2002 CHRYSLER VOYAGER Electronic Control Modules

(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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(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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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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(6) Remove three (3) solenoid/pressure switch
assembly-to-transaxle case bolts (Fig. 315).
(7) Remove solenoid/pressure switch assembly and
gasket (Fig. 316). Use care to prevent gasket mate-
rial and foreign objects from become lodged in the
transaxle case ports.
INSTALLATION
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) Install solenoid/pressure switch assembly and
new gasket to transaxle (Fig. 316).
(2) Install and torque three (3) bolts (Fig. 315) to
13 N´m (110 in. lbs.).
(3) Install input speed sensor (Fig. 314) and torque
to 27 N´m (20 ft. lbs.).
(4) Connect input speed sensor connector.
(5) Install solenoid/pressure switch 8-way connec-
tor and torque to 4 N´m (35 in. lbs.).
(6) Install air cleaner assembly.
(7) Connect battery negative cable.
(8) If solenoid/pressure switch assembly was
replaced, perform TCM Quick Learn procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
SPEED SENSOR - INPUT
DESCRIPTION
The Input Speed Sensor is a two-wire magnetic
pickup device that generates AC signals as rotation
occurs. It is threaded into the transaxle case (Fig. 317) ,
sealed with an o-ring (Fig. 318), and is considered a pri-
mary input to the Transmission Control Module (TCM).
Fig. 315 Solenoid/Pressure Switch Assembly-to-
Case Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
Fig. 316 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 317 Input Speed Sensor Location
1 - INPUT SPEED SENSOR
RS41TE AUTOMATIC TRANSAXLE21 - 281
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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(9) Remove park rod rollers from guide bracket
and remove valve body from transaxle (Fig. 351) (Fig.
352).
CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
DISASSEMBLY
NOTE: If valve body assembly is being recondi-
tioned, the TCM Quick Learn Procedure must be
performed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)(1) Remove manual shaft seal (Fig. 353).
(2) Remove Transmission Range Sensor retaining
screw (Fig. 354).
Fig. 351 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
Fig. 352 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 353 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 354 Remove Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
RS41TE AUTOMATIC TRANSAXLE21 - 297
VALVE BODY (Continued)
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NOTE: Tag all valve/spring assemblies for reassem-
bly identification.
(13) Remove dual retainer plate using Tool 6301
(Fig. 365).
(14) Remove regulator valve spring retainer (Fig.
366).(15) Remove remaining retainers as shown in (Fig.
367).
(16) Remove valves and springs as shown in (Fig.
368).
NOTE: Refer to Valve Body Cleaning and Inspection
for cleaning procedures.
ASSEMBLY
NOTE: If valve body assembly is reconditioned, the
TCM Quick Learn Procedure must be performed.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
(1) Install valves and springs as shown in (Fig.
368).
(2) Install regulator valve spring retainer (Fig.
369).
(3) Install dual retainer plate using Tool 6301 (Fig.
370).
Fig. 365 Remove Dual Retainer Plate using Tool
6301
1 - TOOL 6301
2 - RETAINER
Fig. 366 Remove Regulator Valve Spring Retainer
using Tool 6302
1 - TOOL 6302
2 - RETAINER
Fig. 367 Valve Retainer Location
1 - RETAINER
2 - RETAINER
RS41TE AUTOMATIC TRANSAXLE21 - 301
VALVE BODY (Continued)
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