2004 CHRYSLER VOYAGER lock

(19) Remove 1st gear blocker ring (Fig. 47).
(20) Remove 1st gear friction cone (Fig. 48).(21) Remove 1st gear reactor ring (Fig. 49).
(22) Remove 1st gear from shaft (Fig. 50).
Fig. 47 1st Gear Blocker Ring
1 - 1ST GEAR BLOCKER RING
Fig. 48 1st Gear Friction Cone
1 - 1ST GEAR FRICTION CONE
Fig. 49 1st Gear Reactor Ring
1 - 1ST GEAR REACTOR RING
Fig. 50 1st Gear Removal
1 - 1ST GEAR
RS
T850 MANUAL TRANSAXLE21s-15
INTERMEDIATE SHAFT (Continued)

(6) Install 1/2 synchro to fixture 8483. Insert 1st
gear blocker ring, friction cone, and reactor ring as
shown in (Fig. 61).
(7) Install intermediate shaft to synchro assembly
on fixture (Fig. 62). When installing 1/2 synchro-
nizer, make sure to align oil slots on synchro-
nizer hub face with oil hole in the shaft splined
hub journal. Line up friction cone and reactor ring
tabs to gear slots. Remove shaft assembly from fix-
ture. (8) Install NEW1/2 synchro snap ring (Fig. 63).
Fig. 61 1/2 Synchro on Fixture 8483
1 - FIXTURE 8483
2 - 1ST GEAR BLOCKER RING
3 - 1ST GEAR FRICTION CONE
4 - 1ST GEAR REACTOR RING
5 - 1/2 SYNCHRONIZER
Fig. 62 Install 1/2 Synchro to Intermediate Shaft
1 - INTERMEDIATE SHAFT
2 - 1ST GEAR
3 - 1/2 SYNCHRO ASSEMBLY
4 - FIXTURE 8483
Fig. 63 1/2 Synchro Snap Ring
1 - SNAP RING
2 - 1/2 SYNCHRO HUB
RS T850 MANUAL TRANSAXLE21s-19
INTERMEDIATE SHAFT (Continued)

(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 shaft (Fig. 67) (Fig. 68).
Fig. 64 2nd Gear Blocker Ring
1 - 2ND GEAR BLOCKER RING
Fig. 65 2nd Gear Friction Cone
1 - 2ND GEAR FRICTION CONE
Fig. 66 2nd Gear Reactor Ring
1 - 2ND GEAR REACTOR RING
Fig. 67 2nd Gear Removal/Installation
1 - 2ND GEAR
2 - NEEDLE BEARING
21s - 20 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)

(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 slots on
synchronizer hub face with oil hole in the shaft
splined hub journal.
(18) Install NEW5/R synchro snap ring (Fig. 75).
Fig. 72 5th Gear Needle Bearing Removal/
Installation
1 - 5TH GEAR NEEDLE BEARING
Fig. 73 5th Gear Blocker Ring to Synchro
1 - 5th GEAR BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 74 Install 5/R Synchro and 5th Blocker Ring to 5th Gear
1 - 5/R SYNCHRONIZER
2 - 5TH GEAR BLOCKER RING
3 - 5TH GEAR
Fig. 75 5/R Synchro Snap Ring
1 - SNAP RING
21s - 22 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)

(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 bear-
ing and thrust washer using installer 8482 (Fig. 78). (23) Install NEWintermediate shaft sealed bear-
ing snap ring (Fig. 79).
Fig. 76 Reverse Gear Blocker Ring
1 - REVERSE BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 77 Reverse Gear Needle Bearing
1 - NEEDLE BEARING
Fig. 78 Sealed Roller Bearing Installatiion
1 - ARBOR PRESS
2 - REMOVER/INSTALLER 8482
3 - SEALED ROLLER BEARING
4 - THRUST WASHER
Fig. 79 Intermediate Shaft Bearing Snap Ring
1 - SNAP RING
2 - BEARING
RS T850 MANUAL TRANSAXLE21s-23
INTERMEDIATE SHAFT (Continued)

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

DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS
Inoperative clutches can be located using a series
of tests by substituting air pressure for fluid pressure
(Fig. 5) (Fig. 6). The clutches may be tested by apply-
ing air pressure to their respective passages. The
valve body must be removed and Tool 6056 installed.
To make air pressure tests, proceed as follows:
NOTE: The compressed air supply must be free of
all dirt and moisture. Use a pressure of 30 psi.
Remove oil pan and valve body. See Valve body
removal.
OVERDRIVE CLUTCH
Apply air pressure to the overdrive clutch apply
passage and watch for the push/pull piston to move
forward. The piston should return to its starting
position when the air pressure is removed.
REVERSE CLUTCH
Apply air pressure to the reverse clutch apply pas-
sage and watch for the push/pull piston to move rear-
ward. The piston should return to its starting
position when the air pressure is removed.
2/4 CLUTCH
Apply air pressure to the feed hole located on the
2/4 clutch retainer. Look in the area where the 2/4 piston contacts the first separator plate and watch
carefully for the 2/4 piston to move rearward. The
piston should return to its original position after the
air pressure is removed.
LOW/REVERSE CLUTCH
Apply air pressure to the low/reverse clutch feed
hole (rear of case, between 2 bolt holes). Then, look
in the area where the low/reverse piston contacts the
first separator plate. Watch carefully for the piston to
move forward. The piston should return to its origi-
nal position after the air pressure is removed.
UNDERDRIVE CLUTCH
Because this clutch piston cannot be seen, its oper-
ation is checked by function. Air pressure is applied
to the low/reverse and the 2/4 clutches. This locks the
output shaft. Use a piece of rubber hose wrapped
around the input shaft and a pair of clamp-on pliers
to turn the input shaft. Next apply air pressure to
the underdrive clutch. The input shaft should not
rotate with hand torque. Release the air pressure
and confirm that the input shaft will rotate.
Fig. 5 Air Pressure Test Plate
1 - TOOL 6056
2 - ACCUMULATORS
Fig. 6 Testing Reverse Clutch
1 - TOOL 6056
2 - AIR NOZZLE
21s - 30 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(12) Remove rear mount bracket-to-transaxle case
bolts (Fig. 13). (13) Remove transaxle upper bellhousing-to-block
bolts. (14) Raise vehicle on hoist.
(15) Remove transaxle oil pan and drain fluid into
suitable container. (16) Remove front wheel/tire assemblies.
(17) Remove left and right halfshaft assemblies.
(Refer t o 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - REMOVAL) (18) AWD models: Remove power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - REMOVAL) (19) Remove rear mount bracket-to-transaxle case
lower (horizontal) bolt (Fig. 13). (20) Remove front mount/bracket assembly.
(21) Remove starter motor.
(22) Remove lateral bending brace.
(23) Remove inspection cover.
(24) Remove torque converter-to-drive plate bolts.
(25) Support engine/transaxle assembly at engine
oil pan with screw jack and wood block. (26) Partially remove left wheelhouse splash shield
to gain access to and remove upper mount thru-bolt
(Fig. 14).
Fig. 13 Rear Mount Bracket - Typical
1 - BOLT - VERTICAL
2 - BRACKET - REAR MOUNT 3 - BOLT - HORIZONTAL
Fig. 14 Left Mount-to-Bracket
1 - BOLT - BRACKET TO FRAME RAIL
2 - BOLT - MOUNT TO RAIL THROUGH
3 - BOLT - LEFT MOUNT TO TRANSAXLE
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
RS
40TE AUTOMATIC TRANSAXLE21s-33
40TE AUTOMATIC TRANSAXLE (Continued)