSE CLUTCH SNAP RING (SELECT)
Fig. 228 Pry Reverse Clutch Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
3 - SCREWDRIVER
Fig. 229 Reverse Clutch Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE (INSTALL FLAT SIDE
DOWN)
Fig. 230 Reverse Clutch Pack
1 - REVERSE CLUTCH PLATE
2 - REVERSE CLUTCH DISC
21 - 256 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)
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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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(13) Remove the OD/UD reaction plate tapered
snap ring (Fig. 239).
NOTE: The OD/UD clutch reaction plate has a step
on both sides. Install the OD/UD clutches reaction
plate tapered step side up.
(14) Remove the OD/UD reaction plate (Fig. 240).(15) Remove the first UD clutch disc (Fig. 241).
(16) Remove the UD clutch flat snap ring (Fig.
242).
Fig. 239 OD/UD Reaction Plate Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
Fig. 240 OD/UD Reaction Plate
1 - OD/UD CLUTCH REACTION PLATE (TAPERED STEP SIDE
UP)
Fig. 241 Remove One UD Clutch Disc
1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 242 UD Clutch Flat Snap Ring
1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
RS41TE AUTOMATIC TRANSAXLE21 - 259
INPUT CLUTCH ASSEMBLY (Continued)
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NOTE: Tag underdrive clutch pack for reassembly
identification.
(17) Remove the UD clutch pack (Fig. 243).
CAUTION: Compress return spring just enough to
remove or install snap ring.
(18) Using Tool 5059A and an arbor press, com-
press UD clutch piston enough to remove snap ring
(Fig. 244) (Fig. 245).(19) Remove spring retainer (Fig. 245).
(20) Remove UD clutch piston (Fig. 246).
Fig. 243 Underdrive Clutch Pack
1 - CLUTCH PLATE
2 - ONE UD CLUTCH DISC
3 - CLUTCH DISC
Fig. 244 UD Spring Retainer Snap Ring
1 - SNAP RING PLIERS
2 - ARBOR PRESS RAM
3 - SNAP RING
4 - SPECIAL TOOL 5059A
Fig. 245 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 246 Underdrive Clutch Piston
1 - PISTON
21 - 260 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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