2003 CHRYSLER CARAVAN ABS

(21) Remove #1 needle bearing (Fig. 36).
(22) Remove input clutch assembly (Fig. 37).(23) Remove #4 thrust plate (Fig. 38).
(24) Remove front sun gear assembly and #4
thrust washer (Fig. 39).
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
Fig. 38 No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 39 Remove Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
21 - 132 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(25) Remove front carrier/rear annulus assembly
and #6 needle bearing (Fig. 40).
(26) Remove rear sun gear and #7 needle bearing
(Fig. 41).
NOTE: The number 7 needle bearing has three anti-
reversal tabs and is common with the number five
and number two position. The orientation should
allow the bearing to seat flat against the rear sun
gear (Fig. 42). A small amount of petrolatum can be
used to hold the bearing to the rear sun gear.(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.
Fig. 40 Remove Front Carrier and Rear Annulus
Assembly
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 41 Remove Rear Sun Gear
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
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
RS41TE AUTOMATIC TRANSAXLE21 - 133
41TE AUTOMATIC TRANSAXLE (Continued)
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(23) Bend tabs on strap up against flats of bolts
(Fig. 112).
(24) Install transfer shaft bearing cone using Tool
6052 (Fig. 113).(25) Install bearing cup and oil baffle to transfer
shaft (Fig. 114).
(26) Using Tool 5049A, install transfer shaft (Fig.
115).
Fig. 112 Bend Tabs On Strap Up Against Flats Of
Bolts
1 - RETAINING STRAP TABS
2 - RETAINING STRAP
3 - STIRRUP
Fig. 113 Install Transfer Shaft Bearing Cone
1 - TOOL 6052
2 - NEW BEARING CONE
3 - TRANSFER SHAFT
4 - ARBOR PRESS RAM
Fig. 114 Install Bearing Cup to Shaft
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
Fig. 115 Install Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
21 - 152 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(49) Install rear sun gear and #7 needle bearing
(Fig. 138).
NOTE: The number seven needle bearing has three
anti-reversal tabs and is common with the number
five and number two position. The orientation
should allow the bearing to seat flat against the
rear sun gear (Fig. 137). A small amount of petrola-
tum can be used to hold the bearing to the rear sun
gear.
(50) Install front carrier/rear annulus assembly
and #6 needle bearing (Fig. 139).
(51) Install front sun gear assembly and #4 thrust
washer (Fig. 140).(52)DETERMINING #4 THRUST PLATE
THICKNESS / INPUT SHAFT END PLAY:
(a) Select the thinnest #4 thrust plate thickness
and install to input clutch assembly (Fig. 141). Use
petrolatum to retain.
(b) Install input clutch assembly into position
and verify that it is completely seated by viewing
through input speed sensor hole. If view through
input speed sensor hole is not as shown in (Fig.
142), the input clutch assembly is not seated prop-
erly.
(c) Remove oil pump o-ring (Fig. 143).Be sure
to reinstall oil pump o-ring after selecting the
proper #4 thrust plate.
Fig. 137 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 138 Install Rear Sun Gear and #7 Needle
Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 139 Install Front Carrier and Rear Annulus
Assembly
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 140 Install Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
21 - 160 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(d) Install pump and gasket to transmission.
Install and torque bolts.
(e) Set up input shaft for measurement with
Indicator Set C3339 and End Play Set 8266 as
shown in (Fig. 144).
(f) Measure the input shaft end play with the
transaxle in the vertical position.Input shaft end
play must be within 0.005 to 0.025 inch.For
example, if end play reading is 0.055 inch, select
No. 4 Thrust Plate which is 0.071 to 0.074 thick.
This should provide an input shaft end play read-
ing of 0.020 inch which is within specifications.
(g) Refer to the No. 4 thrust plate chart to select
the proper No. 4 thrust plate:
Fig. 141 Select Thinnest No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 142 View Through Input Speed Sensor Hole
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
Fig. 143 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 144 Measure Input Shaft End Play Using End
Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
RS41TE AUTOMATIC TRANSAXLE21 - 161
41TE AUTOMATIC TRANSAXLE (Continued)
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(2) Install side gear to differential case (Fig. 193).
(3) Install both pinion gears and washers to case,
while orientating washer tabs to notch in case (Fig.
194).(4) Install pinion shaft (Fig. 195).
(5) Install side gear to case (Fig. 196).
Fig. 193 Side Gear Installation
1 - DIFFERENTIAL SIDE GEAR
Fig. 194 Pinion Gear and Washer Installation
1 - PINION GEAR
2 - TABBED WASHER
3 - LOCATING TAB
4 - NOTCH
Fig. 195 Pinion Shaft Installation
1 - PINION SHAFT
Fig. 196 Side Gear Installation
1 - DIFFERENTIAL SIDE GEAR
21 - 196 41TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)
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Fig. 230 Overdrive/Underdrive Shafts
1 - OVERDRIVE SHAFT
2 - #3 THRUST PLATE (3 TABS)
3 - #3 THRUST WASHER (5 TABS)4 - UNDERDRIVE SHAFT
5 - #2 NEEDLE BEARING (3 TABS)
6 - INPUT CLUTCH ASSEMBLY
RS41TE AUTOMATIC TRANSAXLE21 - 211
INPUT CLUTCH ASSEMBLY (Continued)
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Fig. 233 Underdrive Clutch Piston, Spring and Retainer
1 - SNAP RING
2 - SPRING RETAINER
3 - SPRING
4 - UD CLUTCH PISTON5 - SEAL, OUTER
6 - SEAL, INNER
7 - INPUT CLUTCH ASSEMBLY
Fig. 234 Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERSFig. 235 Tap on Input Hub
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - PLASTIC HAMMER
RS41TE AUTOMATIC TRANSAXLE21 - 213
INPUT CLUTCH ASSEMBLY (Continued)
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