2004 CHRYSLER VOYAGER Service Manual

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Page 1953 of 2585

CHRYSLER VOYAGER 2004 Service Manual Installer 6053
Button 6055
Plate 6056
Disk 6057
Installer 6061
Remover 6062-A
Holder 6259
Bolt 6260
Installer 6261
Tip 6268
21s - 92 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

Page 1954 of 2585

CHRYSLER VOYAGER 2004 Service Manual Remover/Installer 6301
Remover/Installer 6302
Installer 6536-A
Puller 7794-A
End Play Socket Set 8266
Input Clutch Pressure Fixture 8391
RS40TE AUTOMATIC TRANSAXLE21s-93
40TE AUTOMATIC TRANSAXLE (Cont

Page 1955 of 2585

CHRYSLER VOYAGER 2004 Service Manual ACCUMULATOR
DESCRIPTION
The 4XTE underdrive, overdrive, low/reverse, and
2/4 clutch hydraulic circuits each contain an accumu-
lator. An accumulator typically consists of a piston,
return spring(s), a

Page 1956 of 2585

CHRYSLER VOYAGER 2004 Service Manual 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

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. 167). The input clutch assembly also
contains: ² Input shaft
² Input hub
² Clutch retainer
² Underdrive piston
² Overdrive/reverse piston
² Overdrive hub
² Underdrive 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
DESCRIPTION
The 4XTE differential is a conventional open
design. It consists of a ring gear and a differential
case. The differential case consists of pinion and side
gears, and a pinion shaft. The differential case is
supported in the transaxle by tapered roller bearings
(Fig. 168).
Fig. 167 Input Clutch Assembly
1 - INPUT SHAFT
2 - UNDERDRIVE CLUTCH
3 - OVERDRIVE CLUTCH
4 - REVERSE CLUTCH
5 - OVERDRIVE SHAFT
6 - UNDERDRIVE SHAFT
Fig. 168 Differential Assembly
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - TRANSFER SHAFT
4 - PINION GEAR
5 - PINION SHAFT
6 - SIDE GEAR
RS 40TE AUTOMATIC TRANSAXLE21s-95

Page 1957 of 2585

CHRYSLER VOYAGER 2004 Service Manual OPERATION
The differential assembly is driven by the transfer
shaft by way of the differential ring gear. The ring
gear drives the differential case, and the case drives
the driveshafts through the di

Page 1958 of 2585

CHRYSLER VOYAGER 2004 Service Manual (5) Set up dial indicator set C-3339 and tool
C-4996 as shown in (Fig. 173) (Fig. 174) to measure
side gear end play. Side gear end play must be
within 0.001-0.013 in. (6) Use Miller Special Tool 5048

Page 1959 of 2585

CHRYSLER VOYAGER 2004 Service Manual (8) Using Miller Special Tool L-4518, remove the
differential bearing race from the extension housing/
adapter plate. (9) Using Miller Special Tool 6062A, remove the
differential bearing race from the

Page 1960 of 2585

CHRYSLER VOYAGER 2004 Service Manual ASSEMBLY
NOTE: The differential is serviced as an assembly.
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
any other part fails within th

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