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).
- 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 (Fig 4) and torque to 5 N.m (45 in. lbs.).
- 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 (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.
OUTPUT GEAR BEARING SHIM CHART
OUTPUT GEAR BEARING SHIM CHARTEnd 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).
- 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).
- 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.
- Install output gear stirrup with serrated side out (Fig 22).
- Install retaining strap.
- Install strap bolts but do not tighten at this time (Fig 23).
- Rotate stirrup clockwise against flats of retaining bolt (Fig 24).
- Torque stirrup strap bolts to 23 N.m (200 in. lbs.) (Fig 25).
- Bend tabs on strap up against flats of bolts (Fig 26).
- Install transfer shaft bearing cone using Tool 6052 (Fig 27).
- Install bearing cup and oil baffle to transfer shaft (Fig 28).
- Using Tool 5049A, install transfer shaft (Fig 29).
- Using Tool 6051, install transfer shaft bearing snap ring (Fig 30).
- Install transfer shaft bearing cup into retainer using Tool 6061 (Fig 31).
- Install bearing cup retainer to transaxle (Fig 32).
- Install transfer gear bearing cone to transfer gear using Tool 5052 (Fig 33).
- 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.
TRANSFER SHAFT BEARING SHIM CHART
TRANSFER SHAFT BEARING SHIM CHARTEnd 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).
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).
- 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).
- Install transfer gear cover-to-case bolts and torque to 20 N.m (175 in. lbs.) torque (Fig 38).
- Install low/reverse clutch pack (Fig 39). Leave uppermost disc out until snap ring is installed.
- Install low/reverse reaction plate flat snap ring (Fig 40).
- Install remaining low/reverse clutch disc (Fig 41).
- Install low/reverse reaction plate with flat side up (Fig 42).
- Install tapered snap ring (with tapered side up) as shown in (Fig 43) (Fig 44).
- 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.
LOW/REVERSE REACTION PLATE CHART
LOW/REVERSE REACTION PLATE CHARTPART 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).
- Orient 2/4 clutch return spring to retainer as shown in (Fig 47), and install to transaxle (Fig 48).
Courtesy of DAIMLERCHRYSLER CORP.
- Using tool 5058, compress 2/4 clutch return spring just enough to install snap ring (Fig 49).
- Install snap ring.
- 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.
- 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.
- Install front carrier/rear annulus assembly and #6 needle bearing (Fig 53).
- Install front sun gear assembly and #4 thrust washer (Fig 54).
- 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.
NO. 4 THRUST PLATE CHART
NO. 4 THRUST PLATE CHARTPART 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).
- Install #1 caged needle bearing (Fig 60).
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).
- Install oil pump gasket (Fig 62).
- Install oil pump assembly (Fig 63).
- Install oil pump-to-case bolts and torque to 27 N.m (20 ft. lbs.) (Fig 64).
- Install low/reverse accumulator (Fig 65).
- Install low/reverse accumulator plug (Fig 66).
- Install low/reverse accumulator snap ring (Fig 67).
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).
- 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.
- Install and torque valve body-to-case bolts to 12 N.m (105 in. lbs.) (Fig 72).
- Install oil filter and new o-ring (Fig 73).
- Apply an 1/8" bead of Mopar® ATF RTV (MS-GF41) to oil pan and immediately install to case (Fig 74).
- 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).
- Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts to 12 N.m (110 in. lbs.) (Fig 76).
- Install and torque input and output speed sensors to case to 27 N.m (20 ft. lbs.).