2005 CHRYSLER CARAVAN Service Manual

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Page 1529 of 2339

CHRYSLER CARAVAN 2005 Service Manual SPECIAL TOOLS
Puller C-637
Pressure Gauge (High) C-3293SP
Dial Indicator C-3339
Oil Pump Puller C-3752
Seal Puller C-3981B
Universal Handle C-4171
Seal Installer C-4193A
Adapter C-4996
Remover Kit L-4

Page 1530 of 2339

CHRYSLER CARAVAN 2005 Service Manual Gear Puller L-4407A
Bearing Installer L-4410
Gear Checking Plate L-4432
Bearing Puller L-4435
Differential Tool L-4436A
Special Jaw Set L-4518
Installer L-4520
Thrust Button L-4539-2
Adapter L-4559
Ad

Page 1531 of 2339

CHRYSLER CARAVAN 2005 Service Manual Bearing Splitter P-334
Puller Set 5048
Remover/Installer 5049-A
Installer 5050A
Installer 5052
Compressor 5058A
Compressor 5059-A
Installer 5067
Pliers 6051
Installer 6052
21 - 70 40TE AUTOMATIC TRANS

Page 1532 of 2339

CHRYSLER CARAVAN 2005 Service Manual Installer 6053
Button 6055
Plate 6056
Disk 6057
Installer 6061
Remover 6062-A
Holder 6259
Bolt 6260
RS40TE AUTOMATIC TRANSAXLE21-71
40TE AUTOMATIC TRANSAXLE (Continued)

Page 1533 of 2339

CHRYSLER CARAVAN 2005 Service Manual Installer 6261
Tip 6268
Remover/Installer 6301
Remover/Installer 6302
Installer 6536-A
Puller 7794-A
End Play Socket Set 8266
Input Clutch Pressure Fixture 8391
21 - 72 40TE AUTOMATIC TRANSAXLERS
40TE

Page 1534 of 2339

CHRYSLER CARAVAN 2005 Service Manual ACCUMULATOR
DESCRIPTION
The 4XTE underdrive, overdrive, low/reverse, and
2/4 clutch hydraulic circuits each contain an accumu-
lator. An accumulator typically consists of a piston,
return spring(s), a

Page 1535 of 2339

CHRYSLER CARAVAN 2005 Service Manual DRIVING CLUTCHES
DESCRIPTION
Three hydraulically applied input clutches are used
to drive planetary components. The underdrive, over-
drive, and reverse clutches are considered input
clutches and are

DRIVING CLUTCHES
DESCRIPTION
Three hydraulically applied input clutches are used
to drive planetary components. The underdrive, over-
drive, and reverse clutches are considered input
clutches and are contained within the input clutch
assembly (Fig. 167). The input clutch assembly also
contains:
²Input shaft
²Input hub
²Clutch retainer
²Underdrive piston
²Overdrive/reverse piston
²Overdrive hub
²Underdrive hub
OPERATION
The three input clutches are responsible for driving
different components of the planetary geartrain.
NOTE: Refer to the ªElements In Useº chart in Diag-
nosis and Testing for a collective view of which
clutch elements are applied at each position of the
selector lever.
UNDERDRIVE CLUTCH
The underdrive clutch is hydraulically applied in
first, second, and third (direct) gears by pressurized
fluid against the underdrive piston. When the under-
drive clutch is applied, the underdrive hub drives the
rear sun gear.
OVERDRIVE CLUTCH
The overdrive clutch is hydraulically applied in
third (direct) and overdrive gears by pressurized fluid
against the overdrive/reverse piston. When the over-
drive clutch is applied, the overdrive hub drives the
front planet carrier.
REVERSE CLUTCH
The reverse clutch is hydraulically applied in
reverse gear only by pressurized fluid against the
overdrive/reverse piston. When the reverse clutch is
applied, the front sun gear assembly is driven.
FINAL DRIVE
DESCRIPTION
The 4XTE differential is a conventional open
design. It consists of a ring gear and a differential
case. The differential case consists of pinion and side
gears, and a pinion shaft. The differential case is
supported in the transaxle by tapered roller bearings
(Fig. 168).
Fig. 167 Input Clutch Assembly
1 - INPUT SHAFT
2 - UNDERDRIVE CLUTCH
3 - OVERDRIVE CLUTCH
4 - REVERSE CLUTCH
5 - OVERDRIVE SHAFT
6 - UNDERDRIVE SHAFT
Fig. 168 Differential Assembly
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - TRANSFER SHAFT
4 - PINION GEAR
5 - PINION SHAFT
6 - SIDE GEAR
21 - 74 40TE AUTOMATIC TRANSAXLERS

Page 1536 of 2339

CHRYSLER CARAVAN 2005 Service Manual OPERATION
The differential assembly is driven by the transfer
shaft by way of the differential ring gear. The ring
gear drives the differential case, and the case drives
the driveshafts through the di

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