41AE/Te Automatic Transaxle: Assembly

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/PCM Quick Learn procedure must be performed. (Refer to STANDARD PROCEDURE - QUICK LEARN PROCEDURE )

Install both output bearing cups using Tool 5050 (Fig 1).

Fig 1: Installing Both Output Bearing Cups
Courtesy of DAIMLERCHRYSLER CORP.
Install low/reverse piston retainer gasket (Fig 2). Make sure gasket holes line up with case.

Fig 2: Install Piston Retainer Gasket
Courtesy of DAIMLERCHRYSLER CORP.
Install low/reverse piston retainer (Fig 3).

Fig 3: Install Piston Retainer
Courtesy of DAIMLERCHRYSLER CORP.
Install low/reverse piston retainer-to-case bolts (Fig 4) and torque to 5 N.m (45 in. lbs.).

Fig 4: Install Piston Retainer Attaching Screws
Courtesy of DAIMLERCHRYSLER CORP.
Install low/reverse clutch piston (Fig 5).

Fig 5: Install Low/Reverse Clutch Piston
Courtesy of DAIMLERCHRYSLER CORP.
Assemble park guide bracket assembly (Fig 7) (Fig 6).

Fig 6: Guide Bracket Disassembled
Courtesy of DAIMLERCHRYSLER CORP.

Fig 7: Guide Bracket
Courtesy of DAIMLERCHRYSLER CORP.
Install guide bracket into position and insert pivot shaft (Fig 8).

Fig 8: Pivot Shaft and Guide Bracket
Courtesy of DAIMLERCHRYSLER CORP.
Install anchor shaft and plug (Fig 9). Make sure guide bracket and split sleeve are in contact with the rear of the transaxle case.

Fig 9: Install Anchor Shaft and Plug
Courtesy of DAIMLERCHRYSLER CORP.
Install low/reverse piston return spring (Fig 10).

Fig 10: Low/Reverse Piston Return Spring
Courtesy of DAIMLERCHRYSLER CORP.
Install low/reverse spring compressor into position (Fig 11). Compress low/reverse piston and install snap ring as shown in (Fig 12).

Fig 11: Compressor Tool in Use
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Fig 12: Install Snap Ring
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Install rear carrier bearing cone using Tool 6053 (Fig 13).

Fig 13: Install Rear Carrier Bearing Cone
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Install rear carrier assembly to transaxle case (Fig 14).

Fig 14: Install Rear Carrier Assembly
Courtesy of DAIMLERCHRYSLER CORP.
Install output gear bearing cone using Tool 5052 (Fig 15).

Fig 15: Install Output Gear Bearing Cone
Courtesy of DAIMLERCHRYSLER CORP.

OUTPUT GEAR BEARING ADJUSTMENT:

With output gear removed, install a 4.50 mm (0.177 in.) gauging shim (Fig 17) on the rear carrier assembly hub, using grease to hold the shim in place.
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 16).
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 16).
Refer to the OUTPUT GEAR BEARING SHIM CHART 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.

Fig 16: Checking Output Gear Bearings End Play

Courtesy of DAIMLERCHRYSLER CORP.

Fig 17: Output Gear and (Select) Shim

Courtesy of DAIMLERCHRYSLER CORP.

OUTPUT GEAR BEARING SHIM CHART

End Play	Shim Needed	Part Number	End Play	Shim Needed	Part Number
0.05mm (0.002 in.)	4.42mm (0.174 in.)	4412830AB	0.53mm (0.021 in.)	3.94mm (0.155 in.)	4412818AB
0.08mm (0.003 in.)	4.38mm (0.172 in.)	4412829AB	0.56mm (0.022 in.)	3.90mm (0.154 in.)	4412817AB
0.10mm (0.004 in.)	4.38mm (0.172 in.)	4412829AB	0.58mm (0.023 in.)	3.90mm (0.154 in.)	4412817AB
0.13mm (0.005 in.)	4.34mm (0.171 in.)	4412828AB	0.61mm (0.024 in.)	3.86mm (0.152 in.)	4412816AB
0.15mm (0.006 in.)	4.30mm (0.169 in.)	4412827AB	0.64mm (0.025 in.)	3.82mm (0.150 in.)	4412815AB
0.18mm (0.007 in.)	4.30mm (0.169 in.)	4412827AB	0.66mm (0.026 in.)	3.82mm (0.150 in.)	4412815AB
0.20mm (0.008 in.)	4.26mm (0.168 in.)	4412826AB	0.69mm (0.027 in.)	3.78mm (0.149 in.)	4412814AB
0.23mm (0.009 in.)	4.22mm (0.166 in.)	4412825AB	0.71mm (0.028 in.)	3.74mm (0.147 in.)	4412813AB
0.25mm (0.010 in.)	4.22mm (0.166 in.)	4412825AB	0.74mm (0.029 in.)	3.74mm (0.147 in.)	4412813AB
0.28mm (0.011 in.)	4.18mm (0.165 in.)	4412824AB	0.76mm (0.030 in.)	3.70mm (0.146 in.)	4412812AB
0.30mm (0.012 in.)	4.14mm (0.163 in.)	4412823AB	0.79mm (0.031 in.)	3.66mm (0.144 in.)	4412811AB
0.33mm (0.013 in.)	4.14mm (0.163 in.)	4412823AB	0.81mm (0.032 in.)	3.66mm (0.144 in.)	4412811AB
0.36mm (0.014 in.)	4.10mm (0.161 in.)	4412822AB	0.84mm (0.033 in.)	3.62mm (0.143 in.)	4412810AB
0.38mm (0.015 in.)	4.10mm (0.161 in.)	4412822AB	0.86mm (0.034 in.)	3.62mm (0.143 in.)	4412810AB
0.41mm (0.016 in.)	4.06mm (0.160 in.)	4412821AB	0.89mm (0.035 in.)	3.58mm (0.141)	4412809AB
0.43mm (0.017 in.)	4.02mm (0.158 in.)	4412820AB	0.91mm (0.036in.)	3.54mm (0.139 in.)	4412808AB
0.46mm (0.018 in.)	4.02mm (0.158 in.)	4412820AB	0.94mm (0.037 in.)	3.54mm (0.139 in.)	4412808AB
0.48mm (0.019 in.)	3.98mm (0.157 in.)	4412819AB	0.97mm (0.038 in.)	3.50mm (0.138 in.)	4412807AB
0.51mm (0.020 in.)	3.94mm (0.155 in.)	4412818AB

Install the output gear and bearing assembly using Tool 6261 (Fig 18).

Fig 18: OUTPUT GEAR BEARING SHIM CHART Install Output Gear
Courtesy of DAIMLERCHRYSLER CORP.
Install NEW output gear retaining bolt and washer (Fig 19). Using Tool 6259, torque output gear retaining bolt to 271 N.m (200 ft. lbs.) (Fig 20).

Fig 19: Output Gear Bolt and Washer
Courtesy of DAIMLERCHRYSLER CORP.

Fig 20: Tightening Transfer Shaft Gear (With Torque Specification)
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Using an inch pound torque wrench (+)Fig 21), 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.

Fig 21: Check Output Gear Bearings Turning Torque
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Install output gear stirrup with serrated side out (Fig 22).

Fig 22: Install Stirrup
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Install retaining strap.
Install strap bolts but do not tighten at this time (Fig 23).

Fig 23: Install Strap Bolts
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Rotate stirrup clockwise against flats of retaining bolt (Fig 24).

Fig 24: Turn Stirrup Clockwise Against Bolt Flats
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Torque stirrup strap bolts to 23 N.m (200 in. lbs.) (Fig 25).

Fig 25: Tighten Stirrup Strap Bolts To 23 N.m (200 in.) lbs.)
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Bend tabs on strap up against flats of bolts (Fig 26).

Fig 26: Bend Tabs On Strap Up Against Flats Of Bolts
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Install transfer shaft bearing cone using Tool 6052 (Fig 27).

Fig 27: Install Transfer Shaft Bearing Cone
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Install bearing cup and oil baffle to transfer shaft (Fig 28).

Fig 28: Install Bearing Cup to Shaft
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Using Tool 5049A, install transfer shaft (Fig 29).

Fig 29: Install Transfer Shaft
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Using Tool 6051, install transfer shaft bearing snap ring (Fig 30).

Fig 30: Install Transfer Shaft Bearing Snap Ring
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Install transfer shaft bearing cup into retainer using Tool 6061 (Fig 31).

Fig 31: Install Transfer Shaft Bearing Cup Into Retainer
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Install bearing cup retainer to transaxle (Fig 32).

Fig 32: Remove Bearing Cup Retainer
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Install transfer gear bearing cone to transfer gear using Tool 5052 (Fig 33).

Fig 33: Install Transfer Gear Bearing Cone
Courtesy of DAIMLERCHRYSLER CORP.

TRANSFER GEAR BEARING ADJUSTMENT:

Install a 4.66 mm (0.184 in.) gauging shim on the transfer shaft (Fig 34).
Install transfer shaft gear using Tool 6261. Using Tool 6259, install transfer shaft gear retaining nut 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 CHART 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 (Fig 34) and install the proper shim indicated by the chart.

Fig 34: Install Transfer Shaft Gear and (Select) Shim

Courtesy of DAIMLERCHRYSLER CORP.

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.)	4505588AB	0.76mm (0.030 in.)	3.94mm (0.155 in.)	4412818AB
0.08mm (0.003 in.)	4.62mm (0.182 in.)	4412835AB	0.79mm (0.031 in.)	3.90mm (0.154 in.)	4412817AB
0.10mm (0.004 in.)	4.58mm (0.180 in.)	4412834AB	0.81mm (0.032 in.)	3.90mm (0.154 in.)	4412817AB
0.13mm (0.005 in.)	4.58mm (0.180 in.)	4412834AB	0.84mm (0.033 in.)	3.86mm (0.152 in.)	4412816AB
0.15mm (0.006 in.)	4.54mm (0.178 in.)	4412833AB	0.86mm (0.034 in.)	3.82mm (0.150 in.)	4412815AB
0.18mm (0.007 in.)	4.50mm (0.177 in.)	4412832AB	0.89mm (0.035 in.)	3.82mm (0.150 in.)	4412815AB
0.20mm (0.008 in.)	4.50mm (0.177 in.)	4412832AB	0.91mm (0.036 in.)	3.78mm (0.149 in.)	4412814AB
0.23mm (0.009 in.)	4.46mm (0.175 in.)	4412831AB	0.94mm (0.037 in.)	3.74mm (0.147 in.)	4412813AB
0.25mm (0.010 in.)	4.46mm (0.175 in.)	4412831AB	0.97mm (0.038 in.)	3.74mm (0.147 in.)	4412813AB
0.28mm (0.011 in.)	4.42mm (0.174 in.)	4412830AB	0.99mm (0.039 in.)	3.70mm (0.146 in.)	4412812AB
0.30mm (0.012 in.)	4.38mm (0.172 in.)	4412829AB	1.02mm (0.040 in.)	3.66mm (0.144 in.)	4412811AB
0.33mm (0.013 in.)	4.38mm (0.172 in.)	4412829AB	1.04mm (0.041 in.)	3.66mm (0.144 in.)	4412811AB
0.36mm (0.014 in.)	4.34mm (0.171 in.)	4412828AB	1.07mm (0.042 in.)	3.62mm (0.143 in.)	4412810AB
0.38mm (0.015 in.)	4.30mm (0.169 in.)	4412827AB	1.08mm (0.043 in.)	3.62mm (0.143 in.)	4412810AB
0.41mm (0.016 in.)	4.30mm (0.169 in.)	4412827AB	1.12mm (0.044 in.)	3.58mm (0.141)	4412809AB
0.43mm (0.017 in.)	4.26mm (0.168 in.)	4412826AB	1.14mm (0.045 in.)	3.54mm (0.139 in.)	4412808AB
0.46mm (0.018 in.)	4.22mm (0.166 in.)	4412825AB	1.17mm (0.046 in.)	3.54mm (0.139 in.)	4412808AB
0.48mm (0.019 in.)	4.22mm (0.166 in.)	4412825AB	1.19mm (0.047 in.)	3.50mm (0.138 in.)	4412807AB
0.50mm (0.020 in.)	4.18mm (0.165 in.)	4412824AB	1.22mm (0.048 in.)	3.46mm (0.136 in.)	4412806AB
0.53mm (0.021 in.)	4.18mm (0.165 in.)	4412824AB	1.24mm (0.049 in.)	3.46mm (0.136 in.)	4412806AB
0.56mm (0.022 in.)	4.14mm (0.163 in.)	4412823AB	1.27mm (0.050 in.)	3.42mm (0.135 in.)	4412805AB
0.58mm (0.023 in.)	4.10mm (0.161 in.)	4412822AB	1.30mm (0.051 in.)	3.38mm (0.133 in.)	4412804AB
0.61mm (0.024 in.)	4.10mm (0.161 in.)	4412822AB	1.32mm (0.052 in.)	3.38mm (0.133 in.)	4412804AB
0.64mm (0.025 in.)	4.06mm (0.160 in.)	4412821AB	1.35mm (0.053 in.)	3.34mm (0.132 in.)	4412803AB
0.66mm (0.026 in.)	4.02mm (0.158 in.)	4412820AB	1.37mm (0.054 in.)	3.34mm (0.132 in.)	4412803AB
0.69mm (0.027 in.)	4.02mm (0.158 in.)	4412820AB	1.40mm (0.055 in.)	3.30mm (0.130 in.)	4412802AB
0.71mm (0.028 in.)	3.98mm (0.157 in.)	4412819AB	1.45mm (0.057 in	3.26mm (0.128 in.)	4412801AB
0.74mm (0.029 in.)	3.94mm (0.155 in.)	4412818AB	1.47mm (0.058 in.)	2.22mm (0.127 in.)	4505570AB

Install the transfer shaft gear using Tool 6261 (Fig 35).

Fig 35: Installing Transfer Shaft Gear
Courtesy of DAIMLERCHRYSLER CORP.

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 36).

Fig 36: Tightening Transfer Gear Nut To 271 N.M (200 Ft. Lbs.)
Courtesy of DAIMLERCHRYSLER CORP.
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 gear cover (Fig 37).

Fig 37: Installing Rear Cover
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Install transfer gear cover-to-case bolts and torque to 20 N.m (175 in. lbs.) torque (Fig 38).

Fig 38: Installing Rear Cover Bolts
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Install low/reverse clutch pack (Fig 39). Leave uppermost disc out until snap ring is installed.

Fig 39: Installing Low/Reverse Clutch Pack
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Install low/reverse reaction plate flat snap ring (Fig 40).

Fig 40: Installing Low/Reverse Reaction Plate Snap Ring
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Install remaining low/reverse clutch disc (Fig 41).

Fig 41: Installinhg One Disc
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Install low/reverse reaction plate with flat side up (Fig 42).

Fig 42: Installing Low/Reverse Reaction Plate
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Install tapered snap ring (with tapered side up) as shown in (Fig 43) (Fig 44).

Fig 43: Installing Tapered Snap Ring Instructions
Courtesy of DAIMLERCHRYSLER CORP.

Fig 44: Identifying Snap Ring Installed
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Set up dial indicator as shown in (Fig 45) 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 45: Checking Low/Reverse Clutch Clearance

Courtesy of DAIMLERCHRYSLER CORP.

LOW/REVERSE REACTION PLATE CHART

PART NUMBER	THICKNESS
4799846AA	5.88 mm (0.232 in.)
4799847AA	6.14 mm (0.242 in.)
4799848AA	6.40 mm (0.252 in.)
4799849AA	6.66 mm (0.262 in.)
4799855AA	6.92 mm (0.273 in.)

Install 2/4 clutch pack (Fig 46).

Fig 46: Installing 2/4 Clutch Pack
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Orient 2/4 clutch return spring to retainer as shown in (Fig 47), and install to transaxle (Fig 48).

Fig 47: Installing Proper Orientation Of 2/4 Clutch Retainer And Spring
Courtesy of DAIMLERCHRYSLER CORP.

Fig 48: Identifying 2/4 Clutch Retainer
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Using tool 5058, compress 2/4 clutch return spring just enough to install snap ring (Fig 49).
Install snap ring.

Fig 49: Installing 2/4 Clutch Retainer Snap Ring
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Set up dial indicator as shown in (Fig 50) 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.

Fig 50: Checking 2/4 Clutch Clearance
Courtesy of DAIMLERCHRYSLER CORP.
Install rear sun gear and #7 needle bearing (Fig 52).
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 51). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.

Fig 51: Removing Number 7 Bearing
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Fig 52: Install Rear Sun Gear and #7 Needle Bearing
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Install front carrier/rear annulus assembly and #6 needle bearing (Fig 53).
Install front sun gear assembly and #4 thrust washer (Fig 54).

Fig 53: Installing Front Carrier And Rear Annulus Assembly
Courtesy of DAIMLERCHRYSLER CORP.

Fig 54: Installing Front Sun Gear Assembly
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DETERMINING #4 THRUST PLATE THICKNESS / INPUT SHAFT END PLAY:

Select the thinnest #4 thrust plate thickness and install to input clutch assembly (Fig 55). 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 56), the input clutch assembly is not seated properly.
Remove oil pump o-ring (Fig 57). Be sure to reinstall oil pump o-ring after selecting the proper #4 thrust plate.
Install pump and gasket to transmission. Install and torque bolts.
Set up input shaft for measurement with Indicator Set C3339 and End Play Set 8266 as shown in (Fig 58).
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.

Refer to the NO. 4 THRUST PLATE CHART to select the proper No. 4 thrust plate.

Fig 55: Removing Thrust Plate

Courtesy of DAIMLERCHRYSLER CORP.

Fig 56: Identifying View Through Input Speed Sensor Hole

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Fig 57: Removing Oil Pump O-Ring

Courtesy of DAIMLERCHRYSLER CORP.

Fig 58: Measuring Input Shaft End Play Using End Play Set 8266

Courtesy of DAIMLERCHRYSLER CORP.

NO. 4 THRUST PLATE CHART

PART NUMBER	THICKNESS
4431665AB	1.60mm (0.063 in.)
3836237AB	1.73mm (0.068 in.)
4431666AB	1.80mm (0.071 in.)
3836238AB	1.96mm (0.077 in.)
4431667AB	2.03mm (0.080 in.)
3836239AB	2.16mm (0.085 in.)
4431668AB	2.24mm (0.088 in.)
3836240AB	2.39mm (0.094 in.)
4431669AB	2.46mm (0.097 in.)
3836241AB	2.62mm (0.103 in.)
4446670AB	2.67mm (0.105 in.)
4446671AB	2.90mm (0.114 in.)

Install input clutch assembly (Fig 59).

Fig 59: Installing Input Clutch Assembly
Courtesy of DAIMLERCHRYSLER CORP.
Install #1 caged needle bearing (Fig 60).

Fig 60: Installing Caged Needle Bearing
Courtesy of DAIMLERCHRYSLER CORP.

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 61).

Fig 61: Installing Cooler Bypass Valve
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Install oil pump gasket (Fig 62).

Fig 62: Installing Oil Pump Gasket
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Install oil pump assembly (Fig 63).

Fig 63: Installing Oil Pump
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Install oil pump-to-case bolts and torque to 27 N.m (20 ft. lbs.) (Fig 64).

Fig 64: Installing Pump-To-Case Bolts
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Install low/reverse accumulator (Fig 65).

Fig 65: Installing Low/Reverse Accumulator
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Install low/reverse accumulator plug (Fig 66).

Fig 66: Installing Low/Reverse Accumulator Plug (Cover)
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Install low/reverse accumulator snap ring (Fig 67).

Fig 67: Installing Low/Reverse Accumulator Snap Ring
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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 68) (Fig 69) (Fig 70).

Fig 68: Removing Accumulator (Underdrive)
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Fig 69: Removing Accumulator (Overdrive)
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Fig 70: Installing Underdrive And Overdrive Accumulators
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Install valve body to transaxle (Fig 71). Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are positioned within park guide bracket.

Fig 71: Installing Valve Body
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Install and torque valve body-to-case bolts to 12 N.m (105 in. lbs.) (Fig 72).

Fig 72: Installing Valve Body-To-Case Bolts
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Install oil filter and new o-ring (Fig 73).

Fig 73: Installing Oil Filter
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Apply an 1/8" bead of Mopar® ATF RTV (MS-GF41) to oil pan and immediately install to case (Fig 74).

Fig 74: Installing Oil Pan
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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 75).

Fig 75: Identifying Solenoid/Pressure Switch Assembly And Gasket
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Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts to 12 N.m (110 in. lbs.) (Fig 76).

Fig 76: Identifying Attaching Bolts
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Install and torque input and output speed sensors to case to 27 N.m (20 ft. lbs.).