2005 CHRYSLER CARAVAN tow

(9) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 24).
(10) Disconnect return hose at power steering gear
(Fig. 21).
(11) Remove power steering fluid return hose with
cooler from vehicle.
INSTALLATION
INSTALLATION - 2.4L ENGINE
(1) Remove any used O-rings from ends of power
steering hose.
(2) Using a lint free towel, wipe clean hose ends,
power steering pump fitting and steering gear port.
(3) Install new O-ring on power steering gear end
of return hose. Lubricate O-ring using clean power
steering fluid.
CAUTION: Use care not to bend tube ends of the
power steering hoses when installing. Leaks and
restrictions may occur.
CAUTION: If a new return hose is being installed
and it does not have an insulating heat sleeve
installed, the heat shield from the original hose
must be transferred before hose installation.
(4) Route hose along rear of cradle crossmember
and start gear end of hose into gear port. Do not
tighten hose tube nut at this time.(5) Attach hose to suspension cradle crossmember
using two routing clamps and bolts (Fig. 20). Tighten
clamp bolts to 23 N´m (200 in. lbs.) torque.
(6) Tighten return hose tube nut at power steering
gear port to 31 N´m (275 in. lbs.) torque.
(7) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 24). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.).
CAUTION: Power steering fluid hoses must remain
away from the exhaust system and must not come
in contact with any unfriendly surfaces on the vehi-
cle.
(8) Route pump end of hose over cradle crossmem-
ber toward pump avoiding tight bends or kinking.
(9) Install return hose onto power steering pump
return fitting and secure with hose clamp (Fig. 20).
Tighten the screw-type clamp to a torque of 2 N´m
(18 in. lbs.).
CAUTION: To prevent overheating of power steering
fluid return hose, protective heat shield sleeve must
cover entire rubber hose.
(10) Slide insulating heat shield up over the clamp
on the return hose and tie-strap it in place.
(11) Install front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - INSTALLATION)
(12) Lower vehicle.
(13) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure. (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE)
(14) Inspect system for leaks.
INSTALLATION - 3.3L/3.8L ENGINE
(1) Remove any used O-rings from ends of power
steering hose.
(2) Using a lint free towel, wipe clean hose ends
and power steering gear hose port.
(3) Install a new O-ring on gear port end of power
steering fluid hose. Lubricate O-ring using clean
power steering fluid.
CAUTION: Use care not to bend tube ends of the
power steering hoses when installing. Leaks and
restrictions may occur.
CAUTION: Power steering fluid hoses must remain
away from the exhaust system and must not come
in contact with any unfriendly surfaces on the vehi-
cle.
Fig. 24 POWER STEERING COOLER
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
19 - 50 PUMPRS
HOSE - POWER STEERING RETURN (Continued)

(4) Route hose (with cooler attached) up toward
reservoir avoiding tight bends or kinking.
(5) Start steering gear end of hose into gear port.
Do not tighten hose tube nut at this time.
(6) Attach return hose tubes to suspension cradle
crossmember using routing clamp and bolt (Fig. 21).
Tighten clamp bolt to 23 N´m (200 in. lbs.) torque.
(7) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 24). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.). When installing mounting bolts, include pres-
sure hose routing clamp.
(8) Tighten hose tube nut at power steering gear
port to 31 N´m (275 in. lbs.) torque.
(9) Install front emissions vapor canister. (Refer to
25 - EMISSIONS CONTROL/EVAPORATIVE EMIS-
SIONS/VAPOR CANISTER - INSTALLATION)
(10) Lower vehicle.
(11) Install return hose tube into retainer on ABS
bracket (Fig. 21). Close the bracket.
(12) Install return hose onto reservoir (Fig. 22).
Slide the hose clamp into position on fluid reservoir
and attach it.Be sure hose clamp in installed
past bead on fluid reservoir fitting.
(13) Fill and bleed power steering system using
the Power Steering Pump Initial Operation Proce-
dure. (Refer to 19 - STEERING/PUMP - STANDARD
PROCEDURE)
(14) Inspect system for leaks.
HOSE - POWER STEERING
SUPPLY
REMOVAL
REMOVAL - 2.4L ENGINE
(1) Remove filler cap from power steering fluid res-
ervoir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove hose clamp securing supply hose to
power steering pump, then remove supply hose from
pump fitting.
(5) Lower vehicle.
(6) Remove hose clamp attaching power steering
fluid supply hose to power steering fluid reservoir,
then remove supply hose.
(7) Remove the power steering fluid supply hose
from the vehicle.
REMOVAL - 3.3L/3.8L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Place an oil drain pan under vehicle to catch
any draining power steering fluid.
(4) Remove clamp attaching supply hose to power
steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 22).
(5) Pull upward on hose routing clip releasing it
from bracket on cylinder head cover (Fig. 22).
NOTE: It may be necessary to remove air cleaner
housing to gain greater access to supply hose at
power steering pump. (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL)
(6) Remove clamp attaching supply hose to power
steering pump. Disconnect hose from pump and
remove from vehicle (Fig. 22).
INSTALLATION
INSTALLATION - 2.4L ENGINE
(1) Install and correctly route power steering fluid
supply hose from remote fluid reservoir to power
steering pump.
(2) Install fluid supply hose onto power steering
fluid reservoir. Install hose clamp.Be sure hose
clamp is installed past bead on fluid reservoir
fitting.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Install power steering fluid supply hose on
power steering pump supply fitting. Install hose
clamp.Be sure hose clamp is installed past bead
on pump fitting.
(5) Lower vehicle.
(6) Fill and bleed power steering system using
Power Steering Pump Initial Operation Procedure.
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE)
(7) Inspect system for leaks.
RSPUMP19-51
HOSE - POWER STEERING RETURN (Continued)

INSTALLATION - 3.3L/3.8L ENGINE
(1) Install supply hose onto supply fitting on power
steering pump (Fig. 22). Slide the hose clamp into
position on fluid reservoir and attach it.Be sure
hose clamp in installed past bead on fluid res-
ervoir fitting.
(2) Align routing clip located toward center of sup-
ply hose with hole in bracket on cylinder head cover
and push into place (Fig. 22).
(3) Install supply hose onto reservoir (Fig. 22).
Slide the hose clamp into position on fluid reservoir
and attach it.Be sure hose clamp in installed
past bead on fluid reservoir fitting.
(4) Fill and bleed power steering system using
Power Steering Pump Initial Operation Procedure.
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE)
(5) Inspect system for leaks.
RESERVOIR - POWER
STEERING FLUID
DESCRIPTION
DESCRIPTION - 2.4L/3.3L/3.8L ENGINE
All vehicles use a remote mounted power steering
fluid reservoir. The power steering fluid reservoir is
mounted to the engine near the battery (Fig. 25).
DESCRIPTION - DIESEL
All vehicles use a remote mounted power steering
fluid reservoir. The power steering fluid reservoir is
mounted to a bracket on the engine manifold (Fig.
26).
OPERATION
The power steering fluid reservoir stores and sup-
plies power steering fluid for the power steering sys-
tem.
REMOVAL
REMOVAL - 2.4L ENGINE
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Open retainer on side of reservoir and remove
cables from retainer.
(4) Remove clamp attaching supply hose to power
steering fluid reservoir. Disconnect hose from reser-
voir.
(5) Remove bolts and nut securing reservoir in
place.
(6) Remove reservoir.
REMOVAL - 3.3L/3.8L ENGINE
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Open retainer on side of reservoir and remove
cables from retainer.
(4) Remove clamp attaching supply hose to power
steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 22).
(5) Remove clamp attaching return hose to power
steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 22).
(6) Remove bolts and nut securing reservoir in
place (Fig. 22).
(7) Remove reservoir.
REMOVAL - DIESEL
(1) Open hood.
(2) Remove engine cover.
(3) Remove the filler cap from remote power steer-
ing fluid reservoir.
(4) Siphon as much fluid as possible from the fluid
reservoir.
(5) Remove the clamp attaching the return hose to
the power steering fluid reservoir. Disconnect hose
from reservoir (Fig. 26).
(6) Remove the clamp attaching the supply hose to
the power steering fluid reservoir. Disconnect hose
from reservoir (Fig. 26).
Fig. 25 Power Steering Fluid Reservoir (Typical)
19 - 52 PUMPRS
HOSE - POWER STEERING SUPPLY (Continued)

NO. 4 THRUST PLATE CHART
PART NUMBER THICKNESS
4431665AB 1.60mm (0.063 in.)
3836237AB 1.73mm (0.068 in.)
4431666AB 1.80mm (0.071 in.)
3836238AB 1.96mm (0.077 in.)
4431667AB 2.03mm (0.080 in.)
3836239AB 2.16mm (0.085 in.)
4431668AB 2.24mm (0.088 in.)
3836240AB 2.39mm (0.094 in.)
4431669AB 2.46mm (0.097 in.)
3836241AB 2.62mm (0.103 in.)
4446670AB 2.67mm (0.105 in.)
4446671AB 2.90mm (0.114 in.)
(53) Install input clutch assembly (Fig. 143).(54) Install #1 caged needle bearing (Fig. 144).
CAUTION: The cooler bypass valve must be
replaced if transaxle failure has occurred. Do not
attempt to reuse or clean old valve.
(55) Install cooler bypass valve with o-ring end
towards rear of case (Fig. 145).
Fig. 143 Install Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 144 Install No. 1 Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 145 Install Cooler Bypass Valve
1 - COOLER BYPASS VALVE
RS40TE AUTOMATIC TRANSAXLE21-47
40TE AUTOMATIC TRANSAXLE (Continued)

(21) Install the OD clutch pack (Fig. 236).
(22) Install OD pressure plate waved snap ring
(Fig. 237).(23) Install the OD/Reverse pressure plate with
large step down (towards OD clutch pack) (Fig. 238).
(24) Install OD pressure plate flat snap ring (Fig.
239) (Fig. 240).
Fig. 236 Install Overdrive Clutch Pack
1 - CLUTCH DISC
2 - CLUTCH PLATE
Fig. 237 Install Waved Snap Ring
1 - OVERDRIVE PRESSURE PLATE WAVED SNAP RING
2 - SCREWDRIVER
Fig. 238 OD/Reverse Reaction Plate
1 - OVERDRIVE/REVERSE PRESSURE PLATE
2 - (STEP SIDE DOWN)
Fig. 239 Install Flat Snap Ring
1 - ARBOR PRESS RAM
2 - TOOL 5059A
3 - FLAT SNAP RING
RS40TE AUTOMATIC TRANSAXLE21 - 103
INPUT CLUTCH ASSEMBLY (Continued)

(25) Measure OD clutch pack clearance. Set up
dial indicator on top of the OD/Reverse pressure
plate as shown in (Fig. 241).
(26) Zero dial indicator and apply 30 psi (206 kPa)
air pressure to the overdrive clutch hose on Tool
8391. Measure and record OD clutch pack measure-
ment in four (4) places, 90É apart.
(27) Take average of four measurements and com-
pare with OD clutch pack clearance specification.
The overdrive (OD) clutch pack clearance is
1.07-3.25 mm (0.042-0.128 in.).
If not within specifications, the clutch is not
assembled properly. There is no adjustment for the
OD clutch clearance.
(28) Install reverse clutch pack (two frictions/one
steel) (Fig. 242).
(29) Install reverse clutch reaction plate with the
flat side down towards reverse clutch (Fig. 243).
Fig. 241 Measure OD Clutch Pack Clearance
1 - DIAL INDICATOR
2 - OD/REVERSE REACTION PLATE
Fig. 242 Install Reverse Clutch Pack
1 - REVERSE CLUTCH PLATE
2 - REVERSE CLUTCH DISCS
Fig. 243 Install Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)
RS40TE AUTOMATIC TRANSAXLE21 - 105
INPUT CLUTCH ASSEMBLY (Continued)

OPERATION
The converter impeller (Fig. 303) (driving member),
which is integral to the converter housing and bolted
to the engine drive plate, rotates at engine speed.
The converter turbine (driven member), which reacts
from fluid pressure generated by the impeller, rotates
and turns the transmission input shaft.
TURBINE
As the fluid that was put into motion by the impeller
blades strikes the blades of the turbine, some of the
energy and rotational force is transferred into the tur-
bine and the input shaft. This causes both of them (tur-
bine and input shaft) to rotate in a clockwise direction
following the impeller. As the fluid is leaving the trail-
ing edges of the turbine's blades it continues in a ªhin-
deringº direction back toward the impeller. If the fluid
is not redirected before it strikes the impeller, it will
strike the impeller in such a direction that it would
tend to slow it down.
STATOR
Torque multiplication is achieved by locking the sta-
tor's over-running clutch to its shaft (Fig. 304). Under
stall conditions (the turbine is stationary), the oil leaving
the turbine blades strikes the face of the stator blades
and tries to rotate them in a counterclockwise direction.
When this happens the over±running clutch of the stator
locks and holds the stator from rotating. With the stator
locked, the oil strikes the stator blades and is redirected
into a ªhelpingº direction before it enters the impeller.This circulation of oil from impeller to turbine, turbine to
stator, and stator to impeller, can produce a maximum
torque multiplication of about 2.4:1. As the turbine
begins to match the speed of the impeller, the fluid that
was hitting the stator in such as way as to cause it to
lock±up is no longer doing so. In this condition of opera-
tion, the stator begins to free wheel and the converter
acts as a fluid coupling.
Fig. 303 Torque Converter Fluid Operation
1 - APPLY PRESSURE 3 - RELEASE PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD
Fig. 304 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
21 - 128 40TE AUTOMATIC TRANSAXLERS
TORQUE CONVERTER (Continued)

NO. 4 THRUST PLATE CHART
PART NUMBER THICKNESS
4431665AB 1.60mm (0.063 in.)
3836237AB 1.73mm (0.068 in.)
4431666AB 1.80mm (0.071 in.)
3836238AB 1.96mm (0.077 in.)
4431667AB 2.03mm (0.080 in.)
3836239AB 2.16mm (0.085 in.)
4431668AB 2.24mm (0.088 in.)
3836240AB 2.39mm (0.094 in.)
4431669AB 2.46mm (0.097 in.)
3836241AB 2.62mm (0.103 in.)
4446670AB 2.67mm (0.105 in.)
4446671AB 2.90mm (0.114 in.)
(53) Install input clutch assembly (Fig. 143).(54) Install #1 caged needle bearing (Fig. 144).
CAUTION: The cooler bypass valve must be
replaced if transaxle failure has occurred. Do not
attempt to reuse or clean old valve.
(55) Install cooler bypass valve with o-ring end
towards rear of case (Fig. 145).
Fig. 143 Install Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 144 Install Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 145 Install Cooler Bypass Valve
1 - COOLER BYPASS VALVE
21 - 192 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)