2004 CHRYSLER VOYAGER ABS

(10) Remove and inspect OD and UD Shafts, as
well as #3 thrust washer and plate, and #2 needle
bearing (Fig. 202).
Fig. 202 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
21s - 110 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(15) Remove input hub tapered snap ring (Fig.
206) (Fig. 212).
(16) Tap on input hub with soft faced hammer and
separate input hub from OD/Reverse piston and
clutch retainer (Fig. 207). (17) Separate clutch retainer from OD/Reverse pis-
ton (Fig. 208).
Fig. 206 Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
Fig. 207 Tap on Input Hub
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - PLASTIC HAMMER
Fig. 208 Pull Retainer from Piston
1 - OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
RS 40TE AUTOMATIC TRANSAXLE21s - 113
INPUT CLUTCH ASSEMBLY (Continued)

(4) Install the OD/Reverse piston assembly to the
input clutch retainer as shown in (Fig. 217).
(5) Install the input hub/shaft assy. to the OD/Re-
verse piston/clutch retainer assy. (Fig. 218). (6) Install input hub tapered snap ring (Fig. 219)
(Fig. 220).
Fig. 217 Install OD/Reverse Piston
1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
Fig. 218 Install Input Shaft Hub Assembly
1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY
(ROTATE TO ALIGN SPLINES)
2 - OD/REV. PISTON
Fig. 219 Install Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
RS 40TE AUTOMATIC TRANSAXLE21s - 117
INPUT CLUTCH ASSEMBLY (Continued)

(33) Using moderate pressure, press down and
hold (near indicator) reverse clutch disc with screw-
driver or suitable tool and zero dial indicator (Fig.
248). When releasing pressure, indicator should
advance 0.005-0.010. as clutch pack relaxes.
(34) Apply 30 psi (206 kPa) air pressure to the
reverse clutch hose on Tool 8391. Measure and record
reverse clutch pack measurement in four (4) places,
90É apart. (35) Take average of four measurements and com-
pare with reverse clutch pack clearance specification.
The reverse clutch pack clearance is 0.89-1.37
mm (0.035-0.054 in.). Select the proper reverse
clutch snap ring to achieve specifications:
REVERSE CLUTCH SNAP RING THICKNESS
4377195 1.53-1.58 mm (0.060-0.062 in.)
4412871 1.77-1.83 mm (0.070-0.072 in.)
4412872 2.02-2.07 mm (0.080-0.082 in.)
4412873 2.27-2.32 mm (0.090-0.091 in.) (36) To complete the assembly, reverse clutch and
overdrive clutch must be removed. (37) Install the #2 needle bearing (Fig. 249).
(38) Install the underdrive shaft assembly (Fig.
250).
Fig. 248 Press Down on Reverse Clutch and Zero Indicator
1 - DIAL INDICATOR
2 - REVERSE CLUTCH
Fig. 249 Install No. 2 Needle Bearing
1 - #2 NEEDLE BEARING (NOTE 3 SMALL TABS)
2 - TABS UP
Fig. 250 Install Underdrive Shaft Assembly
1 - UNDERDRIVE SHAFT ASSEMBLY
2 - #2 NEEDLE BEARING
21s - 128 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(39) Install the #3 thrust washer to the underdrive
shaft assembly. Be sure five tabs are seated properly
(Fig. 251).
(40) Install the #3 thrust plate to the bottom of the
overdrive shaft assembly. Retain with petrolatum or
transmission assembly gel (Fig. 252). (41) Install the overdrive shaft assembly (Fig. 253)
(Fig. 254).
(42) Reinstall overdrive and reverse clutch as
shown. Rechecking these clutch clearances is
not necessary.
Fig. 251 Install No. 3 Thrust Washer
1 - #3 THRUST WASHER (NOTE 5 TABS)
2 - UNDERDRIVE SHAFT ASSEMBLY
Fig. 252 Install No. 3 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - DABS OF PETROLATUM (FOR RETENTION)
3 - #3 THRUST PLATE (NOTE 3 TABS)
Fig. 253 Install Overdrive Shaft Assembly
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #3 THRUST PLATE
3 - #3 THRUST WASHER
RS 40TE AUTOMATIC TRANSAXLE21s - 129
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 254 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
21s - 130 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(22) Remove #4 thrust plate (Fig. 22).
(23) Remove front sun gear assembly and #4
thrust washer (Fig. 23). (24) Remove front carrier/rear annulus assembly
and #6 needle bearing (Fig. 24).
(25) Remove rear sun gear and #7 needle bearing
(Fig. 25).
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. 26). A small amount of petrolatum can be
used to hold the bearing to the rear sun gear.
Fig. 22 No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 23 Remove Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
Fig. 24 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. 25 Remove Rear Sun Gear
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
21s - 172 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

(23) Bend tabs on strap up against flats of bolts
(Fig. 96).
(24) Install transfer shaft bearing cone using Tool
6052 (Fig. 97). (25) Install bearing cup and oil baffle to transfer
shaft (Fig. 98).
(26) Using Tool 5049A, install transfer shaft (Fig.
99).
Fig. 96 Bend Tabs On Strap Up Against Flats Of Bolts
1 - RETAINING STRAP TABS
2 - RETAINING STRAP
3 - STIRRUP
Fig. 97 Install Transfer Shaft Bearing Cone
1 - TOOL 6052
2 - NEW BEARING CONE
3 - TRANSFER SHAFT
4 - ARBOR PRESS RAM
Fig. 98 Install Bearing Cup to Shaft
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
Fig. 99 Install Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
21s - 192 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)