2003 CHRYSLER CARAVAN Service Manual

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Page 1673 of 2177

CHRYSLER CARAVAN 2003 Service Manual (26) Zero dial indicator and apply 30 psi (206 kPa)
air pressure to the overdrive clutch hose on Tool
8391. Measure and record OD clutch pack measure-
ment in four (4) places, 90É apart.
(27) Take av

Page 1674 of 2177

CHRYSLER CARAVAN 2003 Service Manual Fig. 273 Reverse Clutch Assembly
1 - SNAP RING
2 - REACTION PLATE
3 - CLUTCH DISC (2)4 - CLUTCH PLATE (1)
5 - INPUT CLUTCH ASSEMBLY
Fig. 274 Pry Up Reaction Plate to Seat Against Snap
Ring
1 - SCREWDR

Page 1675 of 2177

CHRYSLER CARAVAN 2003 Service Manual (33) Using moderate pressure, press down and
hold (near indicator) reverse clutch disc with screw-
driver or suitable tool and zero dial indicator (Fig.
276). When releasing pressure, indicator should

Page 1676 of 2177

CHRYSLER CARAVAN 2003 Service Manual (39) Install the #3 thrust washer to the underdrive
shaft assembly. Be sure five tabs are seated properly
(Fig. 279).
(40) Install the #3 thrust plate to the bottom of the
overdrive shaft assembly. Re

Page 1677 of 2177

CHRYSLER CARAVAN 2003 Service Manual OIL PUMP
DESCRIPTION
The oil pump is located in the pump housing inside
the bell housing of the transaxle case (Fig. 283). The
oil pump consists of an inner and outer gear, a hous-
ing, and a cover th

Page 1678 of 2177

CHRYSLER CARAVAN 2003 Service Manual (9) Align the Plastigage to a flat area on the reac-
tion shaft support housing.
(10) Install the reaction shaft to the pump hous-
ing. Tighten the bolts to 27 N´m (20 ft. lbs.).
(11) Remove bolts an

Page 1679 of 2177

CHRYSLER CARAVAN 2003 Service Manual ASSEMBLY
(1) Assemble oil pump as shown in (Fig. 287)
(2) Install and torque reaction shaft support-to-oil
pump housing bolts to 28 N´m (20 ft. lbs.) torque.
PLANETARY GEARTRAIN
DESCRIPTION
The plane

Page 1680 of 2177

CHRYSLER CARAVAN 2003 Service Manual INSTALLATION
(1) Using Tool C-4193, install oil pump seal (Fig.
290).
(2) Install transaxle to vehicle (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE
- INSTALLATION).
SHIFT INTERLOCK SOLENOID

INSTALLATION
(1) Using Tool C-4193, install oil pump seal (Fig.
290).
(2) Install transaxle to vehicle (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE
- INSTALLATION).
SHIFT INTERLOCK SOLENOID
DESCRIPTION
The Brake/Transmission Shift Interlock system
consists of an electro-magnetic solenoid mounted to
the steering column (Fig. 291). The solenoid's plunger
consists of an integrated hook, which operates the
shift lever pawl (part of shift lever assembly), and a
plunger return spring (Fig. 292). The solenoid also
has an integrated bracket, which facilitates fastening
to the steering column.
OPERATION
The Brake/Transmission Shift Interlock (BTSI) Sole-
noid prevents the transmission shift lever from being
moved out of PARK (P) unless the brake pedal is
applied. The BTSI solenoid is hardwired to and con-
trolled by the Intelligent Power Module (IPM). Battery
voltage is applied to one side of the solenoid with the
ignition key is in either the OFF, ON/RUN, or START
positions (Fig. 293). The ground side of the solenoid is
controlled by a driver within the IPM. It relies on volt-
age supplied from the stop lamp switch to the stop
lamp sense circuit within the IPM to tell when the
brake pedal is depressed. When the brake pedal is
depressed, the ground circuit opens, de-energizing the
solenoid. When the brake pedal is released, the ground
circuit is closed, energizing the solenoid.
When the ignition key is in either the OFF,
ON/RUN, or START positions, the BTSI solenoid is
energized, and the solenoid plunger hook pulls the
shift lever pawl into position, prohibiting the shift
lever from moving out of PARK (P) (Fig. 294). When
the brake pedal is depressed, the ground circuit
opens, de-energizing the solenoid. This moves the
gearshift lever pawl out of the way (Fig. 295), allow-
ing the shift lever to be moved into any gear position.
Fig. 290 Install Oil Pump Seal
1 - TOOL C-4193
2 - HANDLE TOOL C-4171
Fig. 291 Brake/Transmission Shift Interlock (BTSI)
Solenoid Location
1 - BTSI SOLENOID
Fig. 292 Solenoid Plunger and Return Spring
1 - PLUNGER
2 - RETURN SPRING
3 - BTSI SOLENOID
RS41TE AUTOMATIC TRANSAXLE21 - 233
SEAL - OIL PUMP (Continued)
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