2004 CHRYSLER VOYAGER Service Manual

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Page 1785 of 2585

CHRYSLER VOYAGER 2004 Service Manual ACCUMULATOR
DESCRIPTION
The 41te underdrive, overdrive, low/reverse, and
2/4 clutch hydraulic circuits each contain an accumu-
lator. An accumulator typically consists of a piston,
seals, return sprin

Page 1786 of 2585

CHRYSLER VOYAGER 2004 Service Manual OPERATION
The function of an accumulator is to cushion the
application of a frictional clutch element. When pres-
surized fluid is applied to a clutch circuit, the appli-
cation force is dampened by f

Page 1787 of 2585

CHRYSLER VOYAGER 2004 Service Manual Moving the switch up causes an upshift and moving
the switch down causes a downshift. The instrument
cluster will illuminate the selected gear. The vehicle
can be launched in 1st, 2nd, or 3rd gear whi

Moving the switch up causes an upshift and moving
the switch down causes a downshift. The instrument
cluster will illuminate the selected gear. The vehicle
can be launched in 1st, 2nd, or 3rd gear while in the
Autostick mode. The speed control is operable in 3rd
and 4th gear Autostick mode. Speed control will be
deactivated if the transaxle is shifted to 2nd gear.
Shifting into OD position cancels the Autostick mode,
and the transaxle resumes the OD shift schedule.
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. 172). The input clutch assembly also
contains:
²Input shaft
²Input hub
²Clutch retainer
²Underdrive piston
²Overdrive/reverse piston
²Overdrive hub
²Underdrive 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
DISASSEMBLY
NOTE: The differential is serviced as an assembly.
Differential service is limited to bearing cups and
cones. Any other differential component failure
must be remedied by differential assembly and
transfer shaft replacement.
Fig. 172 Input Clutch Assembly
1 - INPUT SHAFT
2 - UNDERDRIVE CLUTCH
3 - OVERDRIVE CLUTCH
4 - REVERSE CLUTCH
5 - OVERDRIVE SHAFT
6 - UNDERDRIVE SHAFT
21 - 190 41TE AUTOMATIC TRANSAXLERS
AUTOSTICK SWITCH (Continued)

Page 1788 of 2585

CHRYSLER VOYAGER 2004 Service Manual The transfer shaft should be removed for differen-
tial repair and bearing turning torque checking.
(1) Remove the differential cover and bolts (Fig.
173) (Fig. 174).(2) Remove the differential bearin

Page 1789 of 2585

CHRYSLER VOYAGER 2004 Service Manual (4) 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.
(5) Use Miller Special Tool 5048, 5048-4 Collets,
and L-4

Page 1790 of 2585

CHRYSLER VOYAGER 2004 Service Manual (8) Remove ring gear-to-differential case bolts and
floating pinion shaft retainers (Fig. 182).(9) Separate ring gear from differential case (Fig.
183).
(10) Separate differential cover from case usin

Page 1791 of 2585

CHRYSLER VOYAGER 2004 Service Manual (11) Lift support from case (Fig. 185).
(12) Remove side gear thrust washer (Fig. 186).(13) Remove side gear (Fig. 187).
(14) Remove pinion shaft (Fig. 188).
Fig. 185 Differential Support Removal
1 -

Page 1792 of 2585

CHRYSLER VOYAGER 2004 Service Manual (15) Remove pinion gears and tabbed washers
(Fig. 189).
(16) Remove differential side gear (Fig. 190).
(17) Remove side gear thrust washer (Fig. 191).
(18) Inspect all components for excessive wear.
A

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