2005 CHRYSLER CARAVAN clutch

ASSEMBLY
Use petrolatum on all seals to ease assembly of
components.
(1) Using an arbor press, install input shaft to
input shaft hub (Fig. 213).
(2) Install input shaft snap ring (Fig. 214).(3) Using an arbor press and Tool 6057, Install
OD/Reverse piston return spring and snap ring (Fig.
215) (Fig. 216).
Fig. 213 Install Input Shaft
1 - INPUT SHAFT
2 - ARBOR PRESS RAM
3 - INPUT SHAFT HUB ASSEMBLY
Fig. 214 Install Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 215 Return Spring and Snap Ring
1 - OD/REVERSE PISTON
2 - RETURN SPRING
3 - SNAP RING
4 - O-RING
Fig. 216 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
RS40TE AUTOMATIC TRANSAXLE21-95
INPUT CLUTCH ASSEMBLY (Continued)

(4) Install the OD/Reverse piston assembly to the
input clutch retainer as shown in (Fig. 217).
(5) Install the input hub/shaft assy. to the OD/Re-
verse piston/clutch retainer assy. (Fig. 218).(6) Install input hub tapered snap ring (Fig. 219)
(Fig. 220).
Fig. 217 Install OD/Reverse Piston
1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
Fig. 218 Install Input Shaft Hub Assembly
1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY
(ROTATE TO ALIGN SPLINES)
2 - OD/REV. PISTON
Fig. 219 Install Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
21 - 96 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 220 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
RS40TE AUTOMATIC TRANSAXLE21-97
INPUT CLUTCH ASSEMBLY (Continued)

(7) Install UD clutch piston (Fig. 221).
(8) Install UD piston return spring and Tool 5067
as shown in (Fig. 222).(9) Using Tool 5059A and an arbor press, Install
the UD spring retainer and snap ring (Fig. 223) (Fig.
224) (Fig. 225) Compress just enough to install snap
ring.
CAUTION: Compress return spring just enough to
install snap ring.
Fig. 221 Underdrive Clutch Piston
1 - PISTON
Fig. 222 Seal Compressor Special Tool 5067
1 - PISTON RETURN SPRING
2 - SPECIAL TOOL 5067
3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY
Fig. 223 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 224 Install UD Spring Retainer and Snap Ring
1 - ARBOR PRESS RAM
2 - SNAP RING PLIERS
3 - SNAP RING
4 - OD/REVERSE PISTON
5 - TOOL 5067
6 - TOOL 5059A
21 - 98 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 225 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 TRANSAXLE21-99
INPUT CLUTCH ASSEMBLY (Continued)

(10) Install the UD clutch pack. Leave out upper
disc, until snap ring is installed (Fig. 226).
(11) Install the UD clutch flat snap ring (Fig. 227).
(12) Install the last UD clutch disc (Fig. 228).
(13) Install the OD/UD clutch reaction plate and
snap ring (Fig. 229) (Fig. 230). The OD/UD clutches
reaction plate has a step on both sides. Install the
OD/UD clutches reaction plate tapered step side up.
Fig. 226 Install Underdrive Clutch Pack
1 - CLUTCH DISC
2 - CLUTCH PLATE
Fig. 227 UD Clutch Flat Snap Ring
1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
Fig. 228 Install Last UD Clutch Disc
1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 229 OD/UD Reaction Plate
1 - OD/UD CLUTCH REACTION PLATE (TAPERED STEP SIDE UP)
Fig. 230 Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
21 - 100 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

NOTE: Snap ring ends must be located within one
finger of the input clutch hub. Be sure that snap
ring is fully seated, by pushing with screwdriver,
into snap ring groove all the way around.
(14) Seat tapered snap ring to ensure proper
installation (Fig. 231) (Fig. 232).
Fig. 231 Seating Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER
Fig. 232 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
RS40TE AUTOMATIC TRANSAXLE21 - 101
INPUT CLUTCH ASSEMBLY (Continued)

(15) Install input clutch assembly to the Input
Clutch Pressure Fixture±Tool 8391 (Fig. 233).
(16) Set up dial indicator on the UD clutch pack as
shown in (Fig. 234).
(17) Using moderate pressure, press down and
hold (near indicator) the UD clutch pack with screw-
driver or suitable tool and zero dial indicator (Fig.
235). When releasing pressure on clutch pack, indica-
tor reading should advance 0.005±0.010.
CAUTION: Do not apply more than 30 psi (206 kPa)
to the underdrive clutch pack.
(18) Apply 30 psi (206 kPa) to the underdrive hose
on Tool 8391 and measure UD clutch clearance. Mea-
sure and record UD clutch pack measurement in four
(4) places, 90É apart.
(19) Take average of four measurements and com-
pare with UD clutch pack clearance specification.
Underdrive clutch pack clearance must be 0.94-
1.50 mm (0.037-0.059 in.).
(20) If necessary, select the proper reaction plate
to achieve specifications:
UNDERDRIVE REACTION PLATE THICKNESS
4659939AB 5.837-5.937 mm (0.230-0.234 in.)
4659940AB 6.147-6.248 mm (0.242-0.246 in.)
4659941AB 6.457-6.557 mm (0.254-0.258 in.)
Fig. 233 Input Clutch Assembly on Pressure Fixture
Tool 8391
1 - INPUT CLUTCH ASSEMBLY
2 - INPUT CLUTCH PRESSURE FIXTURE 8391
Fig. 234 Set Up Dial Indicator to Measure UD Clutch
Clearance
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
Fig. 235 Press Down on UD Clutch Pack and Zero
Dial Indicator
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
21 - 102 40TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)