2004 CHRYSLER VOYAGER automatic transmission

(16) Install manual shaft seal (Fig. 343).
INSTALLATION
NOTE: If valve body assembly is being replaced or
reconditioned, it is necessary to perform the TCM
Quick Learn Procedure. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install valve body assembly to transaxle (Fig.
344). Install and torque valve body-to-transaxle case
bolts (Fig. 345) to 12 N´m (105 in. lbs.). (2) Install transaxle oil filter (Fig. 346). Inspect
the o-ring and replace if necessary.
Fig. 343 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 344 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 345 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 346 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
21s - 164 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(3) Ensure the transaxle oil pan and transaxle
case sealing surfaces are clean and dry. Install an
1/8º bead of Mopar tSilicone Rubber Adhesive Seal-
ant to the oil pan and install (Fig. 347). Torque oil
pan-to-transaxle case bolts (Fig. 348) 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. 348 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 347 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
RS 40TE AUTOMATIC TRANSAXLE21s - 165
VALVE BODY (Continued)

41TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
41TE AUTOMATIC TRANSAXLE DISASSEMBLY ........................166
ASSEMBLY ...........................184
ACCUMULATOR DESCRIPTION ........................206 VALVE BODY
REMOVAL ............................206
DISASSEMBLY ........................208
ASSEMBLY ...........................212
INSTALLATION ........................217
41TE AUTOMATIC
TRANSAXLE
DISASSEMBLY
NOTE: If transaxle is being overhauled (clutch and/or
seal replacement) or replaced, it is necessary to per-
form the PCM/TCM Quick Learn Procedure. (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES/POW-
ERTRAIN/TRANSMISSION CONTROL MODULE - STAN-
DARD PROCEDURE)
NOTE: This procedure does not include final drive
(differential) disassembly.
(1) Remove input and output speed sensors.
(2) Remove three (3) solenoid/pressure switch
assembly-to-case bolts. (3) Remove solenoid/pressure switch assembly and
gasket (Fig. 1).
Fig. 1 Solenoid/Pressure Switch Assembly and Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
21s - 166 41TE AUTOMATIC TRANSAXLERS

(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. 125). 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. 126), the input
clutch assembly is not seated properly.
(c) Remove oil pump o-ring (Fig. 127). Be sure
to reinstall oil pump o-ring after selecting the
proper #4 thrust plate. (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. 128). (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. 125 Select Thinnest No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 126 View Through Input Speed Sensor Hole
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
Fig. 127 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 128 Measure Input Shaft End Play Using End Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
RS 41TE AUTOMATIC TRANSAXLE21s - 201
41TE AUTOMATIC TRANSAXLE (Continued)

ACCUMULATOR
DESCRIPTION
The 4XTE underdrive, overdrive, low/reverse, and 2/4
clutch hydraulic circuits each contain an accumulator.
An accumulator typically consists of a piston, return
spring(s), and a cover or plug. The overdrive and under-
drive accumulators are located within the transaxle
case, and are retained by the valve body (Fig. 145).
The low reverse accumulator (Fig. 146) is also
located within the transaxle case, but the assembly is
retained by a cover and a snap-ring.
The 2/4 accumulator is located in the valve body. It is
retained by a cover and retaining screws (Fig. 147).
VALVE BODY
REMOVAL
NOTE: If valve body is replaced or reconditioned,
the TCM Quick Learn Procedure must be per-
formed. (Refer t o 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. 148).
Fig. 145 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 146 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
Fig. 147 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
Fig. 148 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
21s - 206 41TE AUTOMATIC TRANSAXLERS

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 PCM/TCM Quick Learn Procedure must
be performed. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Remove manual shaft seal (Fig. 154). (2) Remove Transmission Range Sensor retaining
screw (Fig. 155).
(3) Remove Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 156).
Fig. 153 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 154 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 155 Remove Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
Fig. 156 Manual Shaft/Rooster Comb and Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
21s - 208 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(14) Remove regulator valve spring retainer (Fig.
167).
(15) Remove remaining retainers as shown in (Fig.
168). (16) Remove valves and springs as shown in (Fig.
169).
NOTE: Refer to Valve Body Cleaning and Inspection
for cleaning procedures.
ASSEMBLY
NOTE: If valve body assembly is reconditioned, the
PCM/TCM Quick Learn Procedure must be per-
formed. (Refer t o 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Install valves and springs as shown in (Fig.
169). (2) Install regulator valve spring retainer (Fig.
170). (3) Install dual retainer plate using Tool 6301 (Fig.
171).
Fig. 167 Remove Regulator Valve Spring Retainer using Tool 6302
1 - TOOL 6302
2 - RETAINER
Fig. 168 Valve Retainer Location
1 - RETAINER
2 - RETAINER
21s - 212 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(4) Verify that all retainers are installed as shown
in (Fig. 172). Retainers should be flush or below
valve body surface. (5) Install check balls into position as shown in
(Fig. 173). If necessary, secure them with petrolatum
or transmission assembly gel for assembly ease.
Fig. 172 Valve Retainer Location
1 - RETAINER
2 - RETAINER
Fig. 173 Ball Check Location
1 - (#4) BALL CHECK LOCATION
2 - (#2) BALL CHECK LOCATION
3 - RETAINER 4 - (#3) BALL CHECK LOCATION
5 - LOW/REVERSE SWITCH VALVE
6 - T/C LIMIT VALVE
21s - 214 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)