2005 CHRYSLER CARAVAN clutch

Fig. 249 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
21 - 250 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(10) Install the UD clutch pack. Leave out upper
disc, until snap ring is installed (Fig. 250).
(11) Install the UD clutch flat snap ring (Fig. 251).
(12) Install the last UD clutch disc (Fig. 252).
(13) Install the OD/UD clutch reaction plate and
snap ring (Fig. 253) (Fig. 254). The OD/UD clutches
reaction plate has a step on both sides. Install the
OD/UD clutches reaction plate tapered step side up.
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.
Fig. 250 Underdrive Clutch Pack
1 - CLUTCH PLATE
2 - ONE UD CLUTCH DISC
3 - CLUTCH DISC
Fig. 251 UD Clutch Flat Snap Ring
1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
Fig. 252 Install Last UD Clutch Disc
1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 253 OD/UD Reaction Plate
1 - OD/UD CLUTCH REACTION PLATE (TAPERED STEP SIDE UP)
Fig. 254 Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
RS41TE AUTOMATIC TRANSAXLE21 - 251
INPUT CLUTCH ASSEMBLY (Continued)

(14) Seat tapered snap ring to ensure proper
installation (Fig. 255) (Fig. 256).
Fig. 255 Seating Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER
Fig. 256 Underdrive Clutch Assembly
1 - SNAP RING (TAPERED)
2 - OD/UD REACTION PLATE
3 - CLUTCH DISC4 - SNAP RING (FLAT)
5 - CLUTCH PLATE
6 - INPUT CLUTCH ASSEMBLY
21 - 252 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(15) Install input clutch assembly to the Input
Clutch Pressure Fixture±Tool 8391 (Fig. 257).
(16) Set up dial indicator on the UD clutch pack as
shown in (Fig. 258).
(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.
259). 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. 257 Input Clutch Assembly on Pressure Fixture
Tool 8391
1 - INPUT CLUTCH ASSEMBLY
2 - INPUT CLUTCH PRESSURE FIXTURE 8391
Fig. 258 Set Up Dial Indicator to Measure UD Clutch
Clearance
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
Fig. 259 Press Down on UD Clutch Pack and Zero
Dial Indicator
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
RS41TE AUTOMATIC TRANSAXLE21 - 253
INPUT CLUTCH ASSEMBLY (Continued)

(21) Install the OD clutch pack (four frictions/three
steels) (Fig. 260).
(22) Install OD pressure plate waved snap ring
(Fig. 261).(23) Install the OD/Reverse pressure plate with
large step down (towards OD clutch pack) (Fig. 262).
(24) Install OD pressure plate flat snap ring (Fig.
263) (Fig. 264).
Fig. 260 Install OD Clutch Pack
1 - OVERDRIVE CLUTCH PACK
Fig. 261 Install Waved Snap Ring
1 - OVERDRIVE PRESSURE PLATE WAVED SNAP RING
2 - SCREWDRIVER
Fig. 262 OD/Reverse Pressure Plate
1 - OVERDRIVE/REVERSE PRESSURE PLATE
2 - (STEP SIDE DOWN)
Fig. 263 Install Flat Snap Ring
1 - ARBOR PRESS RAM
2 - TOOL 5059A
3 - FLAT SNAP RING
21 - 254 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 264 Overdrive Clutch Assembly
1 - SNAP RING
2 - OD/REVERSE PRESSURE PLATE
3 - SNAP RING (WAVE)4 - CLUTCH DISC (4)
5 - CLUTCH STEEL (3)
6 - INPUT CLUTCH ASSEMBLY
RS41TE AUTOMATIC TRANSAXLE21 - 255
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. 265).
(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. 266).
(29) Install reverse clutch reaction plate with the
flat side down towards reverse clutch (Fig. 267).
Fig. 265 Measure OD Clutch Pack Clearance
1 - DIAL INDICATOR
2 - OD/REVERSE REACTION PLATE
Fig. 266 Install Reverse Clutch Pack
1 - REVERSE CLUTCH PLATE
2 - REVERSE CLUTCH DISCS
Fig. 267 Install Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)
21 - 256 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)

(30) Tap reaction plate down to allow installation
of the reverse clutch snap ring. Install reverse clutch
snap ring (Fig. 268) (Fig. 269).
(31) Pry up reverse reaction plate to seat against
snap ring (Fig. 270).
Fig. 269 Reverse Clutch Assembly
1 - SNAP RING
2 - REACTION PLATE
3 - CLUTCH DISC (2)4 - CLUTCH PLATE (1)
5 - INPUT CLUTCH ASSEMBLY
Fig. 270 Pry Up Reaction Plate to Seat Against Snap
Ring
1 - SCREWDRIVER
2 - SNAP RING
3 - SCREWDRIVER
4 - MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP
RING
Fig. 268 Install Reverse Clutch Snap Ring
1 - REVERSE CLUTCH SNAP RING (SELECT)
2 - SCREWDRIVER
3 - REVERSE CLUTCH REACTION PLATE
RS41TE AUTOMATIC TRANSAXLE21 - 257
INPUT CLUTCH ASSEMBLY (Continued)