2002 CHRYSLER VOYAGER Starter motor

(9) Install structural collar (Fig. 99).
(10) Connect transaxle cooler lines using service
splice kit. Refer to instructions included with kit.
(11) Install starter motor assembly (Fig. 100).(12) Install front mount and bracket (Fig. 101).
Fig. 99 Structural Collar
1 - BOLT - COLLAR TO OIL PAN
2 - BOLT - COLLAR TO TRANSAXLE
3 - STRUCTURAL COLLAR
4 - OIL PAN
Fig. 100 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT
3 - BOLT
Fig. 101 Front Mount and Bracket
1 - BRACKET - FRONT MOUNT
2 - NUT
3 - BOLT
4 - MOUNT - FRONT INSULATOR
5 - BOLT
6 - BOLT
7 - FRONT CROSSMEMBER
21 - 62 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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TORQUE SPECIFICATIONS
Description N´m Ft. Lbs. In. Lbs.
Bolt, Differential Bearing Retainer-to-Case 34 Ð 300
Bolt, Differential Cover-to-Case 19 Ð 165
Bolt, Differential Ring Gear-to-Case 95 70 Ð
Bolt, Extension Housing-to-Case 28 Ð 250
Bolt, Drive Plate-to-Crankshaft 95 70 Ð
Bolt, Drive Plate-to-Torque Converter 68 50 Ð
Bolt, Governor-to-Support 7 Ð 60
Bolt, Output Gear Strap 23 17 Ð
Bolt, Oil Pan-to-Case 19 Ð 165
Bolt, Oil Pump-to-Case 31 Ð 275
Bolt, Park Rod Support-to-Case 28 Ð 250
Bolt, Reaction Support-to-Pump Body 28 Ð 250
Bolt, Sprag Retainer-to-Case 28 Ð 250
Bolt, Starter Motor-to-Transaxle 54 40 Ð
Bolt, Transaxle Case-to-Engine Block 95 70 Ð
Bolt, Transfer Gear Cover-to-Case 19 Ð 165
Bolt, Transfer Gear Strap 23 17 Ð
Bolt, Valve Body-to-Case 12 Ð 105
Fitting, Transaxle Oil Cooler-to-Case 7 Ð 60
Screw, Fluid Filter 5 Ð 45
Screw, Cooler Bypass Valve-to-Transfer Plate 5 Ð 40
Screw, Governor Counterweight 28 Ð 250
Screw, Manual Valve Lever-to-Shaft 12 Ð 105
Screw, Speedo Adapter-to-Extension Housing 7 Ð 60
Screw, Valve Body-to-Transfer Plate 5 Ð 45
Nut, Kickdown Band Adjuster Lock 47 35 Ð
Nut, Output Gear-to-Shaft 271 200 Ð
Nut, Reverse Band Adjuster Lock 14 Ð 125
Nut, Transfer Gear-to-Shaft 271 200 Ð
Plug, Pressure Tap 5 Ð 45
Plug, Rear Band Lever Pivot Shaft 7 Ð 60
Switch, Park/Neutral 34 25 Ð
21 - 74 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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(18) AWD models: Remove power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - REMOVAL)
(19) Remove rear mount bracket-to-transaxle case
lower (horizontal) bolt (Fig. 13).
(20) Remove front mount/bracket assembly.
(21) Remove starter motor.
(22) Remove lateral bending brace.
(23) Remove inspection cover.
(24) Remove torque converter-to-drive plate bolts.
(25) Support engine/transaxle assembly at engine
oil pan with screw jack and wood block.
(26) Partially remove left wheelhouse splash shield
to gain access to and remove upper mount thru-bolt
(Fig. 14).
(27) Lower engine/transaxle assembly with screw
jack.
(28) Obtain helper and/or transmission jack.
Secure transmission jack to transaxle assembly.
(29) Remove upper mount bracket from transaxle
(Fig. 14).
(30) Remove remaining transaxle bellhousing-to-
engine bolts.
(31) Remove transaxle assembly from vehicle.DISASSEMBLY
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)
NOTE: If transaxle is being overhauled (clutch
and/or seal replacement) or replaced, it is neces-
sary to perform the TCM Quick Learn Procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
NOTE: This procedure does not include final drive
(differential) disassembly.
(1) Remove input and output speed sensors.
(2) Remove three (3) solenoid/pressure switch
assembly-to-case bolts.
Fig. 13 Rear Mount Bracket - Typical
1 - BOLT - VERTICAL
2 - BRACKET - REAR MOUNT3 - BOLT - HORIZONTAL
RS41TE AUTOMATIC TRANSAXLE21 - 171
41TE AUTOMATIC TRANSAXLE (Continued)
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(69) Install and tighten solenoid/pressure switch
assembly-to-transaxle case bolts to 12 N´m (110 in.
lbs.) (Fig. 163).
(70) Install and torque input and output speed
sensors to case to 27 N´m (20 ft. lbs.).
INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perfrom the TCM Quick Learn proce-
dure. (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Using a transmission jack and a helper, posi-
tion transaxle assembly to engine. Install and torque
bellhousing bolts to 95 N´m (70 ft. lbs.).
(2) Install upper mount assembly to transaxle and
torque bolts to 54 N´m (40 ft. lbs.) (Fig. 164).
(3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 164).(4) Remove transmission jack and screw jack.
(5) Secure left wheelhouse splash shield.
(6) Install torque converter-to-drive plate bolts and
torque to 88 N´m (65 ft. lbs.)
(7) Install inspection cover.
(8) Install lateral bending brace.
(9) Install starter motor.
(10) Install front mount/bracket assembly.
Fig. 163 Attaching Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
Fig. 164 Left Mount to Bracket and Transaxle
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
RS41TE AUTOMATIC TRANSAXLE21 - 213
41TE AUTOMATIC TRANSAXLE (Continued)
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(9) Using Tool 6638A, disconnect clutch hydraulic
circuit quick connect (located on slave cylinder tube).
Remove clutch slave cylinder by depressing towards
case and rotating counter-clockwise 60É, while lifting
anti-rotation tab out of case slot with screwdriver
(Fig. 12).
(10) Remove engine left mount bracket.
(11) Remove starter motor (Fig. 13).
(12) Disconnect back-up lamp switch connector.
(13) Remove structural collar.
(14) Remove modular clutch assembly-to-drive
plate bolts.
(15) Position screw jack and wood block to engine
oil pan.
(16) Remove transmission upper mount through-
bolt from left frame rail.
(17) Lower engine/transaxle assembly on screw
jack.
Fig. 11 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 12 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 13 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
RST850 MANUAL TRANSAXLE21 - 319
T850 MANUAL TRANSAXLE (Continued)
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(11) Raise vehicle on hoist.
(12) Remove front wheel/tires and halfshafts.
(13) Remove underbody splash shield.
(14) Drain transaxle fluid into suitable container.
(15) Remove front harness retainer and secure
harness out of way.
(16) Using Tool 6638A, disconnect clutch hydrau-
lic circuit quick connect (located on slave cylinder
tube). Remove clutch slave cylinder by depressing
towards case and rotating counter-clockwise 60É,
while lifting anti-rotation tab out of case slot with
screwdriver (Fig. 21).
(17) Remove engine left mount bracket (Fig. 22).
(18) Remove starter motor (Fig. 23).
(19) Disconnect back-up lamp switch connector.
(20) Position screw jack and wood block to engine
oil pan.
(21) Remove transmission upper mount through-
bolt from left frame rail.
(22) Lower engine/transaxle assembly on screw
jack.
Fig. 21 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 22 Left Mount Bracket Removal/Installation
1 - BOLT (2)
2 - MOUNT BRACKET
3 - BOLT (2)
Fig. 23 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
21 - 322 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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INSTALLATION
INSTALLATION - 2.4L GAS
(1) Install modular clutch assembly to transaxle.
Assemble transaxle to engine.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.).
(3) Raise transaxle/engine assembly into position
and install upper mount through-bolt. Torque
through-bolt to 75 N´m (55 ft. lbs.).
(4) Remove screw jack.
(5) Install and torque modular clutch assembly-to-
drive plate bolts to 88 N´m (65 ft. lbs.)
(6) Install structural collar.
(7) Connect back-up lamp switch connector.
(8) Install starter motor into position (Fig. 78).
Install and torque bolts to 54 N´m (40 ft. lbs.).
(9) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).
(10) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs (Fig. 79). While
depressing inward, rotate slave cylinder clockwise
60tÉ into position until nylon locating tab rests
within transaxle case cutout, and hydraulic tube is
vertical. Connect ªquick-connectº connection until an
audible ªclickº is heard. Verify connection by pulling
outward on connection.
Fig. 77 Release Bearing and Lever
1 - RELEASE LEVER
2 - RELEASE BEARING
Fig. 78 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 79 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
21 - 338 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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(7) Install starter motor into position (Fig. 84).
Install and torque bolts to 54 N´m (40 ft. lbs.).
(8) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).
(9) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs (Fig. 85). Whiledepressing inward, rotate slave cylinder clockwise
60É into position until nylon locating tab rests within
transaxle case cutout, and hydraulic tube is vertical.
Connect ªquick-connectº connection until an audible
ªclickº is heard. Verify connection by pulling outward
on connection.
(10) Install underbody splash panel.
(11) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(12) Lower vehicle.
(13) Install right mount bracket to transaxle (Fig.
86).
Fig. 85 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 84 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 86 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
RST850 MANUAL TRANSAXLE21 - 341
T850 MANUAL TRANSAXLE (Continued)
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