2005 CHRYSLER CARAVAN ABS

(8) Remove pressure hose routing bracket bolt at
engine (Fig. 22). Bolt can be accessed through hole in
cradle crossmember (Fig. 23).
(9) Disconnect pressure hose tube nut at power
steering pump (Fig. 22).
(10) Remove power steering fluid pressure hose
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 pressure outlet fitting and
steering gear port.
(3) Install new O-rings on ends of power steering
fluid pressure hose. Lubricate O-rings using clean
power steering fluid.CAUTION: Use care not to bend tube ends of power
steering hoses when installing. Leaks and restric-
tions may occur.
CAUTION: Power steering fluid hoses must remain
away from exhaust system and must not come in
contact with any unfriendly surfaces on vehicle.
(4) Route hose up through cradle crossmember
toward power steering pump avoiding tight bends or
kinking.
(5) Install power steering pressure hose end into
pump pressure outlet fitting (Fig. 20). Thread tube
nut into outlet fitting, but do not tighten at this time.
(6) Route hose behind cradle crossmember and
start hose end into gear port. Do not tighten hose
tube nut at this time.
(7) Install hose into right routing clamp (Fig. 20),
then install mounting bolt into cradle crossmember.
Tighten bolt to 23 N´m (200 in. lbs.) torque.
Fig. 21 HOSES TO POWER STEERING GEAR - 3.3L/3.8L ENGINE
1 - RETURN HOSE (TO RESERVOIR)
2 - PRESSURE HOSE (FROM PUMP)
3 - CRADLE CROSSMEMBER
4 - PRESSURE HOSE ROUTING CLAMP
5 - RETURN HOSE ROUTING CLAMP
6 - PRESSURE HOSE TUBE NUT7 - POWER STEERING GEAR
8 - ABS BRACKET
9 - ROUTING CLIP
10 - LEAK DETECTION PUMP FILTER
11 - RETURN HOSE TUBE NUT
12 - ROUTING CLIP
RSPUMP19-47
HOSE - POWER STEERING PRESSURE (Continued)

(3) Install new O-rings on ends of power steering
fluid pressure hose. Lubricate O-rings 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.
(4) Route hose up behind engine toward pump
avoiding tight bends or kinking.
(5) Install power steering pressure hose end into
pump pressure outlet fitting (Fig. 22). Thread tube
nut into outlet fitting, but do not tighten at this time.
(6) Attach pressure hose routing bracket to engine
(Fig. 22). Tighten bolt to 23 N´m (200 in. lbs.) torque.
(7) Tighten hose tube nut at pump outlet fitting to
31 N´m (275 in. lbs.) torque.
(8) Route hose behind cradle crossmember and
start hose end into gear port. Do not tighten hose
tube nut at this time.
(9) Attach hose to suspension cradle crossmember
and steel reinforcement using two routing clamps
and bolts (Fig. 21). Tighten clamp bolt at steel rein-
forcement to 11 N´m (100 in. lbs.) torque. Tighten
clamp bolt at cradle crossmember to 23 N´m (200 in.
lbs.) torque.
(10) Tighten hose tube nut at power steering gear
port to 31 N´m (275 in. lbs.) torque.
(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.
HOSE - POWER STEERING
RETURN
REMOVAL
REMOVAL - 2.4L 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) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(5) Place an oil drain pan under vehicle to catch
power steering fluid.
(6) Cut tie-strap securing insulating heat sleeve to
power steering fluid return hose near power steering
pump. Pull back heat sleeve to expose hose clamp.
(7) Remove clamp, then return hose from power
steering pump (Fig. 20).
(8) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 24).
(9) Remove bolts attaching routing clamps to front
suspension cradle crossmember (Fig. 20). Remove
return hose from clamps.
(10) Back out return hose tube nut at power steer-
ing gear and remove hose (Fig. 20).
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 return hose to power
steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 22).
(5) Follow return hose downward and open
retainer at ABS bracket (Fig. 21). Remove hose tube
from retainer.
(6) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(7) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(8) Remove bolt securing return hose routing
clamp to suspension cradle crossmember (Fig. 21).
RSPUMP19-49
HOSE - POWER STEERING PRESSURE (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)

(20) Remove #1 needle bearing (Fig. 34).
(21) Remove input clutch assembly (Fig. 35).(22) Remove #4 thrust plate (Fig. 36).
(23) Remove front sun gear assembly and #4
thrust washer (Fig. 37).
Fig. 34 Remove No. 1 Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 35 Remove Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 36 No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 37 Remove Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
RS40TE AUTOMATIC TRANSAXLE21-17
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.
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
21 - 18 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(23) Bend tabs on strap up against flats of bolts
(Fig. 110).
(24) Install transfer shaft bearing cone using Tool
6052 (Fig. 111).(25) Install bearing cup and oil baffle to transfer
shaft (Fig. 112).
(26) Using Tool 5049A, install transfer shaft (Fig.
113).
Fig. 110 Bend Tabs On Strap Up Against Flats Of
Bolts
1 - RETAINING STRAP TABS
2 - RETAINING STRAP
3 - STIRRUP
Fig. 111 Install Transfer Shaft Bearing Cone
1 - TOOL 6052
2 - NEW BEARING CONE
3 - TRANSFER SHAFT
4 - ARBOR PRESS RAM
Fig. 112 Install Bearing Cup to Shaft
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
Fig. 113 Install Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
RS40TE AUTOMATIC TRANSAXLE21-37
40TE AUTOMATIC TRANSAXLE (Continued)

(49) Install rear sun gear and #7 needle bearing
(Fig. 136).
NOTE: The number seven 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. 135). A small amount of petrola-
tum can be used to hold the bearing to the rear sun
gear.(50) Install front carrier/rear annulus assembly
and #6 needle bearing (Fig. 137).
(51) Install front sun gear assembly and #4 thrust
washer (Fig. 138).
Fig. 135 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 136 Install Rear Sun Gear and #7 Needle
Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 137 Install 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. 138 Install Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
RS40TE AUTOMATIC TRANSAXLE21-45
40TE AUTOMATIC TRANSAXLE (Continued)

(52)DETERMINING #4 THRUST PLATE
THICKNESS / INPUT SHAFT END PLAY:
(a) Select the thinnest #4 thrust plate thickness
and install to input clutch assembly (Fig. 139). Use
petrolatum to retain.
(b) Install input clutch assembly into position
and verify that it is completely seated by viewing
through input speed sensor hole. If view through
input speed sensor hole is not as shown in (Fig.
140), the input clutch assembly is not seated prop-
erly.
(c) Remove oil pump o-ring (Fig. 141).Be sure
to reinstall oil pump o-ring after selecting the
proper #4 thrust plate.
(d) Install pump and gasket to transmission.
Install and torque bolts.(e) Set up input shaft for measurement with
Indicator Set C3339 and End Play Set 8266 as
shown in (Fig. 142).
(f) Measure the input shaft end play with the
transaxle in the vertical position.Input shaft end
play must be within 0.005 to 0.025 inch.For
example, if end play reading is 0.055 inch, select
No. 4 Thrust Plate which is 0.071 to 0.074 thick.
This should provide an input shaft end play read-
ing of 0.020 inch which is within specifications.
(g) Refer to the No. 4 thrust plate chart to select
the proper No. 4 thrust plate:
Fig. 139 Select Thinnest No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 140 View Through Input Speed Sensor Hole
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
Fig. 141 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 142 Measure Input Shaft End Play
Using Tool 8266ÐTypical
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
21 - 46 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)