2004 CHRYSLER VOYAGER ECU

INSTALLATION
(1) Fish gear shift cable dash panel opening into
engine compartment and secure grommet (Fig. 218).
(2) Install gear shift cable through column bracket
(Fig. 219) until audible ªclickº is heard.(3) Connect gear shift cable to gear shift lever (Fig.
219).
Fig. 216 Gearshift Cable at Column
1 - GEAR SHIFT CABLE
Fig. 217 Gearshift Cable/Grommet at Dash Panel
1 - CABLE GROMMET
2 - DASH PANEL
Fig. 218 Gearshift Cable/Grommet at Dash Panel
1 - CABLE GROMMET
2 - DASH PANEL
Fig. 219 Gearshift Cable at Column
1 - GEAR SHIFT CABLE
RS41TE AUTOMATIC TRANSAXLE21 - 205
GEAR SHIFT CABLE (Continued)

TORQUE CONVERTER CLUTCH (TCC)
In a standard torque converter, the impeller and
turbine are rotating at about the same speed and the
stator is freewheeling, providing no torque multipli-
cation. By applying the turbine's piston to the front
cover's friction material, a total converter engage-
ment can be obtained. The result of this engagement
is a direct 1:1 mechanical link between the engine
and the transmission.
The engagement and disengagement of the TCC
are automatic and controlled by the Powertrain Con-
trol Module (PCM). The engagement cannot be acti-
vated in the lower gears because it eliminates the
torque multiplication effect of the torque converter
necessary for acceleration. Inputs that determine
clutch engagement are: coolant temperature, vehicle
speed and throttle position. The torque converter
clutch is engaged by the clutch solenoid on the valve
body. The clutch will engage at approximately 56
km/h (35 mph) with light throttle, after the shift to
third gear.
REMOVAL
(1) Remove transmission and torque converter
from vehicle. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE - REMOVAL)
(2) Place a suitable drain pan under the converter
housing end of the transmission.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pull the torque converter forward until the cen-
ter hub clears the oil pump seal.
(4) Separate the torque converter from the trans-
mission.
INSTALLATION
Check converter hub and drive notches for sharp
edges, burrs, scratches, or nicks. Polish the hub and
notches with 320/400 grit paper or crocus cloth if nec-
essary. The hub must be smooth to avoid damaging
the pump seal at installation.
(1) Lubricate converter hub and oil pump seal lip
with transmission fluid.
(2) Place torque converter in position on transmis-
sion.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.(3) Align torque converter to oil pump seal open-
ing.
(4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 326). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter is fully seated.
(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.
(8) Install the transmission in the vehicle. (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE - INSTALLATION)
(9) Fill the transmission with the recommended
fluid. (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 41TE/FLUID - STANDARD PROCE-
DURE)TRANSMISSION CONTROL
RELAY
DESCRIPTION
The transmission control relay (Fig. 327) is located
in the Intelligent Power Module (IPM), which is
located on the left side of the engine compartment
between the battery and left fender.
Fig. 326 Checking Torque Converter Seating
1 - SCALE
2 - STRAIGHTEDGE
RS41TE AUTOMATIC TRANSAXLE21 - 247
TORQUE CONVERTER (Continued)

(2) Install regulator valve spring retainer (Fig.
354).
(3) Install dual retainer plate using Tool 6301 (Fig.
355).(4) Verify that all retainers are installed as shown
in (Fig. 356). Retainers should be flush or below
valve body surface.
(5) Install check balls into position as shown in
(Fig. 357). If necessary, secure them with petrolatum
or transmission assembly gel for assembly ease.
Fig. 354 Install Regulator Valve Spring Retainer
using Tool 6302
1 - TOOL 6302
2 - RETAINER
Fig. 355 Install Dual Retainer Plate using Tool 6301
1 - TOOL 6301
2 - RETAINER
Fig. 356 Valve Retainer Location
1 - RETAINER
2 - RETAINER
21 - 258 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

TRANSMISSION/TRANSAXLE
TABLE OF CONTENTS
page page
T850 MANUAL TRANSAXLE ................1
40TE AUTOMATIC TRANSAXLE .............2441TE AUTOMATIC TRANSAXLE
............166
T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
INPUT SHAFT DESCRIPTION ..........................1
DISASSEMBLY ..........................1
ASSEMBLY .............................5 INTERMEDIATE SHAFT
DESCRIPTION ..........................9
DISASSEMBLY .........................10
ASSEMBLY ............................17
INPUT SHAFT
DESCRIPTION
The input shaft assembly (Fig. 1) is part of the
transaxle geartrain, is driven by the clutch assembly,
and consists of the following components: ² Input Mainshaft
² 3rd Speed Gear
² 4th Speed Gear
² 3/4 Synchronizer
² 5th Input Gear
The input shaft meshes with the intermediate
shaft, and is supported by a needle bearing at the
front of the transaxle, and a sealed roller bearing at
the rear of the transaxle.
DISASSEMBLY
NOTE: When servicing the input shaft assembly, all
snap rings which are removed MUST be replaced
with new snap rings upon reassembly. The 5th gear
nut must be replaced also.
(1) Invert input shaft assembly and place in fix-
ture 8487. (2) Remove input bearing snap ring (Fig. 2).
(3) Remove input bearing. Place input shaft
assembly onto arbor press table, with the input bear-
ing supported by bearing splitter (Fig. 3). Using
adapter 8486-4, press bearing off of shaft, while
helper supports shaft to prevent dropping. (4) Place input shaft assembly back into fixture
8487. Secure fixture to bench with fasteners, or
secure to bench vise.
RS TRANSMISSION/TRANSAXLE21s-1

(27) Lower engine/transaxle assembly with screw
jack. (28) Obtain helper and/or transmission jack.
Secure transmission jack to transaxle assembly. (29) Remove upper mount bracket from transaxle
(Fig. 14). (30) Remove remaining transaxle bellhousing-to-
engine bolts. (31) Remove transaxle assembly from vehicle.
DISASSEMBLY
NOTE: If transaxle is being overhauled (clutch
and/or seal replacement) or replaced, it is neces-
sary to perform the PCM/TCM Quick Learn Proce-
dure. (Refer t o 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/POWERTRAIN/TRANSMIS-
SION CONTROL MODULE - STANDARD PROCE-
DURE)
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. 15). (4) Remove oil pan-to-case bolts (Fig. 16).
(5) Remove oil pan (Fig. 17).
Fig. 15 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 16 Remove Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
Fig. 17 Remove Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPAR TATF RTV (MS-GF41)
3 - OIL FILTER
21s - 34 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is nec-
essary to perfrom the TCM Quick Learn procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
(1) Using a transmission jack and a helper, posi-
tion transaxle assembly to engine. Install and torque
bellhousing bolts to 95 N´m (70 ft. lbs.). (2) Install upper mount assembly to transaxle and
torque bolts to 54 N´m (40 ft. lbs.) (Fig. 159). (3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 159). (4) Remove transmission jack and screw jack.
(5) Secure left wheelhouse splash shield.
(6) Install torque converter-to-drive plate bolts and
torque to 88 N´m (65 ft. lbs.) (7) Install inspection cover.
(8) Install lateral bending brace.
(9) Install starter motor.
(10) Install front mount/bracket assembly.
(11) Align and install rear mount bracket-to-case
bolts by hand (Fig. 160). Torque horizontal bolt to
102 N´m (75 ft. lbs.). (12) AWD models: Install power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - INSTALLATION)
Fig. 160 Rear Mount Bracket - Typical
1 - BOLT - VERTICAL 102 N´m (75 ft. lbs.)
2 - BRACKET - REAR MOUNT 3 - BOLT - HORIZONTAL 102 N´m (75 ft. lbs.)
Fig. 159 Left Mount to Bracket and Transaxle
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
RS
40TE AUTOMATIC TRANSAXLE21s-73
40TE AUTOMATIC TRANSAXLE (Continued)

STATOR
Torque multiplication is achieved by locking the
stator's over-running clutch to its shaft (Fig. 300).
Under stall conditions (the turbine is stationary), the
oil leaving the turbine blades strikes the face of the
stator blades and tries to rotate them in a counter-
clockwise direction. When this happens the over±run-
ning clutch of the stator locks and holds the stator
from rotating. With the stator locked, the oil strikes
the stator blades and is redirected into a ªhelpingº
direction before it enters the impeller. This circula-
tion of oil from impeller to turbine, turbine to stator,
and stator to impeller, can produce a maximum
torque multiplication of about 2.4:1. As the turbine
begins to match the speed of the impeller, the fluid
that was hitting the stator in such as way as to
cause it to lock±up is no longer doing so. In this con-
dition of operation, the stator begins to free wheel
and the converter acts as a fluid coupling.
TORQUE CONVERTER CLUTCH (TCC)
In a standard torque converter, the impeller and
turbine are rotating at about the same speed and the
stator is freewheeling, providing no torque multipli-
cation. By applying the turbine's piston to the front
cover's friction material, a total converter engage-
ment can be obtained. The result of this engagement
is a direct 1:1 mechanical link between the engine
and the transmission. The engagement and disengagement of the TCC
are automatic and controlled by the Powertrain Con-
trol Module (PCM). The engagement cannot be acti-
vated in the lower gears because it eliminates the
torque multiplication effect of the torque converter
necessary for acceleration. Inputs that determine clutch engagement are: coolant temperature, vehicle
speed and throttle position. The torque converter
clutch is engaged by the clutch solenoid on the valve
body. The clutch will engage at approximately 56
km/h (35 mph) with light throttle, after the shift to
third gear.
REMOVAL
(1) Remove transmission and torque converter
from vehicle. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE - REMOVAL) (2) Place a suitable drain pan under the converter
housing end of the transmission.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pull the torque converter forward until the cen-
ter hub clears the oil pump seal. (4) Separate the torque converter from the trans-
mission.
INSTALLATION
Check converter hub and drive notches for sharp
edges, burrs, scratches, or nicks. Polish the hub and
notches with 320/400 grit paper or crocus cloth if nec-
essary. The hub must be smooth to avoid damaging
the pump seal at installation. (1) Lubricate converter hub and oil pump seal lip
with transmission fluid. (2) Place torque converter in position on transmis-
sion.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
(3) Align torque converter to oil pump seal open-
ing. (4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears. (6) Check converter seating with a scale and
straightedge (Fig. 301). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter is fully seated. (7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing. (8) Install the transmission in the vehicle. (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE - INSTALLATION)
Fig. 300 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
RS 40TE AUTOMATIC TRANSAXLE21s - 149
TORQUE CONVERTER (Continued)

(2) Install regulator valve spring retainer (Fig.
329).
(3) Install dual retainer plate using Tool 6301 (Fig.
330). (4) Verify that all retainers are installed as shown
in (Fig. 331). Retainers should be flush or below
valve body surface.
(5) Install check balls into position as shown in
(Fig. 332). If necessary, secure them with petrolatum
or transmission assembly gel for assembly ease. (6) Install thermal valve into transfer plate (Fig.
333). (7) Install separator plate to valve body (Fig. 334).
Fig. 329 Install Regulator Valve Spring Retainer using Tool 6302
1 - TOOL 6302
2 - RETAINER
Fig. 330 Install Dual Retainer Plate using Tool 6301
1 - TOOL 6301
2 - RETAINER
Fig. 331 Valve Retainer Location
1 - RETAINER
2 - RETAINER
21s - 160 40TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)