2005 CHRYSLER CARAVAN automatic transmission

(69) Install and tighten solenoid/pressure switch
assembly-to-transaxle case bolts to 12 N´m (110 in.
lbs.) (Fig. 158).
(70) Install and torque input and output speed
sensors to case to 27 N´m (20 ft. lbs.).
INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perfrom the ªQuick-Learnº procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
(1) Using a transmission jack and a helper, posi-
tion transaxle assembly to engine. Install and torque
bellhousing bolts to 95 N´m (70 ft. lbs.).
(2) Install upper mount assembly to transaxle and
torque bolts to 54 N´m (40 ft. lbs.) (Fig. 159).
(3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 159).
(4) Remove transmission jack and screw jack.
(5) Secure left wheelhouse splash shield.
(6) Install torque converter-to-drive plate bolts and
torque to 88 N´m (65 ft. lbs.)
(7) Install inspection cover.
(8) Install lateral bending brace.
(9) Install starter motor.(10) Install front mount/bracket assembly.
(11) Align and install rear mount bracket-to-case
bolts by hand (Fig. 160). Torque horizontal bolt to
102 N´m (75 ft. lbs.).
(12) AWD models: Install power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - INSTALLATION)
(13) Install left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
(14) Install front wheel/tire assemblies.
(15) Lower vehicle.
(16) Torque remaining rear mount bracket-to-tran-
saxle vertical bolts (Fig. 160) to 102 N´m (75 ft. lbs.).
(17) Install transaxle upper bellhousing-to-block
bolts and torque to 95 N´m (70 ft. lbs.).
(18) Install and connect crank position sensor (if
equipped).
(19) Connect gearshift cable to upper mount
bracket and transaxle manual valve lever (Fig. 161).
(20) Connect solenoid/pressure switch assembly
(Fig. 162).
(21) Connect transmission range sensor connector
(Fig. 162).
(22) Connect input and output speed sensor con-
nectors (Fig. 162).
Fig. 158 Attaching Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
Fig. 159 Left Mount to Bracket and Transaxle
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
RS40TE AUTOMATIC TRANSAXLE21-51
40TE AUTOMATIC TRANSAXLE (Continued)

Fig. 160 Rear Mount Bracket - Typical
1 - BOLT - VERTICAL 102 N´m (75 ft. lbs.)
2 - BRACKET - REAR MOUNT3 - BOLT - HORIZONTAL 102 N´m (75 ft. lbs.)
Fig. 161 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 162 Component Connector Location - Typical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
21 - 52 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(23) Remove plugs and connect transaxle oil cooler
lines. (Refer to 7 - COOLING/TRANSMISSION -
STANDARD PROCEDURE)
(24) Remove plug and Install fluid level indicator/
tube assembly.
(25) Install coolant recovery bottle (Fig. 163).
(26) Install battery shield.
(27) Connect battery cables.
(28) Fill transaxle with suitable amount of ATF+4
(Automatic Transmission FluidÐType 9602). (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE/FLUID - STANDARD PROCEDURE)
Fig. 163 Coolant Recovery Bottle
1 - COOLANT RECOVERY CONTAINER
2 - HOSE
3 - BOLT
4 - SUB FRAME RAIL
RS40TE AUTOMATIC TRANSAXLE21-53
40TE AUTOMATIC TRANSAXLE (Continued)

INPUT SHAFT
DESCRIPTION METRIC SPECIFICATION
End Play 0.127-0.635mm 0.005-0.025 in.
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt, Differential
Cover-to-Case19 Ð 165
Bolt, Differential Ring
Gear-to-Case95 70 Ð
Bolt, Differential Bearing
Retainer-to-Case28 21 Ð
Bolt, Driveplate-to-
Crankshaft95 70 Ð
Bolt, Extension Housing/
Plate-to-Case28 21 Ð
Bolt, Oil Pan-to-Case 19 Ð 165
Bolt, Output Gear 271 200 Ð
Bolt, Output Gear
Stirrup/Strap23 17 Ð
Bolt, Oil Pump-to-Case 27 20 Ð
Bolt, Reaction Support-to-
Case27 20 Ð
Bolt, Solenoid/Pressure
Switch Assy.-to-Case12 Ð 110
Bolt, Torque Converter-to-
Driveplate75 55 Ð
Bolt, Transfer Gear Cover 20 Ð 175
Bolt, Valve Body-to-Case 12 Ð 105
Fitting, Oil Cooler Line 12 Ð 105
Nut, Tranfer Gear 271 200 Ð
Tap, Transaxle Pressure 5 Ð 45
Screw, L/R Clutch
Retainer5Ð45
Screw, Solenoid/Pressure
Switch Assy. Connector4Ð35
Screw, Valve Body-to-
Transfer Plate5Ð45
Sensor, Input Speed 27 20 Ð
Sensor, Output Speed 27 20 Ð
Sensor, Transmission
Range Sensor5Ð45
RS40TE AUTOMATIC TRANSAXLE21-67
40TE AUTOMATIC TRANSAXLE (Continued)

DIFFERENTIAL SERVICE TOOLS
COMPONENT REMOVER INSTALLER
Diff. Bear. On
Retainer Side5048, 5048-4
Collets,
L-4539-2
Button5052, C-4171
Diff. Bear. On
Ext. Hous. Side5048, 5048-3
Collets,
L-4539-2
ButtonL-4410, C-4171
Diff. Race. On
Retainer Side6062-A 6061, C-4171
Diff. Race. On
Ext. Hous. SideL-4518 L-4520, C-4171
Extension
Housing Seal7794-A, C-637
Slide HammerL-4520, C-4171
Bearing
Retainer Seal794-A, C-637
Slide HammerL-4520, C-4171
ASSEMBLY
NOTE: The differential is serviced as an assembly.
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
any other part fails within the differential, you must
replace the differential assembly along with the
transfer shaft.
NOTE: Use MoparTATF RTV (MS-GF41), or equiva-
lent, on retainer and extension housing/adapter
plate to seal to case.
(1) Using Miller Special Tool L-4410, and C-4171,
install differential bearing to differential (extension
housing side) (Fig. 180).
(2) Using Miller Special Tool 5052 and C-4171,
install differential bearing to differential (bearing
retainer side).(3) Using Miller Special Tool 6061 and C-4171,
install differential bearing race to bearing retainer
(Fig. 181).
(4) Using Miller Special Tool L±4520 and C-4171,
install differential bearing cup to extension housing.
(5) Measure and adjust differential bearing pre-
load (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 41TE/FINAL DRIVE -
ADJUSTMENTS) .
(6) Install differential assembly to case. Install
extension housing/adapter plate and bearing retainer.
Fig. 180 Position Bearing Cone Onto Differential
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL BEARING
Fig. 181 Differential Bearing Retainer
1 - DIFFERENTIAL BEARING CUP
2 - DIFFERENTIAL BEARING RETAINER
21 - 78 40TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)

FLUID
STANDARD PROCEDURE
FLUID LEVEL AND CONDITION CHECK
NOTE: Only transmission fluid of the type labeled
Mopar ATF+4 (Automatic Transmission Fluid)
should be used in this transaxle.
FLUID LEVEL CHECK
The transmission sump has a fluid level indicator
(dipstick) to check oil similar to most automatic
transmissions. It is located on the left side of the
engine. Be sure to wipe all dirt from dipstick handle
before removing.
The torque converter fills in both the P Park and N
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate.The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground.At normal operating temperature 82É C
(180É F), the fluid level is correct if it is in the HOT
region on the oil level indicator (Fig. 187). The fluid
level should be within the COLD region of the dip-
stick at 27É C (80É F) fluid temperature.
FLUID LEVEL CHECK USING DRB
NOTE: Engine and Transaxle should be at normal
operating temperature before performing this proce-
dure.
(1) Start engine and apply parking brake.
(2) Hook up DRB scan tool and select transmis-
sion.(3) Select sensors.
(4) Read the transmission temperature value.
(5) Compare the fluid temperature value with the
fluid temperature chart (Fig. 188).
(6) Adjust transmission fluid level shown on the
indicator according to the chart.
(7) Check transmission for leaks.
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transaxle vent where it may be mistaken
for a leak.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle recondition is proba-
bly required. Be sure to examine the fluid on the dip-
stick closely. If there is any doubt about its condition,
drain out a sample for a double check.
MopartATF+4 (Automatic Transmission Fluid)
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal.ATF+4 also has a unique odor that
may change with age. Consequently,odor and color
cannot be used to indicate the fluid condition
or the need for a fluid change.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
STANDARD PROCEDURE - FLUID AND FILTER
SERVICE
NOTE: Refer to the maintenance schedules in
LUBRICATION and MAINTENANCE, or the vehicle
owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
Fig. 187 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
21 - 82 40TE AUTOMATIC TRANSAXLERS

NOTE: Only fluids of the type labeled MoparTATF+4
(Automatic Transmission Fluid) should be used. A
filter change should be made at the time of the
transmission oil change. The magnet (on the inside
of the oil pan) should also be cleaned with a clean,
dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Refer to LUBRICA-
TION and MAINTENANCE for proper procedures.
Place a drain container with a large opening, under
transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and o-ring on bottom of the
valve body (Fig. 189).
(4) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.).(5) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) through the dipstick opening.
Fig. 188 Transmission Fluid Temperature Chart
1 - MAX. LEVEL2 - MIN. LEVEL
Fig. 189 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
RS40TE AUTOMATIC TRANSAXLE21-83
FLUID (Continued)

(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 190).
(8) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.). Refer
to Fluid Level and Condition Check for the proper
fluid fill procedure.
(9) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
DIPSTICK TUBE FLUID SUCTION METHOD
(ALTERNATIVE)
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (VaculaŸ
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) through the dipstick opening.(7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 190).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/FLUID - STANDARD PROCEDURE)
(10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
GEAR SHIFT CABLE
REMOVAL
(1) Disconnect battery cables.
(2) Remove battery shield.
(3) Remove battery.
(4) Remove speed control servo and position out of
way.
(5) Disconnect gear shift cable at manual valve
lever (Fig. 191).
(6) Disconnect gear shift cable from upper mount
bracket (Fig. 191).
Fig. 190 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
Fig. 191 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 84 40TE AUTOMATIC TRANSAXLERS
FLUID (Continued)