Chrysler RG Voyager. Manual — part 1036
(e) Set up input shaft for measurement with
Indicator Set C3339 and End Play Set 8266 as
shown in (Fig. 142).
(f) 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 read-
ing of 0.020 inch which is within specifications.
(g) Refer to the No. 4 thrust plate chart to select
the proper No. 4 thrust plate:
Fig. 139 Select Thinnest No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 140 View Through Input Speed Sensor Hole
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
Fig. 141 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 142 Measure Input Shaft End Play Using Tool
8266—Typical
1 - TOOL 8266–8
2 - TOOL 8266–2
3 - TOOL C-3339
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40TE AUTOMATIC TRANSAXLE
21 - 165
40TE AUTOMATIC TRANSAXLE (Continued)
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.)
(53) Install input clutch assembly (Fig. 143).
(54) Install #1 caged needle bearing (Fig. 144).
CAUTION:
The
cooler
bypass
valve
must
be
replaced if transaxle failure has occurred. Do not
attempt to reuse or clean old valve.
(55) Install cooler bypass valve with o-ring end
towards rear of case (Fig. 145).
(56) Install oil pump gasket (Fig. 146).
Fig. 143 Install Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 144 Install No. 1 Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 145 Install Cooler Bypass Valve
1 - COOLER BYPASS VALVE
21 - 166
40TE AUTOMATIC TRANSAXLE
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40TE AUTOMATIC TRANSAXLE (Continued)
(57) Install oil pump assembly (Fig. 147).
(58) Install oil pump-to-case bolts and torque to 27
N·m (20 ft. lbs.) (Fig. 148).
(59) Install low/reverse accumulator (Fig. 149).
(60) Install low/reverse accumulator plug (Fig.
150).
Fig. 146 Install Oil Pump Gasket
1 - PUMP GASKET
Fig. 147 Install Oil Pump
1 - OIL PUMP
2 - GASKET
Fig. 148 Install Pump-to-Case Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 149 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
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40TE AUTOMATIC TRANSAXLE
21 - 167
40TE AUTOMATIC TRANSAXLE (Continued)
(61) Install low/reverse accumulator snap ring
(Fig. 151).
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.
(62) Install underdrive and overdrive accumulators
and springs (Fig. 152).
(63) Install valve body to transaxle (Fig. 153).
Rotate manual valve shaft fully clockwise to ease
installation. Make sure park rod rollers are posi-
tioned within park guide bracket.
(64) Install and torque valve body-to-case bolts to
12 N·m (105 in. lbs.) (Fig. 154).
Fig. 150 Install Low/Reverse Accumulator Plug
1 - ADJUSTABLE PLIERS
2 - PLUG
Fig. 151 Install Low/Reverse Accumulator Snap
Ring
1 - SNAP RING
2 - PLUG
Fig. 152 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 153 Valve Body Removal/Installation
1 - VALVE BODY
21 - 168
40TE AUTOMATIC TRANSAXLE
RS
40TE AUTOMATIC TRANSAXLE (Continued)
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