2004 CHRYSLER VOYAGER differential

(13) Install left and right halfshaft assemblies.
(Refer t o 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION) (14) Install front wheel/tire assemblies.
(15) Lower vehicle.
(16) Torque remaining rear mount bracket-to-tran-
saxle vertical bolts (Fig. 160) to 102 N´m (75 ft. lbs.). (17) Install transaxle upper bellhousing-to-block
bolts and torque to 95 N´m (70 ft. lbs.). (18) Install and connect crank position sensor (if
equipped). (19) Connect gearshift cable to upper mount
bracket and transaxle manual valve lever (Fig. 161).
(20) Connect solenoid/pressure switch assembly
(Fig. 162). (21) Connect transmission range sensor connector
(Fig. 162). (22) Connect input and output speed sensor con-
nectors (Fig. 162). (23) Remove plugs and install transaxle oil cooler
line service splice kit. Refer to instructions included
with kit. (24) Remove plug and Install fluid level indicator/
tube assembly. (25) Install coolant recovery bottle (Fig. 163).
(26) Install battery shield.
(27) Connect battery cables.
(28) Fill transaxle with suitable amount of ATF+4
(Automatic Transmission FluidÐType 9602). (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE/FLUID - STANDARD PROCEDURE)
Fig. 161 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 162 Component Connector Location - Typical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 163 Coolant Recovery Bottle
1 - COOLANT RECOVERY CONTAINER
2 - HOSE
3 - BOLT
4 - SUB FRAME RAIL
21s - 74 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

SPECIFICATIONS - 41TE TRANSAXLE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Transaxle Type Fully adaptive, electronically controlled, four speed
automatic with torque converter and integral differential
Cooling Method Air-to-oil heat exchanger Lubrication Pump (internal-external gear-type
GEAR RATIOS
DESCRIPTION SPECIFICATION First Gear 2.84
Second Gear 1.57 Direct Gear 1.00
Overdrive Gear 0.69 Reverse Gear 2.21
BEARING SETTINGS (END PLAY & TURNING TORQUE)
DESCRIPTION METRIC STANDARD
Differential Assembly 0.6-2 N´m 5-18 in. lbs. Output Hub 0.3-2 N´m 3-8 in. lbs.
Transfer Shaft (End Play) 0.051-0.102 mm 0.002-0.004 in.
Overall Drag At Output Hub 0.3-1.9 N´m 3-16 in. lbs.
CLUTCH CLEARANCES
DESCRIPTION METRIC STANDARD
Low/Rev Clutch (Select Reaction Plate) 0.89-1.47 mm 0.035-0.058 in.
Two/Four Clutch (No Selection) 0.76-2.64 mm 0.030-0.104 in.
Reverse Clutch (Select Snap Ring) 0.89-1.37 mm 0.035-0.054 in. Overdrive Clutch (No Selection) 1.07-3.25 mm 0.042-0.128 in.
Underdrive Clutch (Select Pressure Plate) 0.94-1.50 mm 0.037-0.059 in.
OIL PUMP CLEARANCES
DESCRIPTION METRIC STANDARD
Outer Gear-to-Crescent 0.060-0.298 mm 0.0023-0.0117 in. Inner Gear-to-Crescent 0.093-0.385 mm 0.0036-0.0151 in. Outer Gear-to-Pocket 0.089-0.202 mm 0.0035-0.0079 in.
Outer Gear Side Clearance 0.020-0.046 mm 0.0008-0.0018 in. Inner Gear Side Clearance 0.020-0.046 mm 0.0008-0.0018 in.
RS 40TE AUTOMATIC TRANSAXLE21s-87
40TE AUTOMATIC TRANSAXLE (Continued)

INPUT SHAFT
DESCRIPTION METRIC SPECIFICATIONEnd Play 0.127-0.635mm 0.005-0.025 in.
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt, Differential Cover-to-Case 19 Ð 165
Bolt, Differential Ring Gear-to-Case 95 70 Ð
Bolt, Differential Bearing Retainer-to-Case 28 21 Ð
Bolt, Driveplate-to- Crankshaft 95 70 Ð
Bolt, Extension Housing/ Plate-to-Case 28 21 Ð
Bolt, Oil Pan-to-Case 19 Ð 165 Bolt, Output Gear 271 200 Ð
Bolt, Output Gear Stirrup/Strap 23 17 Ð
Bolt, Oil Pump-to-Case 27 20 Ð
Bolt, Reaction Support-to- Case 27 20 Ð
Bolt, Solenoid/Pressure Switch Assy.-to-Case 12 Ð 110
Bolt, Torque Converter-to- Driveplate 75 55 Ð
Bolt, Transfer Gear Cover 20 Ð 175 Bolt, Valve Body-to-Case 12 Ð 105 Fitting, Oil Cooler Line 12 Ð 105 Nut, Tranfer Gear 271 200 Ð
Tap, Transaxle Pressure 5 Ð 45 Screw, L/R Clutch Retainer 5Ð45
Screw, Solenoid/Pressure Switch Assy. Connector 4Ð35
Screw, Valve Body-to- Transfer Plate 5Ð45
Sensor, Input Speed 27 20 Ð
Sensor, Output Speed 27 20 Ð Sensor, Transmission Range Sensor 5Ð45
21s - 88 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

Gear Puller L-4407A
Bearing Installer L-4410
Gear Checking Plate L-4432
Bearing Puller L-4435
Differential Tool L-4436A
Special Jaw Set L-4518
Installer L-4520
Thrust Button L-4539-2
Adapter L-4559
Adapter L-4559-2
21s - 90 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

DRIVING CLUTCHES
DESCRIPTION
Three hydraulically applied input clutches are used
to drive planetary components. The underdrive, over-
drive, and reverse clutches are considered input
clutches and are contained within the input clutch
assembly (Fig. 167). The input clutch assembly also
contains: ² Input shaft
² Input hub
² Clutch retainer
² Underdrive piston
² Overdrive/reverse piston
² Overdrive hub
² Underdrive hub
OPERATION
The three input clutches are responsible for driving
different components of the planetary geartrain.
NOTE: Refer to the ªElements In Useº chart in Diag-
nosis and Testing for a collective view of which
clutch elements are applied at each position of the
selector lever.
UNDERDRIVE CLUTCH
The underdrive clutch is hydraulically applied in
first, second, and third (direct) gears by pressurized
fluid against the underdrive piston. When the under-
drive clutch is applied, the underdrive hub drives the
rear sun gear.
OVERDRIVE CLUTCH
The overdrive clutch is hydraulically applied in
third (direct) and overdrive gears by pressurized fluid
against the overdrive/reverse piston. When the over-
drive clutch is applied, the overdrive hub drives the
front planet carrier.
REVERSE CLUTCH
The reverse clutch is hydraulically applied in
reverse gear only by pressurized fluid against the
overdrive/reverse piston. When the reverse clutch is
applied, the front sun gear assembly is driven.
FINAL DRIVE
DESCRIPTION
The 4XTE differential is a conventional open
design. It consists of a ring gear and a differential
case. The differential case consists of pinion and side
gears, and a pinion shaft. The differential case is
supported in the transaxle by tapered roller bearings
(Fig. 168).
Fig. 167 Input Clutch Assembly
1 - INPUT SHAFT
2 - UNDERDRIVE CLUTCH
3 - OVERDRIVE CLUTCH
4 - REVERSE CLUTCH
5 - OVERDRIVE SHAFT
6 - UNDERDRIVE SHAFT
Fig. 168 Differential Assembly
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - TRANSFER SHAFT
4 - PINION GEAR
5 - PINION SHAFT
6 - SIDE GEAR
RS 40TE AUTOMATIC TRANSAXLE21s-95

OPERATION
The differential assembly is driven by the transfer
shaft by way of the differential ring gear. The ring
gear drives the differential case, and the case drives
the driveshafts through the differential gears. The
differential pinion and side gears are supported in
the case by thrust washers and a pinion shaft. Dif-
ferential pinion and side gears make it possible for
front tires to rotate at different speeds while corner-
ing.
DISASSEMBLY
NOTE: The differential is serviced as an assembly.
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
any other part fails within the differential, you must
replace the differential assembly along with the
transfer shaft.
The transfer shaft should be removed for differen-
tial repair and bearing turning torque checking. (1) Remove the differential cover and bolts (Fig.
169) (Fig. 170).
(2) Remove the differential bearing retainer and
bolts (Fig. 171) (Fig. 172). (3) Using a plastic hammer, remove extension
housing/adapter plate on the right side of the trans-
axle.
WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
(4) Remove differential assembly.
Fig. 169 Differential Cover Bolts
1 - DIFFERENTIAL COVER BOLTS
2 - DIFFERENTIAL COVER
Fig. 170 Remove Differential Cover
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL COVER
Fig. 171 Differential Retainer Bolts
1 - DIFFERENTIAL RETAINER BOLTS
Fig. 172 Remove Bearing Retainer
1 - DIFFERENTIAL BEARING RETAINER
2 - TOOL L-4435
21s - 96 40TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)

(5) Set up dial indicator set C-3339 and tool
C-4996 as shown in (Fig. 173) (Fig. 174) to measure
side gear end play. Side gear end play must be
within 0.001-0.013 in. (6) Use Miller Special Tool 5048, 5048-3 Collets,
and L-4539-2 Button to remove the differential bear-
ing cone on the extension housing side. (7) Use Miller Special Tool 5048, 5048-4 Collets,
and L-4539-2 Button to remove the differential bear-
ing cone on the bearing retainer side (Fig. 175) (Fig.
176) (Fig. 177).
Fig. 173 Checking Side Gear End Play (Extension Housing Side)
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
4 - SIDE GEAR
Fig. 174 Checking Side Gear End Play (Ring Gear Side)
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
Fig. 175 Position Button and Collets OntoDifferential and Bearing (Ring Gear Side)
1 - SPECIAL TOOL L-4539-2
2 - SPECIAL TOOL 5048
3 - SPECIAL TOOL 5048-4
Fig. 176 Position Tool 5048 Over Button and Collets at Differential Bearing (Ring Gear Side)
1 - SPECIAL TO0L 5048
2 - DIFFERENTIAL
3 - SPECIAL TOOL 5048-4
RS 40TE AUTOMATIC TRANSAXLE21s-97
FINAL DRIVE (Continued)

(8) Using Miller Special Tool L-4518, remove the
differential bearing race from the extension housing/
adapter plate. (9) Using Miller Special Tool 6062A, remove the
differential bearing race from the bearing retainer
(Fig. 178) (Fig. 179).
DIFFERENTIAL SERVICE TOOLS
COMPONENT REMOVER INSTALLER
Diff. Bear. On
Retainer Side 5048, 5048-4
Collets,
L-4539-2
Button5052, C-4171
Diff. Bear. On
Ext. Hous. Side 5048, 5048-3
Collets,
L-4539-2
ButtonL-4410, C-4171
Diff. Race. On
Retainer Side 6062-A 6061, C-4171
Diff. Race. On
Ext. Hous. Side L-4518 L-4520, C-4171
Extension
Housing Seal 7794-A, C-637
Slide HammerL-4520, C-4171
Bearing
Retainer Seal 794-A, C-637
Slide HammerL-4520, C-4171
Fig. 177 Remove Differential Bearing Cone (Ring
Gear Side)
1 - SPECIAL TOOL 5048
2 - RING GEAR
Fig. 178 Position Bearing Cup Remover Tool in Retainer
1 - SPECIAL TOOL 6062A
2 - DIFFERENTIAL BEARING RETAINER
Fig. 179 Remove Bearing Cup
1 - SPECIAL TOOL 6062A
2 - DIFFERENTIAL BEARING RETAINER
21s - 98 40TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)