41TE Automatic Transmission (Service Information): Disassembly: Disassembly

Fig 1: Solenoid/Pressure Switch Assembly and Gasket

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1 - SOLENOID/PRESSURE SWITCH ASSEMBLY

2 - GASKET

NOTE: If transaxle is being overhauled (clutch and/or seal replacement) or replaced, it is necessary to perform the PCM/TCM Quick Learn Procedure. Refer to Electrical/Electronic Control Modules/MODULE, Powertrain Control - Standard Procedure

NOTE: This procedure does not include final drive (differential) disassembly.

1. Remove input and output speed sensors.
2. Remove the solenoid/pressure switch assembly-to-case bolts.
3. Remove solenoid/pressure switch assembly and gasket (2).
   Fig 2: Remove Oil Pan Bolts

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   1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)

4. Remove oil pan-to-case bolts (1) .
   Fig 3: Remove Oil Pan

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   1 - OIL PAN

   2 - 1/8 INCH BEAD OF MOPAR® ATF RTV (MS-GF41)

   3 - OIL FILTER

5. Remove oil pan (1) .
   Fig 4: Remove Oil Filter

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   1 - OIL FILTER

   2 - O-RING

6. Remove oil filter (1) .
   Fig 5: Remove Valve Body Attaching Bolts

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   1 - VALVE BODY ATTACHING BOLTS (18)

   2 - VALVE BODY

7. Turn manual valve fully clockwise to get park rod into position for removal.
8. Remove valve body-to-case bolts (1) .
   Fig 6: Push Park Rod Rollers from Guide Bracket

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   1 - PARK SPRAG ROLLERS

   2 - SCREWDRIVER

   3 - PARK SPRAG GUIDE BRACKET

9. Using a screwdriver (2), push park rod rollers away from guide bracket (3) .
   Fig 7: Remove Valve Body

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   1 - VALVE BODY

   CAUTION: Do not handle the valve body assembly from the manual valve. Damage can result.
10. Remove valve body assembly (1).
    Fig 8: Remove Underdrive and Overdrive Accumulators

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    1 - RETURN SPRING

    2 - UNDERDRIVE CLUTCH ACCUMULATOR

    3 - SEAL RING (2)

    4 - OVERDRIVE CLUTCH ACCUMULATOR

    NOTE: Depending on engine application, some accumulators will have two springs and others will have one spring. The springs are color-coded according to application and year. When disassembling, mark accumulator spring location to ease assembly.
11. Remove underdrive (2) and overdrive (4) accumulators.
    Fig 9: Remove Low/Reverse Accumulator Snap Ring

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    1 - SNAP RING

    2 - PLUG

12. Remove low/reverse accumulator snap ring (1) .
    Fig 10: Remove Low/Reverse Accumulator Plug (Cover)

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    1 - ADJUSTABLE PLIERS

    2 - PLUG

13. Remove low/reverse accumulator plug (2) .
    Fig 11: Low/Reverse Accumulator Piston

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    1 - ACCUMULATOR PISTON

14. Remove low/reverse accumulator piston (1) using suitable pliers.
    Fig 12: Low/Reverse Accumulator

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    1 - ACCUMULATOR PISTON

    2 - SEAL RINGS

    3 - RETURN SPRINGS

    4 - (NOTE NOTCH)

15. Remove low/reverse accumulator return springs (3) .
    Fig 13: Measure Input Shaft End Play Using End Play Set 8266

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    1 - END PLAY FIXTURES 8266A

    2 - DIAL INDICATOR C-3339A

16. Measure input shaft end play. Place transaxle so input shaft is vertical. Set up end play fixtures and dial indicator (2,3) . Input shaft end play should be within 0.13-0.64 mm (0.005-0.025 in.)  If outside of this range, a #4 thrust plate change is required. Record indicator reading for reference upon reassembly.
    Fig 14: Remove Pump Attaching Bolts

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    1 - PUMP ATTACHING BOLTS

    2 - PUMP HOUSING

17. Remove oil pump-to-case bolts (1) .
    Fig 15: Install Tool C-3752

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    1 - SLIDE HAMMERS C-3752

    2 - PUMP

    CAUTION: Be sure input speed sensor is removed before removing oil pump.
18. Install slide hammers C-3752 (1) .
    Fig 16: Remove Oil Pump

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    1 - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP

19. Remove oil pump assembly (1) .
    Fig 17: Remove Oil Pump Gasket

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    1 - PUMP GASKET

20. Remove oil pump gasket (1) .
    Fig 18: Remove Bypass Valve

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    1 - COOLER BYPASS VALVE

    CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt to clean valve.
21. Remove cooler bypass valve (1) .
    Fig 19: Remove Caged Needle Bearing

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    1 - #1 CAGED NEEDLE BEARING

    2 - NOTE: TANGED SIDE OUT

22. Remove #1 needle bearing (1) .
    Fig 20: Remove Input Clutch Assembly

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    1 - INPUT CLUTCH ASSEMBLY

    2 - #4 THRUST WASHER

23. Remove input clutch assembly (1) .
    Fig 21: No. 4 Thrust Plate

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    1 - OVERDRIVE SHAFT ASSEMBLY

    2 - #4 THRUST PLATE (SELECT)

    3 - 3 DABS OF PETROLATUM FOR RETENTION

24. Remove #4 thrust plate (2) .
    Fig 22: Remove Front Sun Gear Assembly

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    1 - FRONT SUN GEAR ASSEMBLY

    2 - #4 THRUST WASHER (FOUR TABS)

25. Remove front sun gear assembly (1) and #4 thrust washer (2).
    Fig 23: Remove Front Carrier and Rear Annulus Assembly

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    1 - #6 NEEDLE BEARING

    2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).

26. Remove front carrier/rear annulus assembly (2) and #6 needle bearing (1).
    Fig 24: Remove Rear Sun Gear

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    1 - #7 NEEDLE BEARING

    2 - REAR SUN GEAR

    NOTE: The number 7 needle bearing (1) 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 (2) when put together. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
27. Remove rear sun gear (2) and #7 needle bearing (1).
    Fig 25: Remove 2/4 Clutch Retainer Snap Ring

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    1 - SPRING COMPRESSOR 5058A

    2 - SCREWDRIVER

    3 - SNAP RING

    4 - 2/4 CLUTCH RETAINER

    NOTE: Verify that spring compressor 5058A is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the 5058 bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.
28. Setup spring compressor 5058A (1) , Compress 2/4 clutch return spring (4) (just enough to remove snap ring) and remove snap ring (3).
    Fig 26: 2/4 Clutch Retainer

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    1 - 2/4 CLUTCH RETAINER

    2 - 2/4 CLUTCH RETURN SPRING

    NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
29. Remove 2/4 clutch retainer (1) .
    Fig 27: Remove 2/4 Clutch Return Spring

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    1 - 2/4 CLUTCH RETURN SPRING

30. Remove 2/4 clutch return spring (1) .
    Fig 28: Remove 2/4 Clutch Pack

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    1 - CLUTCH PLATE (4)

    2 - CLUTCH DISC (4)

31. Remove 2/4 clutch pack (1,2) . Tag 2/4 clutch pack for reassembly identification. 
    Fig 29: Remove Tapered Snap Ring

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    1 - LOW/REVERSE CLUTCH REACTION PLATE

    2 - SCREWDRIVER

    3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)

    4 - OIL PAN FACE

    5 - LONG TAB

32. Remove tapered snap ring (3) .
    Fig 30: Remove Low/Reverse Reaction Plate

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    1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)

33. Remove low/reverse reaction plate (1) .
    Fig 31: Remove One Disc

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    1 - ONE DISC FROM LOW/REVERSE CLUTCH

34. Remove one low/reverse clutch disc (1) .
    Fig 32: Remove Low/Reverse Reaction Plate Snap Ring

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    1 - SCREWDRIVER

    2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING

    3 - DO NOT SCRATCH CLUTCH PLATE

35. Remove low/reverse reaction plate snap ring (2) .
    Fig 33: Remove Low/Reverse Clutch Pack

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    1 - CLUTCH PLATES (5)

    2 - CLUTCH DISCS (5)

36. Remove low/reverse clutch pack (1,2) .
    Fig 34: Remove Rear Cover Bolts

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    1 - REAR COVER BOLTS

    2 - REAR COVER

    3 - USE SEALANT ON BOLTS

37. Remove transfer gear cover-to-case bolts (1) .
    Fig 35: Remove Rear Cover

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    1 - REAR COVER

    2 - 1/8 INCH BEAD OF MOPAR® ATF RTV (MS-GF41)

38. Remove transfer gear cover (1) .
    Fig 36: Remove Transfer Shaft Gear Nut

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    1 - TRANSFER SHAFT GEAR

    2 - OUTPUT GEAR

    3 - HOLDER 6259

39. Install holder 6259 (3) .
    Fig 37: Transfer Shaft Gear Nut and Coned Washer

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    1 - TRANSFER SHAFT

    2 - LOCK WASHER

    3 - NUT

40. Remove transfer shaft gear-to-shaft nut (3) and coned washer (2).
    Fig 38: Remove Transfer Shaft Gear

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    1 - GEAR PULLER L-4407A

    2 - TRANSFER SHAFT GEAR

41. Using Gear Puller L-4407A (3) remove transfer shaft gear (2).
    Fig 39: Remove Transfer Shaft Gear and (Select) Shim

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    1 - TRANSFER SHAFT GEAR

    2 - BEARING CUP RETAINER

    3 - SHIM (SELECT)

42. Remove transfer gear shim (select) (3) .
    Fig 40: Remove Bearing Cup Retainer

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    1 - ALIGN INDEXING TAB TO SLOT

    2 - BEARING CUP RETAINER

43. Remove bearing cup retainer (2) .
    Fig 41: Remove Transfer Gear Bearing Cone

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    1 - WRENCHES

    2 - BEARING PULLER 5048 WITH JAWS 5048-4 AND THRUST PAD L-4539-2

    3 - TRANSFER SHAFT GEAR

44. Remove transfer gear bearing cone using setup using bearing puller Set 5048 with jaws 5048-4 and thrust pad L-4539-2 (2) .
    Fig 42: Remove Transfer Shaft Bearing Cup

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    1 - WRENCHES

    2 - BEARING CUP PULLER 6062A

    3 - TRANSFER SHAFT BEARING CUP RETAINER

45. Remove transfer shaft bearing cup from retainer (3) using bearing cup puller 6062A (2).
    Fig 43: Remove Transfer Shaft Bearing Snap Ring

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    1 - SNAP RING PLIERS 6051A

    2 - TRANSFER SHAFT BEARING SNAP RING

    3 - TRANSFER SHAFT

46. Using Snap Ring Pliers 6051A (1) remove transfer shaft bearing snap ring (2).
    Fig 44: Remove Transfer Shaft

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    1 - REMOVER/INSTALLER 5049-A

    2 - TRANSFER SHAFT

    3 - OUTPUT GEAR

47. Using the Remover/Installer 5049-A (1) remove transfer shaft (2) from transaxle.
    Fig 45: Bearing Cup Removed

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    1 - BEARING CUP

    2 - BEARING CONE

    3 - TRANSFER SHAFT

    4 - OIL BAFFLE

    5 - O-RING

48. Slip bearing cup retainer (1) and oil baffle (4) off of shaft.
    Fig 46: Remove Transfer Shaft Bearing Cone

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    1 - ARBOR PRESS RAM

    2 - TRANSFER SHAFT

    3 - BEARING SPLITTER P-334

    4 - BEARING CONE

49. Using Bearing Splitter P-334 (3) press transfer shaft bearing cone (4) off of shaft (2).
    Fig 47: Remove Strap Bolts

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    1 - RETAINING STRAP

    2 - STIRRUP

    3 - RETAINING STRAP BOLTS

50. Bend output gear retaining strap (1) ears flat to allow bolt removal.
51. Remove output shaft stirrup strap bolts (3).
    Fig 48: Remove Stirrup Strap

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    1 - OUTPUT GEAR BOLT

    2 - RETAINING STRAP

    3 - STIRRUP

52. Remove stirrup (3) and strap (2).
    Fig 49: Remove Output Gear Bolt

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    1 - OUTPUT GEAR

    2 - HOLDER 6259

53. Using Holder 6259 (2) .
    Fig 50: Output Gear Bolt and Washer

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    1 - OUTPUT GEAR

    2 - BOLT

    3 - CONED LOCK WASHER

54. Remove output shaft gear-to-shaft bolt (2) and washer (3).
    Fig 51: Remove Output Gear

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    1 - OUTPUT GEAR

    2 - THRUST BUTTON 6055

    3 - WRENCHES

    4 - GEAR PULLER L4407A

    5 - BOLTS L4407-6

55. Using Gear Puller L4407A, (4) and thrust button 6055 (2), remove output gear (1) from shaft.
    Fig 52: Output Gear and (Select) Shim

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    1 - REAR CARRIER ASSEMBLY

    2 - SHIM (SELECT)

    3 - OUTPUT GEAR

56. Remove output gear bearing shim (select) (2) .
    Fig 53: Remove Bearing Cone

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    1 - EEARING PULLER 5048 WITH JAWS 5048-5 AND THRUST PAD L-4539-2

    2 - WRENCHES

    3 - OUTPUT GEAR

57. Using bearing puller 5048 with jaws 5048-5 and thrust pad L-4539-2 (1) Remove output gear bearing cone.
    Fig 54: Remove Rear Carrier Assembly

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    1 - REAR CARRIER ASSEMBLY

58. Remove rear carrier assembly (1) from transaxle.
    Fig 55: Remove Rear Carrier Bearing Cone

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    1 - BEARING PULLER 5048 WITH JAWS 5048-3 AND THRUST BUTTON 6055

    2 - WRENCHES

    3 - REAR CARRIER ASSEMBLY

59. Remove rear carrier assembly (3) bearing cone using bearing puller 5048 with jaws 5048-3 and thrust button 6055.
    Fig 56: Low/Reverse Spring Compressor Tool

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    1 - SPRING COMPRESSOR DISC 6057

    2 - SPRING COMPRESSOR 5059-A

    3 - FORCING SCREW 5058A-3

60. Install spring compressor disk 6057 (1) , spring compressor 5059-A (2) and forcing screw 5058A-3 (3).
    Fig 57: Compressor Tool in Use

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    1 - LOW/REVERSE CLUTCH RETURN SPRING

    2 - SNAP RING (INSTALL AS SHOWN)

    3 - SPRING COMPRESSOR DISC 6057

    4 - SPRING COMPRESSOR 5059-A

    5 - FORCING SCREW 5058A-3

61. Install low/reverse spring compressor .
    Fig 58: Remove Snap Ring

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    1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN)

    2 - SNAP RING PLIERS

    3 - SPRING COMPRESSOR DISC 6057

62. Compress low/reverse piston return spring and remove snap ring (1) .
    Fig 59: Low/Reverse Piston Return Spring

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    1 - LOW/REVERSE PISTON RETURN SPRING

    2 - PISTON

63. Remove low/reverse spring compressor tool and low reverse piston return spring (1) .
    Fig 60: Remove Anchor Shaft and Plug

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    1 - GUIDE BRACKET ANCHOR SHAFT

    2 - PIVOT SHAFT

    3 - ANCHOR SHAFT PLUG

64. Using a suitable punch , drive out park guide bracket pivot shaft plug (3) .
    Fig 61: Pivot Shaft and Guide Bracket

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    1 - ANTIRACHET SPRING

    2 - GUIDE BRACKET

    3 - PIVOT SHAFT

    4 - PAWL

65. Using ordinary pliers, remove pivot shaft (3) and guide bracket assembly (2).
    Fig 62: Guide Bracket Disassembled

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    1 - ANTI-RATCHET SPRING

    2 - GUIDE BRACKET

    3 - SPLIT SLEEVE

    4 - SPACER

    5 - PAWL

    6 - STEPPED SPACER

66. Inspect guide bracket components for excessive wear and replace if necessary .
    Fig 63: Remove Low/Reverse Clutch Piston

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    1 - LOW/REVERSE CLUTCH PISTON

    2 - BONDED SEAL

    3 - BONDED SEAL

    NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
67. Remove low/reverse clutch piston (1) .
    Fig 64: Remove Piston Retainer Attaching Screws

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    1 - LOW/REVERSE CLUTCH PISTON RETAINER

    2 - SCREWDRIVER

    3 - TORX-LOC SCREWS

68. Remove low/reverse piston retainer-to-case screws (3) .
    Fig 65: Remove Piston Retainer

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    1 - LOW/REVERSE CLUTCH PISTON RETAINER

    2 - GASKET

69. Remove low/reverse piston retainer (1) .
    Fig 66: Remove Piston Retainer Gasket

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    1 - GASKET HOLES MUST LINE UP

    2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET

70. Remove low/reverse piston retainer-to-case gasket (2) , gasket holes must line up (1).
    Fig 67: Remove Output Bearing Inner Cup

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    1 - OUTPUT BEARING CUPS (REPLACE IN PAIRS)

    2 - HAMMER

    3 - BRASS DRIFT

71. Using a hammer (2) and suitable drift (3), drive out inner output bearing cup (1).
    Fig 68: Remove Output Bearing Outer Cup

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    1 - BEARING CUP PULLER 6062A

72. Using bearing cup puller 6062A (1) , remove outer output bearing cup.