2004 CHRYSLER VOYAGER sensor

(65) Install oil filter and new o-ring (Fig. 141).
(66) Apply an 1/8º bead of MopartATF RTV (MS-
GF41) to oil pan and immediately install to case (Fig.
142).
(67) Install oil pan-to-case bolts and torque to 19
N´m (165 in. lbs.). (68) Install solenoid/pressure switch assembly and
gasket to case (Fig. 143). (69) Install and tighten solenoid/pressure switch
assembly-to-transaxle case bolts to 12 N´m (110 in.
lbs.) (Fig. 144). (70) Install and torque input and output speed
sensors to case to 27 N´m (20 ft. lbs.).
Fig. 141 Install Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 142 Install Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPAR TATF RTV (MS-GF41)
3 - OIL FILTER
Fig. 143 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 144 Solenoid Pack-to-Transaxle Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
RS 41TE AUTOMATIC TRANSAXLE21s - 205
41TE AUTOMATIC TRANSAXLE (Continued)

CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
DISASSEMBLY
NOTE: If valve body assembly is being recondi-
tioned, the PCM/TCM Quick Learn Procedure must
be performed. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Remove manual shaft seal (Fig. 154). (2) Remove Transmission Range Sensor retaining
screw (Fig. 155).
(3) Remove Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 156).
Fig. 153 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 154 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 155 Remove Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
Fig. 156 Manual Shaft/Rooster Comb and Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
21s - 208 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

(14) Install Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 182).
(15) Make sure Manual Valve control pin is con-
tained within the rooster comb slot (Fig. 183). Install
Transmission Range Sensor retaining screw (Fig.
183) and torque to 5 N´m (45 in. lbs.). (16) Install manual shaft seal (Fig. 184).
INSTALLATION
NOTE: If valve body assembly is being replaced or
reconditioned, it is necessary to perform the TCM
Quick Learn Procedure. (Refer t
o 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install valve body assembly to transaxle (Fig.
185). Install and torque valve body-to-transaxle case
bolts (Fig. 186) to 12 N´m (105 in. lbs.).
Fig. 182 Install Manual Shaft/Rooster Comb and Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
Fig. 183 Install Transmission Range Sensor Retaining Screw
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
Fig. 184 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 185 Valve Body Removal/Installation
1 - VALVE BODY
RS 41TE AUTOMATIC TRANSAXLE21s - 217
VALVE BODY (Continued)

(2) Install transaxle oil filter (Fig. 187). Inspect
the o-ring and replace if necessary.
(3) Ensure the transaxle oil pan and transaxle
case sealing surfaces are clean and dry. Install an
1/8º bead of Mopar tSilicone Rubber Adhesive Seal-
ant to the oil pan and install (Fig. 188). Torque oil
pan-to-transaxle case bolts (Fig. 189) to 19 N´m (165
in. lbs.). (4) Lower vehicle.
(5) Connect transmission range sensor connector.
(6) Install manual valve lever to manual shaft.
(7) Install gearshift cable to manual valve lever.
(8) Connect battery negative cable.
(9) Fill transaxle with Mopar
tATF +4 Transmis-
sion fluid. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
Fig. 186 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 187 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
Fig. 188 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 189 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
21s - 218 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND
WHEEL VIBRATION.....................1
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE AND
WHEEL BALANCE......................5
STANDARD PROCEDURE - TIRE AND
WHEEL MATCH MOUNTING..............7
STANDARD PROCEDURE - TIRE AND
WHEEL ROTATION.....................7
REMOVAL
REMOVAL - TIRE AND WHEEL ASSEMBLY
(ALUMINUM WHEEL)....................7
REMOVAL - TIRE AND WHEEL ASSEMBLY
(STEEL WHEEL).......................8
INSTALLATION
INSTALLATION - TIRE AND WHEEL
ASSEMBLY (ALUMINUM WHEEL)..........8
INSTALLATION - TIRE AND WHEEL
ASSEMBLY (STEEL WHEEL)..............8
TIRE PRESSURE MONITORING
DESCRIPTION..........................9
OPERATION............................9
SENSOR - TPM
DESCRIPTION.........................10
OPERATION...........................10
CAUTION.............................10
DIAGNOSIS AND TESTING - TIRE PRESSURE
SENSOR............................10
STANDARD PROCEDURE - TIRE PRESSURE
SENSOR RETRAIN....................10
REMOVAL.............................11
INSTALLATION.........................12
TIRES
DESCRIPTION
DESCRIPTION - TIRE..................13
DESCRIPTION - RADIAL-PLY TIRES.......14DESCRIPTION - REPLACEMENT TIRES....14
DESCRIPTION - SPARE TIRE
(TEMPORARY).......................14
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - TIRE NOISE . . . 14
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD...............................14
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS..........................16
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS.........................16
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE INFLATION
PRESSURES.........................16
STANDARD PROCEDURE - TIRE
PRESSURE FOR HIGH SPEED
OPERATION.........................17
STANDARD PROCEDURE - TIRE LEAK
REPAIRING..........................17
CLEANING - TIRES.....................17
WHEELS
DESCRIPTION - WHEEL..................18
DIAGNOSIS AND TESTING - WHEEL
INSPECTION.........................18
CLEANING - ALUMINUM WHEEL CARE......18
SPECIFICATIONS
WHEEL.............................19
WHEEL COVER
DESCRIPTION.........................19
REMOVAL.............................19
INSTALLATION.........................19
WHEEL MOUNTING STUDS - FRONT
REMOVAL.............................20
INSTALLATION.........................21
WHEEL MOUNTING STUDS - REAR
REMOVAL.............................21
INSTALLATION.........................22
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND WHEEL
VIBRATION
Tire and wheel imbalance, runout and force varia-
tion can cause vehicles to exhibit steering wheel
vibration.
VISUAL INSPECTION
Visual inspection of the vehicle is recommended
prior to road testing or performing any other proce-
dure. Raise vehicle on a suitable hoist. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
Inspect for the following:
²Verify correct (OEM) wheel and tire, as well as
correct wheel weights. Aluminum wheels require
RSTIRES/WHEELS22-1

(4) Install andlightly tightenthe three remain-
ing wheel mounting nuts, securing the wheel cover in
place (Fig. 12).
(5) Progressively tighten all five wheel mounting
nuts in the proper sequence (Fig. 16). Tighten wheel
nuts to a torque of 135 N´m (100 ft. lbs.).
(6) Lower the vehicle.
TIRE PRESSURE MONITORING
DESCRIPTION
Some versions of this vehicle are equipped with a
Tire Pressure Monitoring (TPM) system. It monitors
air pressure in the four road tires (excludes spare).
Pressure in the spare tire is not monitored.
There is a sensor (transmitter) in each of the vehi-
cle's four road wheels. The system alerts the driver
when tire pressure falls outside predetermined
thresholds (pressure too low or too high). A message
is then displayed on the Electronic Vehicle Informa-
tion Center (EVIC) located in the overhead console.
For further information, refer to the Owners Man-
ual or the appropriate diagnostic information.
OPERATION
The Tire Pressure Monitoring (TPM) system uses
radio and sensor technology to monitor tire air pres-
sure levels. Sensors, mounted to each road wheel as
part of the valve stem, transmit tire pressure read-
ings to a receiver located in the overhead console.
These transmissions occur once every minute at
speeds over 20 mph (32 km/h). The Tire Pressure
Monitoring system remains active even if no tire
pressure related message is displayed in the EVIC.
If any road tire pressure has exceeded the low or
high pressure threshold (refer to chart below), the
TPM system will display a message in the EVIC and
sound a chime. This message will be displayed for
the rest of the ignition cycle, or until either the Low/
High Tire pressure condition has been corrected. If
the C/T, MENU, STEP or RESET button is pressed,
the message is replaced by the new message
requested; however, if the Low/High Tire condition
has not been corrected, the Low/High Tire pressure
message will again be displayed.
Fig. 14 TWO WHEEL MOUNTING NUTS INSTALLED
1 - WHEEL
2 - VALVE STEM
3 - HUB PILOT
4 - NUTS
Fig. 15 WHEEL COVER INSTALLATION OVER TWO
NUTS
1 - RETAINING TABS
2 - VALVE STEM
3 - BOLT-ON WHEEL COVER
Fig. 16 NUT TIGHTENING SEQUENCE
RSTIRES/WHEELS22-9
TIRES/WHEELS (Continued)

If a road tire is replaced by the spare, the TPM
system will detect the swap and the message9SPARE
TIRE IN USE? Y/N9(along with a chime) will be dis-
played.
For further information, refer to the Owners Man-
ual or the Appropriate Diagnostic Information.
TPM THRESHOLD PRESSURES
High Pressure ON Threshold 48 PSI (331 kPa)
High Pressure OFF Threshold 43 PSI (296 kPa)
Placard Pressure (Cold) 36 PSI (248 kPa)
Low Pressure OFF Threshold 33 PSI (228 kPa)
Low Pressure ON Threshold 28 PSI (193 kPa)
SENSOR - TPM
DESCRIPTION
On vehicles equipped with Tire Pressure Monitor-
ing, one tire pressure sensor is mounted to each
wheel (Fig. 19). Each sensor has an internal battery
that lasts up to 10 years. The battery is not service-
able. At the time of battery failure, the sensor must
be replaced. The serviceable components of the tire
pressure sensor are:
²Sensor-To-Wheel Grommet
²Valve Stem Cap
²Valve Stem Core
Valve stem caps and cores are specifically designed
for the tire pressure monitoring sensors. Although
similar to standard valve stem caps and cores, they
are different.
CAUTION: Do not use a standard valve stem cap or
core in a tire pressure sensor. Always use the orig-
inal equipment style sensor cap and core.
CAUTION: Do not reuse the Sensor-To Wheel Grom-
met. Always use a new grommet when installing a
pressure sensor and properly torque the sensor
nut.
CAUTION: Do not try to install a tire pressure sen-
sor in a steel wheel or aftermarket wheel. Use only
in original style factory wheels.
OPERATION
Tire pressure sensors are battery operated. They
transmit tire pressure data once every minute at
speeds above 20 mph (32 km/h) or up to once every
hour when stationary (parked). For additional infor-
mation, refer to Appropriate Diagnostic Information.
CAUTION
CAUTION: The use of tire sealants is strictly prohib-
ited for vehicles equipped with the Tire Pressure
Monitoring system. Tire sealants can clog tire pres-
sure sensors.
CAUTION: Tire pressure sensor valve stem caps
and cores are specially designed for the sensors.
Due to risk of corrosion, do not use a standard
valve stem cap or core in a tire pressure sensor in
place of the original equipment style sensor cap
and core.
CAUTION: Do not attempt to install a tire pressure
sensor in a steel wheel or aftermarket wheel. Use
tire pressure sensors in original style factory
wheels only.
NOTE: TPM thresholds have been established for
the original tire size equipped on the vehicle. Use
original size tires only to maintain system accuracy.
DIAGNOSIS AND TESTING - TIRE PRESSURE
SENSOR
NOTE: Tire pressure may increase from 2 to 6 psi
(14 to 41 kPa) during normal driving conditions. Do
NOT reduce this normal pressure build up.
If a fault in the system is detected, always check
air pressure in the tires first with a known accurate
air gauge and correct the inflation pressure. If any
tire is low, inspectalltires.
If gauge-read pressure in the tires does not reflect
the reading on the EVIC, retrain the sensors, then
reevaluate (Refer to 22 - TIRES/WHEELS/TIRE
PRESSURE MONITORING/SENSOR - STANDARD
PROCEDURE). Refer to the appropriate diagnostic
information for complete diagnosis of the Tire Pres-
sure Monitoring System.
STANDARD PROCEDURE - TIRE PRESSURE
SENSOR RETRAIN
WARNING: DEATH OR SERIOUS INJURY CAN
OCCUR IF MAGNETICALLY SENSITIVE DEVICES
ARE EXPOSED TO THE RELEARN MAGNET. MAG-
NETS CAN AFFECT PACEMAKERS.
22 - 10 TIRES/WHEELSRS
TIRE PRESSURE MONITORING (Continued)

CAUTION: Never attempt to train more than one
vehicle at a time. System is capable of reading tire
pressure sensor transmissions from other near-by
vehicles.
Each time a wheel rotation or tire pressure sensor
replacement occurs the tire pressure sensors must be
retrained. This is necessary to inform the Electronic
Vehicle Information Center (EVIC) that a sensor
change was made and where. Retraining is accom-
plished through the EVIC used in conjunction with a
Re-learn Magnet, Special Tool 8821.
NOTE: Use the following procedure to retrain all
four (4) road wheel tire pressure sensors. No
attempt should be made to retrain individual sen-
sors.
(1) Retrieve Re-learn Magnet, Special Tool 8821.
(2) Press MENU Button on EVIC until9RETRAIN
TIRE SENSORS - NO9is displayed.
(3) Press STEP button to select9YES9.
NOTE: There is a 60 second timer for training the
first sensor and a 60 second timer between training
the remaining sensors. If any of these timers expire,
the EVIC will abort the training procedure.
NOTE: If at any time the EVIC display reads(TRAIN-
ING ABORTED(, move the vehicle ahead at least
one foot and repeat the entire retraining procedure.
(4) Press MENU button to start retraining. Dis-
play will read9TRAIN LEFT FRONT TIRE9
NOTE: The order for retraining all four sensors is:
²Left Front
²Right Front
²Right Rear
²Left Rear
(5) Starting at left front tire, place Re-learn Mag-
net over valve stem (Fig. 17). Within approximately 5
seconds, vehicle horn will chirp indicating training
complete at that particular sensor. Remove the mag-
net.
(6) Repeat step (5) on remaining sensors as indi-
cated by EVIC until all four TPM sensors positions
are trained.
(7) Once EVIC displays9TRAINING COMPLETE9,
pressing either STEP, C/T, RESET or MENU button
will exit training routine.
REMOVAL
(1) Remove tire and wheel assembly from vehicle.
(Refer to 22 - TIRES/WHEELS - REMOVAL)
CAUTION: The cap used on this valve stem con-
tains an O-ring seal to prevent contamination and
moisture from entering the valve stem. Retain this
valve stem cap for reuse. Do not substitute a regu-
lar valve stem cap in its place.
CAUTION: The valve stem used on this vehicle is
made of aluminum and the core is nickel plated
brass. The original valve stem core must be rein-
stalled and not substituted with a valve stem core
made of a different material. This is required to pre-
vent corrosion in the valve stem caused by the dif-
ferent metals.
(2) Dismount tire from wheel following tire
changer manufacturers instructions while paying
special attention to the following to avoid damaging
the pressure sensor:
(a) When breaking the tire bead loose from the
wheel rim, avoid using the Bead Breaker in the
area of the sensor. That includes both front and
rear beads of the tire.
(b) When preparing to dismount the tire from
the wheel, carefully insert the mounting/dimount-
ing tool at the valve stem   10É (Fig. 18), then pro-
ceed to dismount the tire from the wheel. Use this
process on both the upper and lower tire beads.
(3) Using a thin wall socket, remove special nut
retaining sensor to wheel (Fig. 19).
(4) Remove sensor from wheel (Fig. 19).
Fig. 17 Magnet Placement Over Valve Stem
1 - RE-LEARN MAGNET
2 - VALVE STEM
RSTIRES/WHEELS22-11
SENSOR - TPM (Continued)