2004 CHRYSLER VOYAGER Service Manual

spare tire location child lock air condition headlamp steering brake rotor

Load previous 8 pages

Page 1881 of 2585

CHRYSLER VOYAGER 2004 Service Manual (9) Install 2nd gear blocker ring (Fig. 64).
(10) Install 2nd gear friction cone (Fig. 65).(11) Install 2nd gear reactor ring (Fig. 66).
(12) Install 2nd gear and needle bearing to inter-
mediate shaf

Page 1882 of 2585

CHRYSLER VOYAGER 2004 Service Manual (13) Press 3/4 cluster gear onto intermediate shaft
using cup 8481 (Fig. 69). (14) Install
NEW3/4 cluster gear snap ring (Fig.
70).
(15) Install 5th gear and needle bearing to inter-
mediate shaft (Fi

Page 1883 of 2585

CHRYSLER VOYAGER 2004 Service Manual (16) Install 5th gear blocker ring to synchronizer
(Fig. 73). (17) Install 5th gear synchronizer assembly to
intermediate shaft (Fig. 74). When installing 5/R
synchronizer, make sure to align oil slot

Page 1884 of 2585

CHRYSLER VOYAGER 2004 Service Manual (19) Install reverse gear blocker ring (Fig. 76).
(20) Install reverse gear needle bearing (Fig. 77).
(21) Install reverse gear to intermediate shaft.
(22) Install intermediate shaft sealed roller bea

Page 1885 of 2585

CHRYSLER VOYAGER 2004 Service Manual 40TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
40TE AUTOMATIC TRANSAXLE DESCRIPTION .........................25
OPERATION ...........................27
DIAGNOSIS AND TESTING DIAGNOSIS AND TESTIN

40TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
40TE AUTOMATIC TRANSAXLE DESCRIPTION .........................25
OPERATION ...........................27
DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - 4XTETRANSAXLE GENERAL DIAGNOSIS .......27
DIAGNOSIS AND TESTING - ROAD TEST . . . 27
DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TESTS ....................28
DIAGNOSIS AND TESTING - CLUTCH AIR PRESSURE TESTS ....................30
DIAGNOSIS AND TESTING - TORQUE CONVERTER HOUSING FLUID LEAKAGE . . . 31
REMOVAL .............................31
DISASSEMBLY .........................34
ASSEMBLY ............................51
INSTALLATION .........................73
SCHEMATICS AND DIAGRAMS 4XTE TRANSAXLE HYDRAULICSCHEMATICS ........................75
SPECIFICATIONS - 41TE TRANSAXLE .......87
SPECIAL TOOLS .......................89
ACCUMULATOR DESCRIPTION .........................94
OPERATION ...........................94
DRIVING CLUTCHES DESCRIPTION .........................95
OPERATION ...........................95
FINAL DRIVE DESCRIPTION .........................95
OPERATION ...........................96
DISASSEMBLY .........................96
ASSEMBLY ............................99
ADJUSTMENTS DIFFERENTIAL BEARING PRELOADMEASUREMENT AND ADJUSTMENT ......100
FLUID STANDARD PROCEDURE FLUID LEVEL AND CONDITION CHECK . . . 102
STANDARD PROCEDURE - FLUID ANDFILTER SERVICE .....................104
GEAR SHIFT CABLE REMOVAL ............................105
HOLDING CLUTCHES DESCRIPTION ........................106
OPERATION ..........................106
INPUT CLUTCH ASSEMBLY DISASSEMBLY ........................107
ASSEMBLY ...........................116 OIL PUMP
DESCRIPTION ........................131
OPERATION ..........................131
DISASSEMBLY ........................131
ASSEMBLY ...........................132
PLANETARY GEARTRAIN DESCRIPTION ........................132
OPERATION ..........................132
SEAL - OIL PUMP REMOVAL ............................133
INSTALLATION ........................133
SHIFT INTERLOCK SOLENOID DESCRIPTION ........................133
OPERATION ..........................134
DIAGNOSIS AND TESTING - BRAKE/ TRANSMISSION SHIFT INTERLOCK
SOLENOID ..........................135
REMOVAL ............................135
INSTALLATION ........................136
SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION ........................137
OPERATION ..........................137
REMOVAL ............................138
INSTALLATION ........................139
SPEED SENSOR - INPUT DESCRIPTION ........................140
OPERATION ..........................140
REMOVAL ............................141
INSTALLATION ........................141
SPEED SENSOR - OUTPUT DESCRIPTION ........................142
OPERATION ..........................142
REMOVAL ............................143
INSTALLATION ........................143
TORQUE CONVERTER DESCRIPTION ........................144
OPERATION ..........................148
REMOVAL ............................149
INSTALLATION ........................149
TRANSMISSION CONTROL RELAY DESCRIPTION ........................150
OPERATION ..........................150
TRANSMISSION RANGE SENSOR DESCRIPTION ........................150
OPERATION ..........................151
REMOVAL ............................151
INSTALLATION ........................152
VALVE BODY DESCRIPTION ........................152
21s - 24 40TE AUTOMATIC TRANSAXLERS

Page 1886 of 2585

CHRYSLER VOYAGER 2004 Service Manual OPERATION..........................152
REMOVAL ............................153
DISASSEMBLY ........................155 ASSEMBLY
...........................159
INSTALLATION ........................164

Page 1887 of 2585

CHRYSLER VOYAGER 2004 Service Manual holding clutches: 2nd/4th gear and Low/Reverse. The
primary mechanical components of the transaxle con-
sist of the following:² Three multiple disc input clutches
² Two multiple disc holding clutche

holding clutches: 2nd/4th gear and Low/Reverse. The
primary mechanical components of the transaxle con-
sist of the following:² Three multiple disc input clutches
² Two multiple disc holding clutches
² Four hydraulic accumulators
² Two planetary gear sets
² Hydraulic oil pump
² Valve body
² Solenoid/Pressure switch assembly
² Integral differential assembly
Control of the transaxle is accomplished by fully
adaptive electronics. Optimum shift scheduling is
accomplished through continuous real-time sensor
feedback information provided to the Powertrain
Control Module (PCM) or Transmission Control Mod-
ule (TCM). The PCM/TCM is the heart of the electronic control
system and relies on information from various direct
and indirect inputs (sensors, switches, etc.) to deter-
mine driver demand and vehicle operating condi-
tions. With this information, the PCM/TCM can
calculate and perform timely and quality shifts
through various output or control devices (solenoid
pack, transmission control relay, etc.). The PCM/TCM also performs certain self-diagnos-
tic functions and provides comprehensive information
(sensor data, DTC's, etc.) which is helpful in proper
diagnosis and repair. This information can be viewed
with the DRB scan tool.
TRANSAXLE IDENTIFICATION
The 40TE transaxle is identified by a barcode label
that is fixed to the transaxle case as shown in (Fig.
2). The label contains a series of digits that can be
translated into useful information such as transaxle
part number, date of manufacture, manufacturing
origin, plant shift number, build sequence number,
etc. Refer to (Fig. 3) for identification label break-
down. If the tag is not legible or missing, the ªPKº num-
ber, which is stamped into the transaxle case behind
the transfer gear cover, can be referred to for identi-
fication. This number differs slightly in that it con-
tains the entire transaxle part number, rather than
the last three digits.
Fig. 2 Transaxle Identification Label
1 - IDENTIFICATION LABEL
Fig. 3 Identification Label Breakdown
1 - T=TRACEABILITY
2 - SUPPLIER CODE (PK=KOKOMO)
3 - COMPONENT CODE (TK=KOKOMO TRANSMISSION)
4 - BUILD DAY (344=DEC. 9)
5 - BUILD YEAR (9=1999)
6 - LINE/SHIFT CODE (3=3RD SHIFT)
7 - BUILD SEQUENCE NUMBER
8 - LAST THREE OF P/N
9 - ALPHA
10 - TRANSAXLE PART NUMBER
11 - P=PART NUMBER
21s - 26 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

Page 1888 of 2585

CHRYSLER VOYAGER 2004 Service Manual OPERATION
Transmission output is directed to an integral dif-
ferential by a transfer gear system in the following
input-to-output ratios:
First ............................... 2.84 : 1
Second .......

OPERATION
Transmission output is directed to an integral dif-
ferential by a transfer gear system in the following
input-to-output ratios:
First ............................... 2.84 : 1
Second ............................. 1.57 : 1
Third .............................. 1.00 : 1
Overdrive ........................... 0.69 : 1
Reverse ............................ 2.21 : 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - 4XTE TRANSAXLE
GENERAL DIAGNOSIS
NOTE: Before attempting any repair on a 4XTE four-
speed automatic transaxle, check for diagnostic trou-
ble codes (DTC's) using the DRB scan tool. Refer to
the Transmission Diagnostic Procedures Manual.
Transaxle malfunctions may be caused by these
general conditions: ² Poor engine performance
² Improper adjustments
² Hydraulic malfunctions
² Mechanical malfunctions
² Electronic malfunctions
Diagnosis of these problems should always begin by
checking the easily accessible variables: fluid level and
condition, gearshift cable adjustment. Then perform a
road test to determine if the problem has been corrected
or that more diagnosis is necessary. If the problem per-
sists after the preliminary tests and corrections are com-
pleted, hydraulic pressure checks should be performed.
DIAGNOSIS AND TESTING - ROAD TEST
Prior to performing a road test, verify that the
fluid level, fluid condition, and linkage adjustment
have been approved. During the road test, the transaxle should be oper-
ated in each position to check for slipping and any
variation in shifting. If the vehicle operates properly at highway speeds,
but has poor acceleration, the converter stator over-
running clutch may be slipping. If acceleration is nor-
mal, but high throttle opening is needed to maintain
highway speeds, the converter stator clutch may
have seized. Both of these stator defects require
replacement of the torque converter and thorough
transaxle cleaning. Slipping clutches can be isolated by comparing the
ªElements in Useº chart with clutch operation
encountered on a road test. This chart identifies
which clutches are applied at each position of the
selector lever.
A slipping clutch may also set a DTC and can be deter-
mined by operating the transaxle in all selector positions.
ELEMENTS IN USE AT EACH POSITION OF SELECTOR LEVER
Shift Lever Position INPUT CLUTCHES HOLDING CLUTCHES
Underdrive Overdrive Reverse 2/4 Low/Reverse
P - PARK X
R - REVERSE X X N - NEUTRAL X
OD - OVERDRIVE
First X X
Second X X Direct X X
Overdrive X X
D - DRIVE*
First X X
Second X X Direct X X
L - LOW*
First X X
Second X X
Direct X X
* Vehicle upshift and downshift speeds are increased when in these selector positions.
RS 40TE AUTOMATIC TRANSAXLE21s-27
40TE AUTOMATIC TRANSAXLE (Continued)

Load next 8 pages

Page: < prev 1-10 ... 1849-1856 1857-1864 1865-1872 1873-1880 1881-1888 1889-1896 1897-1904 1905-1912 1913-1920 ... 2592 next >

ABS towing air condition fuse ESP inoperative USB port