2002 CHRYSLER VOYAGER Shift cable

(6) Install gear shift cable to transaxle upper
mount bracket (Fig. 223). An audible ªclickº should
be heard.
(7) Connect gear shift cable end to transaxle man-
ual valve lever (Fig. 223).
(8) Adjust gearshift cable. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 41TE/GEAR
SHIFT CABLE - ADJUSTMENTS)
(9) Install speed control servo into position.
(10) Install battery.
(11) Install battery shield.
(12) Connect battery cables.
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT
VERIFICATION
(1) Place gearshift lever in gated park (P).
(2) Attempt to move vehicle by rocking back and
forth on level ground. If vehicle does not move,
attempt to start engine. If engine starts, the park
position is correct.
(3) Set parking brake.
(4) Turn key to on/run and depress brake pedal.
Place gearshift lever in neutral (N).(5) Attempt to start engine. If engine starts in
both neutral (N) or park (P), gearshift cable is
adjusted properly. No adjustment is required.
(6) If engine does not start in either park (P) or
neutral (N), perform adjustment procedure.
ADJUSTMENT
(1) Park the vehicle on level ground and set the
parking brake.
(2) Place the gearshift lever in gated park (P) and
remove ignition key.
(3) Loosen the cable adjustment screw at the
transaxle manual valve lever (Fig. 224).
(4) Pull the gearshift lever fully forward to the
park detent position.
(5) Release the park brake, then rock the vehicle
to assure it is in park. Reset the park brake.
(6) Tighten the cable adjustment screw to 8 N´m
(70 in. lbs.). Gearshift cable should now be properly
adjusted.
(7) Verify adjustment by using the verification pro-
cedure.
Fig. 223 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 224 Gearshift Cable Adjustment
1 - GEARSHIFT CABLE ADJUSTMENT SCREW
2 - GEARSHIFT CABLE
21 - 254 41TE AUTOMATIC TRANSAXLERS
GEAR SHIFT CABLE (Continued)
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A conventional mechanical interlock system is also
used. This system manually prohibits shifter move-
ment when the ignition switch is in the LOCK or
ACC positions. Solenoid operation is not required in
these key positions.
For intended BTSI system operation, refer to the
following chart:
ACTION EXPECTED RESPONSE
1. Turn key to the9OFF9
position.1. Shifter CAN be shifted
out of park with brake
pedal applied.
2. Turn key to the
9ON/RUN9position.2. Shifter CANNOT be
shifted out of park.
3. Turn key to the
9ON/RUN9position and
depress the brake pedal.3. Shifter CAN be shifted
out of park.
4. Leave shifter in any
gear and try to return key
to the9LOCK9or9ACC9
position.4. Key cannot be
returned to the9LOCK9or
9ACC9position.
5. Return shifter to
9PARK9and try to remove
the key.5. Key can be removed
(after returning to9LOCK9
position).
6. With the key removed,
try to shift out of9PARK9.6. Shifter cannot be
shifted out of9PARK9.
NOTE: Any failure to meet these expected
responses requires system adjustment or repair.
DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK SOLENOID
For intended BTSI system operation, refer to the
following chart:
ACTION EXPECTED RESPONSE
1. Turn key to the9OFF9
position.1. Shifter CAN be shifted
out of park with brake
pedal applied.
2. Turn key to the
9ON/RUN9position.2. Shifter CANNOT be
shifted out of park.
3. Turn key to the
9ON/RUN9position and
depress the brake pedal.3. Shifter CAN be shifted
out of park.
4. Leave shifter in any
gear and try to return key
to the9LOCK9or9ACC9
position.4. Key cannot be
returned to the9LOCK9or
9ACC9position.
5. Return shifter to
9PARK9and try to remove
the key.5. Key can be removed
(after returning to9LOCK9
position).
ACTION EXPECTED RESPONSE
6. With the key removed,
try to shift out of9PARK9.6. Shifter cannot be
shifted out of9PARK9.
NOTE: Any failure to meet these expected
responses requires system repair. Refer to the
appropriate Diagnostic Information.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove instrument panel lower shroud (Fig.
305).
(3) Remove knee bolster (Fig. 306).
Fig. 305 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 306 Knee Bolster
1 - KNEE BOLSTER
RS41TE AUTOMATIC TRANSAXLE21 - 277
SHIFT INTERLOCK SOLENOID (Continued)
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(3) Install steering column lower shroud.
(4) Install knee bolster (Fig. 311).
(5) Install instrument panel lower silencer (Fig.
312).
(6) Connect battery negative cable.
(7) Verify proper shift interlock system operation.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/SHIFT INTERLOCK SOLENOID -
OPERATION)SOLENOID/PRESSURE
SWITCH ASSY
DESCRIPTION
The Solenoid/Pressure Switch Assembly (Fig. 313)
is external to the transaxle and mounted to the
transaxle case. The assembly consists of four sole-
noids that control hydraulic pressure to the LR/CC,
2/4, OD, and UD friction elements. The reverse
clutch is controlled by line pressure from the manual
valve in the valve body. The solenoids are contained
within the Solenoid/Pressure Switch Assembly, and
can only be serviced by replacing the assembly.
The solenoid assembly also contains pressure
switches that monitor and send hydraulic circuit
information to the TCM. Likewise, the pressure
switches can only be service by replacing the assem-
bly.
Fig. 311 Knee Bolster
1 - KNEE BOLSTER
Fig. 312 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCERFig. 313 Solenoid/Pressure Switch Assembly
1 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
RS41TE AUTOMATIC TRANSAXLE21 - 279
SHIFT INTERLOCK SOLENOID (Continued)
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OPERATION
SOLENOIDS
The solenoids receive electrical power from the
Transmission Control Relay through a single wire.
The TCM energizes or operates the solenoids individ-
ually by grounding the return wire of the solenoid
needed. When a solenoid is energized, the solenoid
valve shifts, and a fluid passage is opened or closed
(vented or applied), depending on its default operat-
ing state. The result is an apply or release of a fric-
tional element.
The 2/4 and UD solenoids are normally applied,
which by design allow fluid to pass through in their
relaxed or ªoffº state. This allows transaxle limp-in
(P,R,N,2) in the event of an electrical failure.
The continuity of the solenoids and circuits are
periodically tested. Each solenoid is turned on or off
depending on its current state. An inductive spike
should be detected by the TCM during this test. It no
spike is detected, the circuit is tested again to verify
the failure. In addition to the periodic testing, the
solenoid circuits are tested if a speed ratio or pres-
sure switch error occurs.
PRESSURE SWITCHES
The TCM relies on three pressure switches to mon-
itor fluid pressure in the L/R, 2/4, and OD hydraulic
circuits. The primary purpose of these switches is to
help the TCM detect when clutch circuit hydraulic
failures occur. The range for the pressure switch clos-
ing and opening points is 11-23 psi. Typically the
switch opening point will be approximately one psi
lower than the closing point. For example, a switch
may close at 18 psi and open at 17 psi. The switches
are continuously monitored by the TCM for the cor-
rect states (open or closed) in each gear as shown in
the following chart:
PRESSURE SWITCH STATES
GEAR L/R 2/4 OD
ROPOPOP
P/N CL OP OP
1st CL OP OP
2nd OP CL OP
DOPOPCL
OD OP CL CL
OP = OPEN
CL = CLOSED
A Diagnostic Trouble Code (DTC) will set if the
TCM senses any switch open or closed at the wrong
time in a given gear.The TCM also tests the 2/4 and OD pressure
switches when they are normally off (OD and 2/4 are
tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd
gear). The test simply verifies that they are opera-
tional, by looking for a closed state when the corre-
sponding element is applied. Immediately after a
shift into 1st, 2nd, or 3rd gear with the engine speed
above 1000 rpm, the TCM momentarily turns on ele-
ment pressure to the 2/4 and/or OD clutch circuits to
identify that the appropriate switch has closed. If it
doesn't close, it is tested again. If the switch fails to
close the second time, the appropriate Diagnostic
Trouble Code (DTC) will set.
REMOVAL
NOTE: If solenoid/pressure switch assembly is
being replaced, it is necessary to perform the TCM
Quick Learn Procedure. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly.
(3) Disconnect solenoid/pressure switch assembly
connector.
(4) Disconnect input speed sensor connector.
(5) Remove input speed sensor (Fig. 314).
Fig. 314 Input Speed Sensor
1 - INPUT SPEED SENSOR
21 - 280 41TE AUTOMATIC TRANSAXLERS
SOLENOID/PRESSURE SWITCH ASSY (Continued)
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SOLENOID SWITCH VALVE
The solenoid switch valve controls line pressure
from the LR/CC solenoid. In one position, it allows
the low/reverse clutch to be pressurized. In the other,
it directs line pressure to the converter control and
converter clutch valves.
MANUAL VALVE
The manual valve is operated by the mechanical
shift linkage. Its primary responsibility is to send
line pressure to the appropriate hydraulic circuits
and solenoids. The valve has three operating ranges
or positions.
CONVERTER CLUTCH SWITCH VALVE
The main responsibility of the converter clutch switch
valve is to control hydraulic pressure applied to the front
(off) side of the converter clutch piston. Line pressure
from the regulator valve is fed to the torque converter
regulator valve, where it passes through the valve, and is
slightly regulated. The pressure is then directed to the
converter clutch switch valve and to the front side of the
converter clutch piston. This pressure pushes the piston
back and disengages the converter clutch.
CONVERTER CLUTCH CONTROL VALVE
The converter clutch control valve controls the
back (on) side of the torque converter clutch. When
the TCM energizes or modulates the LR/CC solenoid
to apply the converter clutch piston, both the con-
verter clutch control valve and the converter control
valve move, allowing pressure to be applied to the
back side of the clutch.
T/C REGULATOR VALVE
The torque converter regulator valve slightly regu-
lates the flow of fluid to the torque converter.
LOW/REVERSE SWITCH VALVE
The low/reverse clutch is applied from different
sources, depending on whether low (1st) gear or
reverse is selected. The low/reverse switch valve
alternates positions depending on from which direc-
tion fluid pressure is applied. By design, when the
valve is shifted by fluid pressure from one channel,
the opposing channel is blocked. The switch valve
alienates the possibility of a sticking ball check, thus
providing consistent application of the low/reverse
clutch under all operating conditions.
REMOVAL
REMOVAL
NOTE: If valve body is replaced or reconditioned,
the TCM Quick Learn Procedure must be per-formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Disconnect battery negative cable.
(2) Disconnect gearshift cable from manual valve
lever.
(3) Remove manual valve lever from manual shaft.
(4) Raise vehicle on hoist.
(5) Remove oil pan bolts (Fig. 341).
(6) Remove oil pan (Fig. 342).
Fig. 341 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 342 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
21 - 294 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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REMOVAL
NOTE: If valve body is replaced or reconditioned,
the TCM Quick Learn Procedure must be per-
formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Disconnect battery negative cable.
(2) Disconnect gearshift cable from manual valve
lever.
(3) Remove manual valve lever from manual shaft.
(4) Raise vehicle on hoist.
(5) Remove oil pan bolts (Fig. 347).
(6) Remove oil pan (Fig. 348).(7) Remove oil filter (Fig. 349).
(8) Remove the valve body-to-transaxle case bolts
(Fig. 350).
NOTE: To ease removal of the valve body, turn the
manual valve lever fully clockwise to low or first
gear.
Fig. 347 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 348 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 349 Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 350 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
21 - 296 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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(2) Install transaxle oil filter (Fig. 386). Inspect
the o-ring and replace if necessary.
(3) Ensure the transaxle oil pan and transaxle
case sealing surfaces are clean and dry. Install an
1/8º bead of MopartSilicone Rubber Adhesive Seal-ant to the oil pan and install (Fig. 387). Torque oil
pan-to-transaxle case bolts (Fig. 388) to 19 N´m (165
in. lbs.).
(4) Lower vehicle.
(5) Connect transmission range sensor connector.
(6) Install manual valve lever to manual shaft.
(7) Install gearshift cable to manual valve lever.
(8) Connect battery negative cable.
(9) Fill transaxle with MopartATF +4 Transmis-
sion fluid. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
Fig. 385 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 386 Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 387 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 388 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
RS41TE AUTOMATIC TRANSAXLE21 - 307
VALVE BODY (Continued)
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T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
T850 MANUAL TRANSAXLE
DESCRIPTION........................308
OPERATION..........................311
DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES...................318
REMOVAL............................318
DISASSEMBLY........................323
ASSEMBLY...........................329
INSTALLATION........................338
SPECIFICATIONS - T850 MANUAL
TRANSAXLE........................343
SPECIAL TOOLS - T850 TRANSAXLE.......345
AXLE SEALS
REMOVAL............................348
INSTALLATION........................348
BACK-UP LAMP SWITCH
REMOVAL............................349
INSTALLATION........................349
DIFFERENTIAL
DESCRIPTION........................349
OPERATION..........................349
DISASSEMBLY........................350
ASSEMBLY...........................353
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL TURNING
TORQUE...........................356
ADJUSTMENT - DIFFERENTIAL SIDE GEAR
ENDPLAY..........................358
FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK............................358
STANDARD PROCEDURE - FLUID DRAIN
AND FILL...........................359
GEARSHIFT BOOT
REMOVAL............................359
INSTALLATION........................360GEARSHIFT CABLE - CROSSOVER
REMOVAL............................360
INSTALLATION........................363
ADJUSTMENTS
ADJUSTMENT.......................366
GEARSHIFT CABLE - SELECTOR
REMOVAL............................368
INSTALLATION........................371
GEARSHIFT KNOB
REMOVAL............................374
INSTALLATION........................374
GEARSHIFT MECHANISM
REMOVAL............................375
INSTALLATION........................377
INPUT SHAFT
DESCRIPTION........................380
DISASSEMBLY........................380
ASSEMBLY...........................383
INTERMEDIATE SHAFT
DESCRIPTION........................387
DISASSEMBLY........................388
ASSEMBLY...........................395
SHIFT COVER
DESCRIPTION........................401
SHIFT FORK AND SHAFT
DESCRIPTION........................402
SYNCHRONIZER
DESCRIPTION........................402
DISASSEMBLY........................402
CLEANING
CLEAN............................402
INSPECTION
INSPECT...........................402
ASSEMBLY...........................403
VEHICLE SPEED SENSOR
REMOVAL............................403
INSTALLATION........................403
T850 MANUAL TRANSAXLE
DESCRIPTION
The NV T850 5-speed transaxle (Fig. 1) is a con-
stant-mesh manual transaxle that is synchronized in
all gear ranges, including reverse.
The transaxle consists of three major sub-assem-
blies: the input shaft, intermediate shaft, and differ-ential assembly. The transaxle shift system consists
of a mechanical shift cover, rails, forks, and cables.
The unique design of this shift system provides a
higher mechanical advantage, resulting in less fric-
tion and lower shift cable loads for smoother, more
positive operation.
21 - 308 T850 MANUAL TRANSAXLERS
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