41TE Automatic Transaxle: Assembly
CAUTION:
If transaxle failure has occurred, it is necessary to flush the transaxle oil cooler and lines to remove debris and particles that could contaminate and/or fail a new or rebuilt unit. (Refer to COOLING SYSTEMS
).
CAUTION:
The cooler bypass valve must be replaced if transaxle failure has occurred. DO NOT attempt to reuse or clean old valve.
NOTE:
If transaxle is being overhauled (clutch and/or seal replacement), the TCM Quick Learn procedure must be performed. Refer to DIAGNOSIS - 41TE
article.
- Install both output bearing cups using Tool 5050. (Fig 1).
- Install low/reverse piston retainer gasket. (Fig 2). Make sure gasket holes line up with case.
- Install low/reverse piston retainer. (Fig 3).
- Install low/reverse piston retainer-to-case bolts and torque to 5 N.m (45 in. lbs.). (Fig 4).
- Install low/reverse clutch piston. (Fig 5).
- Assemble park guide bracket assembly. (Fig 7). (Fig 6).
- Install guide bracket into position and insert pivot shaft. (Fig 8).
- Install anchor shaft and plug. (Fig 9). Make sure guide bracket and split sleeve are in contact with the rear of the transaxle case.
- Install low/reverse piston return spring. (Fig 10).
- Install low/reverse spring compressor into position. (Fig 11). Compress low/reverse piston and install snap ring as shown in (Fig 12).
- Install rear carrier bearing cone using Tool 6053. (Fig 13).
- Install rear carrier assembly to transaxle case. (Fig 14).
- Install output gear bearing cone using Tool 5052. (Fig 15).
- OUTPUT GEAR BEARING ADJUSTMENT:
- With output gear removed, install a 4.50 mm (0.177 in.) gauging shim on the rear carrier assembly hub, using grease to hold the shim in place. (Fig 16).
- Using Tool 6259, install output gear and bearing assembly. Torque to 271 N.m (200 ft. lbs.).
- Measure bearing end play. Attach Tool L-4432 to the gear. (Fig 17).
- Push and pull the gear while rotating back and forth to ensure seating of bearing rollers.
- Using a dial indicator mounted to the transaxle case, measure output gear end play as shown in (Fig 17).
- Refer to the output gear bearing shim chart (Fig 18) for the required shim to obtain proper bearing setting.
- Use Tool 6259 to remove the output gear retaining bolt and washer. To remove the output gear, use Tool L4407A.
- Remove the gauging shim and install the proper shim determined by the chart. Use grease to hold the shim in place.
- Install the output gear and bearing assembly using Tool 6261. (Fig 19).
- Install NEW output gear retaining bolt and washer. (Fig 20). Using Tool 6259, torque output gear retaining bolt to 271 N.m (200 ft. lbs.). (Fig 21).
- Using an inch pound torque wrench (Fig 22), check output shaft turning torque. Output shaft turning torque should be within 3-8 in. lbs . If the turning torque is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until the proper turning torque of 3-8 in. lbs. is obtained.
- Install output gear stirrup with serrated side out. (Fig 23).
- Install retaining strap.
- Install strap bolts but DO NOT tighten at this time. (Fig 24).
- Rotate stirrup clockwise against flat of retaining bolt. (Fig 25).
- Torque stirrup strap bolts to 23 N.m (200 in. lbs.). (Fig 26).
- Bend tabs on strap up against flats of bolts. (Fig 27).
- Install transfer shaft bearing cone using Tool 6052. (Fig 28).
- Install bearing cup and oil baffle to transfer shaft. (Fig 29).
- Using Tool 5049A, install transfer shaft. (Fig 30).
- Using Tool 6051, install transfer shaft bearing snap ring. (Fig 31).
- Install transfer shaft bearing cup into retainer using Tool 6061. (Fig 32).
- Install bearing cup retainer to transaxle. (Fig 33).
- Install transfer gear bearing cone to transfer gear using Tool 5052. (Fig 34).
- Transfer Gear Bearing Adjustment:
- Install a 4.66 mm (0.184 in.) gauging shim on the transfer shaft. (Fig 35).
- Install transfer shaft gear using Tool 6261. Using Tool 6259, install transfer shaft gear retaining nut and tighten to 271 N.m (200 ft. lbs.).
- Measure end play. Attach Tool L4432 to the transfer gear.
- Mount a steel ball with grease into the end of the transfer shaft.
- Push and pull the gear while rotating back and forth to ensure seating of the bearing rollers.
- Using a dial indicator, measure transfer shaft end play.
- Refer to the transfer shaft bearing shim charts (Fig 36 or Fig 37) for the required shim combination to obtain the proper bearing setting.
- Use Tool 6259 to remove the retaining nut and washer. Remove the transfer shaft gear using Tool L4407A.
- Remove the gauging shim and install the proper shim (Fig 35) indicated by the chart.
- Install the transfer shaft gear using Tool 626. (Fig 38).
CAUTION: Install a NEW retaining nut, as the original nut MUST NOT be reused.
- Install the new retaining nut and washer.
- Using Tool 6259, torque transfer gear retaining nut to 271 N.m (200 ft. lbs.). (Fig 39).
- Measure transfer shaft end play. Transfer shaft end play should be within 0.05-0.10 mm (0.002-0.004 in.) . If the end play is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the end play is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until 0.05-0.10 mm (0.002-0.004 in.) end play is obtained.
- Install a bead of Mopar® ATF RTV (MS-GF41) to transfer rear cover. (Fig 40).
- Install transfer rear cover-to-case bolts and torque to 20 N.m (175 in. lbs.). (Fig 41).
- Install low/reverse clutch pack. (Fig 42). Leave uppermost disc out until snap ring is installed.
- Install low/reverse reaction plate flat snap ring. (Fig 43).
- Install remaining low/reverse clutch disc. (Fig 44).
- Install low/reverse reaction plate with flat side up. (Fig 45).
- Install tapered snap ring (with tapered side up) as shown in (Fig 46 and Fig 47
).
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- Set up dial indicator as shown in (Fig 48) to measure low/reverse clutch clearance. Press down on clutch pack with finger and zero dial indicator. Low/Reverse clutch pack clearance is 0.89-1.47 mm (0.035-0.058 in.) . Set up indicator and record measurement in four (4) places. Take average of readings and select the proper low/reverse reaction plate to achieve specifications. (Fig 49).
- Install 2/4 clutch pack (Fig 50), staggering clutch plate pads as shown in (Fig 51).
- Orient 2/4 clutch return spring to retainer as shown in (Fig 52), and install to transaxle (Fig 53).
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- Using tool 5058, compress 2/4 clutch return spring just enough to install snap ring. (Fig 54).
- Install snap ring.
- Set up dial indicator as shown in (Fig 55) and measure 2/4 clutch clearance. Press down on clutch pack with finger and zero dial indicator. 2/4 clutch pack clearance is 0.76-2.64 mm (0.030-0.104 in.) . Set up indicator and record measurement in four (4) places. Take average of readings. If clearance is outside this range, the clutch is assembled improperly. There is no adjustment for 2/4 clutch clearance .
- Install rear sun gear and #7 needle bearing. (Fig 56).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 57). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
- Install front carrier/rear annulus assembly and #6 needle bearing. (Fig 58).
- Install front sun gear assembly and #4 thrust washer. (Fig 59).
- DETERMINING #4 THRUST PLATE THICKNESS/INPUT SHAFT END PLAY:
- Select the thinnest #4 thrust plate thickness and install to input clutch assembly. (Fig 60). Use petrolatum to retain.
- 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 61), the input clutch assembly is not seated properly.
- Remove oil pump "O" ring. (Fig 62). Be sure to reinstall oil pump "O" ring after selecting the proper #4 thrust plate .
- Set up input shaft for measurement with Indicator Set C3339 and End Play Set 8266 as shown in (Fig 63).
- 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 reading of 0.020 inch which is within specifications. (Fig 64).
- Refer to the No. 4 thrust plate chart to select the proper No. 4 thrust plate:
- Install input clutch assembly. (Fig 65).
- Install #1 caged needle bearing. (Fig 66).
CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. DO NOT attempt to reuse or clean old valve.
- Install cooler bypass valve with O-ring end towards rear of case. (Fig 67).
- Install oil pump gasket. (Fig 68).
- Install oil pump assembly. (Fig 69).
- Install oil pump-to-case bolts and torque to 27 N.m (20 ft. lbs.). (Fig 70).
- Install low/reverse accumulator. (Fig 71).
- Install low/reverse accumulator plug. (Fig 72).
- Install low/reverse accumulator snap ring. (Fig 73).
NOTE: Depending on engine application, some accumulators will have two springs, and others will have one spring. The springs are color coded for application and year.
- Install underdrive and overdrive accumulators. (Fig 74, Fig 75 and Fig 76 ).
- Install valve body to transaxle. (Fig 77). Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are positioned within park guide bracket.
- Install and torque valve body-to-case bolts to 12 N.m (105 in. lbs.). (Fig 78).
- Install oil filter and new O-ring. (Fig 79).
- Apply an 1/8" bead of Mopar® ATF RTV (MS-GF41) to oil pan and immediately install to case. (Fig 80).
- Install oil pan-to-case bolts and torque to 19 N.m (165 in. lbs.).
- Install solenoid/pressure switch assembly and gasket to case. (Fig 81).
- Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts to 12 N.m (110 in. lbs.). (Fig 82).
- Install and torque input and output speed sensors to case to 27 N.m (20 ft. lbs.).