2005 CHRYSLER CARAVAN Service Manual

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Page 1641 of 2339

CHRYSLER CARAVAN 2005 Service Manual (15) Install the output gear and bearing assembly
using Tool 6261 (Fig. 102).
(16) Install NEW output gear retaining bolt and
washer (Fig. 103). Using Tool 6259, torque output
gear retaining bolt to 2

Page 1642 of 2339

CHRYSLER CARAVAN 2005 Service Manual (18) Install output gear stirrup with serrated side
out (Fig. 106).
(19) Install retaining strap.
(20) Install strap bolts but do not tighten at this
time (Fig. 107).(21) Rotate stirrup clockwise agai

Page 1643 of 2339

CHRYSLER CARAVAN 2005 Service Manual (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).

Page 1644 of 2339

CHRYSLER CARAVAN 2005 Service Manual (27) Using Tool 6051, install transfer shaft bearing
snap ring (Fig. 114).
(28) Install transfer shaft bearing cup into retainer
using Tool 6061 (Fig. 115).(29) Install bearing cup retainer to transax

Page 1645 of 2339

CHRYSLER CARAVAN 2005 Service Manual (31)TRANSFER GEAR BEARING ADJUST-
MENT:
(a) Install a 4.66 mm (0.184 in.) gauging shim
on the transfer shaft (Fig. 118).
(b) Install transfer shaft gear using Tool 6261.
Using Tool 6259, install trans

(31)TRANSFER GEAR BEARING ADJUST-
MENT:
(a) Install a 4.66 mm (0.184 in.) gauging shim
on the transfer shaft (Fig. 118).
(b) Install transfer shaft gear using Tool 6261.
Using Tool 6259, install transfer shaft gear retain-
ing nut to 271 N´m (200 ft. lbs.).
(c) Measure end play. Attach Tool L4432 to the
transfer gear.
(d) Mount a steel ball with grease into the end
of the transfer shaft.
(e) Push and pull the gear while rotating back
and forth to ensure seating of the bearing rollers.
(f) Using a dial indicator, measure transfer shaft
end play.
(g) Refer to the transfer shaft bearing shim
chart for the required shim combination to obtain
the proper bearing setting.
(h) Use Tool 6259 to remove the retaining nut
and washer. Remove the transfer shaft gear using
Tool L4407A.
(i) Remove the gauging shim (Fig. 118) and
install the proper shim indicated by the chart.
TRANSFER SHAFT BEARING SHIM CHART
End Play Shim Needed Part Number End Play Shim Needed Part Number
0.05mm
(0.002 in.)4.66mm
(0.183 in.)4505588AB0.76mm
(0.030 in.)3.94mm
(0.155 in.)4412818AB
0.08mm
(0.003 in.)4.62mm
(0.182 in.)4412835AB0.79mm
(0.031 in.)3.90mm
(0.154 in.)4412817AB
0.10mm
(0.004 in.)4.58mm
(0.180 in.)4412834AB0.81mm
(0.032 in.)3.90mm
(0.154 in.)4412817AB
0.13mm
(0.005 in.)4.58mm
(0.180 in.)4412834AB0.84mm
(0.033 in.)3.86mm
(0.152 in.)4412816AB
0.15mm
(0.006 in.)4.54mm
(0.178 in.)4412833AB0.86mm
(0.034 in.)3.82mm
(0.150 in.)4412815AB
0.18mm
(0.007 in.)4.50mm
(0.177 in.)4412832AB0.89mm
(0.035 in.)3.82mm
(0.150 in.)4412815AB
0.20mm
(0.008 in.)4.50mm
(0.177 in.)4412832AB0.91mm
(0.036 in.)3.78mm
(0.149 in.)4412814AB
0.23mm
(0.009 in.)4.46mm
(0.175 in.)4412831AB0.94mm
(0.037 in.)3.74mm
(0.147 in.)4412813AB
0.25mm
(0.010 in.)4.46mm
(0.175 in.)4412831AB0.97mm
(0.038 in.)3.74mm
(0.147 in.)4412813AB
0.28mm
(0.011 in.)4.42mm
(0.174 in.)4412830AB0.99mm
(0.039 in.)3.70mm
(0.146 in.)4412812AB
0.30mm
(0.012 in.)4.38mm
(0.172 in.)4412829AB1.02mm
(0.040 in.)3.66mm
(0.144 in.)4412811AB
0.33mm
(0.013 in.)4.38mm
(0.172 in.)4412829AB1.04mm
(0.041 in.)3.66mm
(0.144 in.)4412811AB
Fig. 118 Install Transfer Shaft Gear and
(Select) Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM
(SELECT)
21 - 184 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

Page 1646 of 2339

CHRYSLER CARAVAN 2005 Service Manual End Play Shim Needed Part Number End Play Shim Needed Part Number
0.36mm
(0.014 in.)4.34mm
(0.171 in.)4412828AB1.07mm
(0.042 in.)3.62mm
(0.143 in.)4412810AB
0.38mm
(0.015 in.)4.30mm
(0.169 in.)4412827

Page 1647 of 2339

CHRYSLER CARAVAN 2005 Service Manual (32) Install the transfer shaft gear using Tool 6261
(Fig. 119).
CAUTION: Install a NEW retaining nut, as the origi-
nal nut MUST NOT be reused.
(33) Install the new retaining nut and washer.
(34) Usi

Page 1648 of 2339

CHRYSLER CARAVAN 2005 Service Manual (38) Install low/reverse clutch pack (Fig. 123).
Leave uppermost disc out until snap ring is installed.
(39) Install low/reverse reaction plate flat snap
ring (Fig. 124).(40) Install remaining low/rev

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