2005 CHRYSLER CARAVAN clutch

(4) Pry up and remove reverse clutch reaction
plate (Fig. 199).
(5) Remove reverse clutch pack (Fig. 200).Ta g
components for assembly identification.
Fig. 199 Pry Reverse Clutch Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
3 - SCREWDRIVER
Fig. 200 Reverse Clutch Assembly
1 - SNAP RING
2 - REACTION PLATE
3 - CLUTCH DISC (2)4 - CLUTCH PLATE (1)
5 - INPUT CLUTCH ASSEMBLY
RS40TE AUTOMATIC TRANSAXLE21-87
INPUT CLUTCH ASSEMBLY (Continued)

(6) Remove the OD/Reverse pressure plate snap
ring (Fig. 201).
(7) Remove OD/Reverse pressure plate (Fig. 201).
(8) Remove OD/Reverse pressure plate wave snap
ring (Fig. 201).
(9) Remove OD clutch pack (Fig. 201).Tag com-
ponents for assembly identification.
Fig. 201 Overdrive Clutch Assembly
1 - SNAP RING
2 - OD/REVERSE PRESSURE PLATE
3 - SNAP RING (WAVE)4 - CLUTCH DISC (3)
5 - CLUTCH STEEL (2)
6 - INPUT CLUTCH ASSEMBLY
21 - 88 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(10) Remove and inspect OD and UD Shafts, as
well as #3 thrust washer and plate, and #2 needle
bearing (Fig. 202).
Fig. 202 Overdrive/Underdrive Shafts
1 - OVERDRIVE SHAFT
2 - #3 THRUST PLATE (3 TABS)
3 - #3 THRUST WASHER (5 TABS)4 - UNDERDRIVE SHAFT
5 - #2 NEEDLE BEARING (3 TABS)
6 - INPUT CLUTCH ASSEMBLY
RS40TE AUTOMATIC TRANSAXLE21-89
INPUT CLUTCH ASSEMBLY (Continued)

(11) Remove the OD/UD reaction plate tapered
snap ring, reaction plate, and first friction disc (Fig.
203).
(12) Remove the UD clutch flat snap ring and rest
of UD clutch pack (Fig. 203).Tag clutch pack for
assembly identification.
Fig. 203 Underdrive Clutch Assembly
1 - SNAP RING (TAPERED)
2 - OD/UD REACTION PLATE
3 - CLUTCH DISC (3)4 - SNAP RING (FLAT)
5 - CLUTCH PLATE (3)
6 - INPUT CLUTCH ASSEMBLY
21 - 90 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

CAUTION: Compress return spring just enough to
remove or install snap ring.
(13) Using Tool 5059A and an arbor press, com-
press UD clutch piston/spring enough to remove snap
ring (Fig. 204) (Fig. 205).
(14) Remove spring retainer, spring, and piston
(Fig. 205).
Fig. 204 UD Spring Retainer Snap Ring
1 - SNAP RING PLIERS
2 - ARBOR PRESS RAM
3 - SNAP RING
4 - SPECIAL TOOL 5059A
Fig. 205 Underdrive Clutch Piston, Spring and Retainer
1 - SNAP RING
2 - SPRING RETAINER
3 - SPRING
4 - UD CLUTCH PISTON5 - SEAL, OUTER
6 - SEAL, INNER
7 - INPUT CLUTCH ASSEMBLY
RS40TE AUTOMATIC TRANSAXLE21-91
INPUT CLUTCH ASSEMBLY (Continued)

(15) Remove input hub tapered snap ring (Fig.
206) (Fig. 212).
(16) Tap on input hub with soft faced hammer and
separate input hub from OD/Reverse piston and
clutch retainer (Fig. 207).(17) Separate clutch retainer from OD/Reverse pis-
ton (Fig. 208).
(18) Using Tool 6057 and an arbor press, compress
return OD/Reverse piston return spring just enough
to remove snap ring (Fig. 209).
Fig. 206 Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
Fig. 207 Tap on Input Hub
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - PLASTIC HAMMER
Fig. 208 Pull Retainer from Piston
1 - OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
Fig. 209 Install Snap Ring
1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST
ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
3 - SNAP RING
4 - SPECIAL TOOL 6057
5 - OD/REVERSE PISTON
6 - RETURN SPRING
21 - 92 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(19) Remove input shaft to input clutch hub snap
ring (Fig. 210) (Fig. 212).(20) Using a suitably sized socket and an arbor
press, remove input shaft from input shaft hub (Fig.
211).
Fig. 210 Remove Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SHARP-POINTED TOOL
3 - SNAP RING
4 - O-RINGS
5 - SEALSFig. 211 Remove Input Shaft
1 - ARBOR PRESS RAM
2 - SOCKET
3 - SEAL
4 - O-RINGS
5 - INPUT SHAFT
6 - SEAL
7 - INPUT SHAFT HUB ASSEMBLY
RS40TE AUTOMATIC TRANSAXLE21-93
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 212 Input Clutch Hub, Retainer, and OD/Reverse Piston
1 - SNAP RING (INPUT SHAFT)
2 - SNAP RING
3 - CLUTCH RETAINER
4 - SEAL, OUTER
5 - SEAL, INNER
6 - OD/REVERSE PISTON7 - SEAL, INPUT SHAFT
8 - SHAFT, INPUT
9 - HUB
10 - SEAL
11 - SNAP RING
12 - BELLEVILLE SPRING
21 - 94 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)