Chrysler PT Cruiser. Manual — part 840
INSTALLATION
NOTE: To ease installation of the valve body, turn
the manual valve lever fully clockwise.
(1) Install overdrive and underdrive accumulators
and springs as previously removed (Fig. 383).
(2) Guide park rod rollers into guide bracket while
installing valve body to the transaxle case (Fig. 381)
(Fig. 382).
(3) Install
the
valve
body-to-case
bolts
(Fig.
380)and torque to 12 N·m (105 in. lbs.).
(4) Install the oil filter (Fig. 379). Inspect the
o-ring for damage and replace as necessary.
(5) Install an 1/8’ bead of RTV as shown in (Fig.
378)and install pan to case.
(6) Install oil pan bolts (Fig. 377) and torque to 19
N·m (165 in. lbs.) torque.
(7) Lower vehicle.
(8) Install manual valve lever to manual shaft
(Fig. 376).
(9) Install gearshift cable to manual valve lever
(Fig. 376).
(10) Install the battery tray (Fig. 375).
(11) Install the battery and hold down clamp (Fig.
374).
(12) Install air cleaner assembly (Fig. 373).
(13) Connect battery cables.
(14) Fill transaxle with fluid. Refer to SERVICE
PROCEDURES for proper fluid fill procedure.
Fig. 413 Install Transmission Range Sensor
Retaining Screw
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
Fig. 414 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
21 - 314
40TE AUTOMATIC TRANSAXLE
PT
VALVE BODY (Continued)
41TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page
page
41TE AUTOMATIC TRANSAXLE
. . . . . . . . . . . . . . . . . . . . . . . . 316
TRANSAXLE GENERAL DIAGNOSIS . . . . . . 318
DIAGNOSIS AND TESTING - ROAD TEST
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS . . . . . . . . . . . . . . . . . . . 319
DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS . . . . . . . . . . . . . . . . . . . 322
DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE . . 323
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
. . . . . . . . . . . . . . . . . . . . . . . . 327
. . . . . . . . . . . . . . . . . . . . . . . . . . . 344
. . . . . . . . . . . . . . . . . . . . . . . . 366
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . 367
. . . . . . . . . . . . . . . . . . . . . . 379
. . . . . . . . . . . . . . . . . . . . . . . 381
ACCUMULATOR
. . . . . . . . . . . . . . . . . . . . . . . . 387
. . . . . . . . . . . . . . . . . . . . . . . . . . 387
DRIVING CLUTCHES
. . . . . . . . . . . . . . . . . . . . . . . . 387
. . . . . . . . . . . . . . . . . . . . . . . . . . 387
FINAL DRIVE
. . . . . . . . . . . . . . . . . . . . . . . . 388
. . . . . . . . . . . . . . . . . . . . . . . . . . 388
. . . . . . . . . . . . . . . . . . . . . . . . 389
. . . . . . . . . . . . . . . . . . . . . . . . . . . 394
MEASUREMENT AND ADJUSTMENT . . . . . . 398
FLUID
STANDARD PROCEDURE - FLUID AND
FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . 400
FLUID LEVEL AND CONDITION CHECK
GEAR SHIFT BEZEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
. . . . . . . . . . . . . . . . . . . . . . . . 403
GEAR SHIFT CABLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
. . . . . . . . . . . . . . . . . . . . . . . . 406
. . . . . . . . . . . . . . . . . . 406
GEAR SHIFT KNOB
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
. . . . . . . . . . . . . . . . . . . . . . . . 408
HOLDING CLUTCHES
. . . . . . . . . . . . . . . . . . . . . . . . 408
. . . . . . . . . . . . . . . . . . . . . . . . . . 408
INPUT CLUTCH ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . 409
. . . . . . . . . . . . . . . . . . . . . . . . . . . 418
OIL PUMP
. . . . . . . . . . . . . . . . . . . . . . . . 434
. . . . . . . . . . . . . . . . . . . . . . . . . . 434
. . . . . . . . . . . . . . . . . . . . . . . . 434
. . . . . . . . . . . . . . . . . . . . . . . . . . . 436
PLANETARY GEARTRAIN
. . . . . . . . . . . . . . . . . . . . . . . . 436
. . . . . . . . . . . . . . . . . . . . . . . . . . 436
SEAL - OIL PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
. . . . . . . . . . . . . . . . . . . . . . . . 437
SHIFT INTERLOCK CABLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
. . . . . . . . . . . . . . . . . . . . . . . . 439
SHIFT INTERLOCK MECHANISM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
. . . . . . . . . . . . . . . . . . . . . . . . 441
SHIFT INTERLOCK SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . 441
DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK
SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . 442
BRAKE/TRANSMISSION SHIFT INTERLOCK
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
SHIFT MECHANISM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
. . . . . . . . . . . . . . . . . . . . . . . . 445
SOLENOID/PRESSURE SWITCH ASSY
. . . . . . . . . . . . . . . . . . . . . . . . 445
. . . . . . . . . . . . . . . . . . . . . . . . . . 445
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
. . . . . . . . . . . . . . . . . . . . . . . . 447
SPEED SENSOR - INPUT
. . . . . . . . . . . . . . . . . . . . . . . . 448
. . . . . . . . . . . . . . . . . . . . . . . . . . 448
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
. . . . . . . . . . . . . . . . . . . . . . . . 450
SPEED SENSOR - OUTPUT
. . . . . . . . . . . . . . . . . . . . . . . . 450
. . . . . . . . . . . . . . . . . . . . . . . . . . 451
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
. . . . . . . . . . . . . . . . . . . . . . . . 452
PT
41TE AUTOMATIC TRANSAXLE
21 - 315
TORQUE CONVERTER
. . . . . . . . . . . . . . . . . . . . . . . . 453
. . . . . . . . . . . . . . . . . . . . . . . . . . 456
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
. . . . . . . . . . . . . . . . . . . . . . . . 458
TRANSMISSION CONTROL RELAY
. . . . . . . . . . . . . . . . . . . . . . . . 459
. . . . . . . . . . . . . . . . . . . . . . . . . . 459
TRANSMISSION RANGE SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . 459
. . . . . . . . . . . . . . . . . . . . . . . . . . 459
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
. . . . . . . . . . . . . . . . . . . . . . . . 464
VALVE BODY
. . . . . . . . . . . . . . . . . . . . . . . . 464
. . . . . . . . . . . . . . . . . . . . . . . . . . 464
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
. . . . . . . . . . . . . . . . . . . . . . . . 468
. . . . . . . . . . . . . . . . . . . . . . . . . . . 472
. . . . . . . . . . . . . . . . . . . . . . . . 477
41TE AUTOMATIC
TRANSAXLE
DESCRIPTION
The 41TE (Fig. 1) is a four-speed transaxle that is
a conventional hydraulic/mechanical assembly with
an integral differential, and is controlled with adap-
tive electronic controls and monitors. The hydraulic
system of the transaxle consists of the transaxle
fluid, fluid passages, hydraulic valves, and various
line pressure control components. An input clutch
assembly which houses the underdrive, overdrive,
and reverse clutches is used. It also utilizes separate
holding clutches: 2nd/4th gear and Low/Reverse. The
primary mechanical components of the transaxle con-
sist of the following:
• Three multiple disc input clutches
• Two multiple disc holding clutches
• Four hydraulic accumulators
• Two planetary gear sets
• Hydraulic oil pump
• Valve body
• Solenoid/Pressure switch assembly
• Integral differential assembly
Control of the transaxle is accomplished by fully
adaptive electronics. Optimum shift scheduling is
accomplished through continuous real-time sensor
feedback information provided to the Powertrain
Control Module (PCM) or Transmission Control Mod-
ule (TCM).
The PCM/TCM is the heart of the electronic control
system and relies on information from various direct
and indirect inputs (sensors, switches, etc.) to deter-
mine driver demand and vehicle operating condi-
tions. With this information, the PCM/TCM can
calculate and perform timely and quality shifts
through various output or control devices (solenoid
pack, transmission control relay, etc.).
The PCM/TCM also performs certain self-diagnos-
tic functions and provides comprehensive information
(sensor data, DTC’s, etc.) which is helpful in proper
diagnosis and repair. This information can be viewed
with the DRB scan tool.
21 - 316
41TE AUTOMATIC TRANSAXLE
PT
Fig. 1 41TE Automatic Transaxle
1 - TRANSAXLE CASE
7 - REVERSE CLUTCH
13 - OUTPUT SHAFT GEAR
2 - TORQUE CONVERTER
8 - FRONT PLANET CARRIER
14 - TRANSFER SHAFT GEAR
3 - OIL PUMP
9 - 2/4 CLUTCH
15 - TRANSFER SHAFT
4 - INPUT SPEED SENSOR
10 - L/R CLUTCH
16 - DIFFERENTIAL
5 - UNDERDRIVE CLUTCH
11 - OUTPUT SPEED SENSOR
17 - CONVERTER DRIVE PLATE
6 - OVERDRIVE CLUTCH
12 - REAR PLANET CARRIER/OUTPUT
SHAFT
18 - INPUT SHAFT
PT
41TE AUTOMATIC TRANSAXLE
21 - 317
41TE AUTOMATIC TRANSAXLE (Continued)
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