2004 CHRYSLER VOYAGER lock

(6) Remove oil filter (Fig. 18).
(7) Turn manual valve fully clock-wise to get park
rod into position for removal. (8) Remove valve body-to-case bolts (Fig. 19). CAUTION: Do not handle the valve body assembly
from the manual valve. Damage can result.
(9) Using a screwdriver, push park rod rollers
away from guide bracket (Fig. 20) and remove valve
body assembly (Fig. 21).
NOTE: Depending on engine application, some
accumulators will have two springs and others will
have one spring. The springs are color-coded
according to application and year. When disassem-
bling, mark accumulator spring location to ease
assembly.
Fig. 18 Remove Filter and O-Ring
1 - OIL FILTER
2 - O-RING
Fig. 19 Remove Valve Body-to-Case Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 20 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
Fig. 21 Valve Body Removal/Installation
1 - VALVE BODY
RS 40TE AUTOMATIC TRANSAXLE21s-35
40TE AUTOMATIC TRANSAXLE (Continued)

(24) Remove front carrier/rear annulus assembly
and #6 needle bearing (Fig. 38).
(25) Remove rear sun gear and #7 needle bearing
(Fig. 39).
NOTE: The number 7 needle bearing has three anti-
reversal tabs and is common with the number five
and number two position. The orientation should
allow the bearing to seat flat against the rear sun
gear (Fig. 40). A small amount of petrolatum can be
used to hold the bearing to the rear sun gear. (26) Setup tool 5058 as shown in (Fig. 41). Com-
press 2/4 clutch return spring (just enough to remove
snap ring) and remove snap ring.
NOTE: Verify that Tool 5058 is centered properly
over the 2/4 clutch retainer before compressing. If
necessary, fasten the 5058 bar to the bellhousing
flange with any combination of locking pliers and
bolts to center the tool properly.
NOTE: The 2/4 Clutch Piston has bonded seals
which are not individually serviceable. Seal replace-
ment requires replacement of the piston assembly.
Fig. 38 Remove Front Carrier/Rear Annulus Assembly
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 39 Remove Rear Sun Gear
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 40 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 41 Remove 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
21s - 40 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(35) Remove transfer gear cover-to-case bolts (Fig.
50).
(36) Remove transfer gear cover (Fig. 51). (37) Using Tool 6259, remove transfer shaft gear-
to-shaft nut and coned washer (Fig. 52) (Fig. 53).
Fig. 50 Remove Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
Fig. 51 Remove Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPAR TATF RTV (MS-GF41) AS SHOWN
Fig. 52 Remove Transfer Shaft Gear Nut
1 - TRANSFER SHAFT GEAR
2 - OUTPUT GEAR
3 - SPECIAL TOOL 6259
Fig. 53 Transfer Shaft Gear Nut and Coned Washer
1 - TRANSFER SHAFT
2 - LOCK WASHER
3 - NUT
RS 40TE AUTOMATIC TRANSAXLE21s-43
40TE AUTOMATIC TRANSAXLE (Continued)

(46) Using tool P-334, press transfer shaft bearing
cone off of shaft (Fig. 62).
(47) Bend output gear retaining strap ears flat to
allow bolt removal. (48) Remove output shaft stirrup strap bolts (Fig.
63).
(49) Remove stirrup and strap (Fig. 64).
(50) Using Tool 6259 (Fig. 65), remove output shaft
gear-to-shaft bolt and washer (Fig. 66).
Fig. 62 Remove Transfer Shaft Bearing Cone
1 - ARBOR PRESS RAM
2 - TRANSFER SHAFT
3 - TOOL P-334
4 - BEARING CONE
Fig. 63 Remove Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
Fig. 64 Remove Stirrup Strap
1 - OUTPUT GEARBOLT
2 - RETAINING STRAP
3 - STIRRUP
Fig. 65 Remove Output Gear Bolt
1 - OUTPUT GEAR
2 - TOOL 6259
Fig. 66 Output Gear Bolt and Washer
1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
21s - 46 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(15) Install the output gear and bearing assembly
using Tool 6261 (Fig. 102).
(16) Install NEW output gear retaining bolt and
washer (Fig. 103). Using Tool 6259, torque output
gear retaining bolt to 271 N´m (200 ft. lbs.) (Fig.
104). (17) Using an inch pound torque wrench (Fig.
105), check output shaft turning torque. Output
shaft turning torque should be within 3-8 in.
lbs. If the turning torque is too high, install a 0.04
mm (0.0016 in.) thicker shim. If the turning torque is
too low, install a 0.04 mm (0.0016 in.) thinner shim.
Repeat until the proper turning torque of 3-8 in. lbs.
is obtained.
Fig. 102 Install Output Gear
1 - WRENCHES
2 - TOOL 6261 WITH STUD
3 - OUTPUT GEAR
Fig. 103 Output Gear Bolt and Washer
1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
Fig. 104 Tighten Output Gear to 271 N²m (200 ft.
lbs.)
1 - OUTPUT GEAR
2 - TORQUE WRENCH
3 - 200 FT. LBS.
4 - TOOL 6259
Fig. 105 Check Output Gear Bearings Turning Torque
1 - INCH-POUND TORQUE WRENCH
2 - OUTPUT GEAR
RS 40TE AUTOMATIC TRANSAXLE21s-57
40TE AUTOMATIC TRANSAXLE (Continued)

(18) Install output gear stirrup with serrated side
out (Fig. 106).
(19) Install retaining strap (Fig. 107).
(20) Install strap bolts but do not tighten at this
time (Fig. 107). (21) Rotate stirrup clockwise against flats of
retaining bolt (Fig. 108).
(22) Torque stirrup strap bolts to 23 N´m (200 in.
lbs.) (Fig. 109).
Fig. 106 Install Stirrup
1 - STIRRUP
2 - OUTPUT GEAR RETAINING BOLT
Fig. 107 Install Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
Fig. 108 Turn Stirrup Clockwise Against Flats Of Output Gear Retaining Bolt
1 - RETAINING STRAP
2 - STIRRUP
Fig. 109 Tighten Stirrup Strap Bolts to 23 N´m (200 in. lbs.)
1 - RETAINING STRAP
2 - STIRRUP
21s - 58 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(61) Install low/reverse accumulator snap ring
(Fig. 151).
NOTE: Depending on engine application, some
accumulators will have two springs, and others will
have one spring. The springs are color-coded for
application and year.
(62) Install underdrive and overdrive accumulators
and springs (Fig. 152). (63) Install valve body to transaxle (Fig. 153).
Rotate manual valve shaft fully clockwise to ease
installation. Make sure park rod rollers are posi-
tioned within park guide bracket.
(64) Install and torque valve body-to-case bolts to
12 N´m (105 in. lbs.) (Fig. 154).
Fig. 151 Install Low/Reverse Accumulator Snap Ring
1 - SNAP RING
2 - PLUG
Fig. 152 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 153 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 154 Install Valve Body-to-Case Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
RS 40TE AUTOMATIC TRANSAXLE21s-71
40TE AUTOMATIC TRANSAXLE (Continued)

(13) Install left and right halfshaft assemblies.
(Refer t o 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION) (14) Install front wheel/tire assemblies.
(15) Lower vehicle.
(16) Torque remaining rear mount bracket-to-tran-
saxle vertical bolts (Fig. 160) to 102 N´m (75 ft. lbs.). (17) Install transaxle upper bellhousing-to-block
bolts and torque to 95 N´m (70 ft. lbs.). (18) Install and connect crank position sensor (if
equipped). (19) Connect gearshift cable to upper mount
bracket and transaxle manual valve lever (Fig. 161).
(20) Connect solenoid/pressure switch assembly
(Fig. 162). (21) Connect transmission range sensor connector
(Fig. 162). (22) Connect input and output speed sensor con-
nectors (Fig. 162). (23) Remove plugs and install transaxle oil cooler
line service splice kit. Refer to instructions included
with kit. (24) Remove plug and Install fluid level indicator/
tube assembly. (25) Install coolant recovery bottle (Fig. 163).
(26) Install battery shield.
(27) Connect battery cables.
(28) Fill transaxle with suitable amount of ATF+4
(Automatic Transmission FluidÐType 9602). (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE/FLUID - STANDARD PROCEDURE)
Fig. 161 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 162 Component Connector Location - Typical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 163 Coolant Recovery Bottle
1 - COOLANT RECOVERY CONTAINER
2 - HOSE
3 - BOLT
4 - SUB FRAME RAIL
21s - 74 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)