Chrysler Town, Dodge Caravan. Manual — part 391
SYNCHRONIZER
DESCRIPTION
The T850 transaxle uses two styles of synchronizer
assemblies; a conventional single-cone style is used
for the 5th/Reverse and 3rd/4th applications (Fig.
277), and a dual-cone style for the 1st/2nd gear appli-
cation (Fig. 278).
DISASSEMBLY
Place synchronizer in a clean shop towel and wrap.
Press on inner hub. Carefully open up shop towel
and remove springs, balls, keys, hub, and sleeve.
CLEANING
CLEAN
Do not attempt to clean the blocking rings in sol-
vent. The friction material will become contaminated.
Place synchronizer components in a suitable holder
and clean with solvent. Air dry.
INSPECTION
INSPECT
Proper inspection of components involve:
• Teeth, for wear, scuffed, nicked, burred, or broken
teeth
• Keys, for wear or distortion
• Balls and springs, for distortion, cracks, or wear
If any of these conditions exist in these compo-
nents, replace as necessary.
ASSEMBLY
(1) Position synchronizer hub onto work bench.
Hub is non-directional.
(2) Install springs into hub slot.
(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
Insert balls into each key.
(5) Slide sleeve over the hub and depress balls as
you carefully slip the sleeve into position.
Fig. 276 Shift Fork/Shaft Components
1 - 5/R FORK
2 - SHAFT/LINK ASSEMBLY
3 - LINK
4 - 3/4 FORK
5 - 1/2 FORK
Fig. 277 3/4-5/R Synchronizer Assembly
1 - SLEEVE
2 - HUB
3 - BLOCKER RING (2)
4 - SPRING (3)
5 - KEY (3)
6 - BALL (3)
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T850 MANUAL TRANSAXLE
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SHIFT FORK AND SHAFT (Continued)
VEHICLE SPEED SENSOR
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect the speed sensor connector (Fig. 279).
CAUTION: Clean area around speed sensor before
removing to prevent dirt from entering the transaxle
during speed sensor removal.
(3) Remove speed sensor retaining bolt (Fig. 279).
(4) Remove speed sensor from transaxle.
CAUTION: Carefully remove vehicle speed sensor
so that sensor drive gear does not fall into trans-
axle. Should sensor drive gear fall into the trans-
axle during sensor removal, drive gear must be
reattached to sensor.
(5) Remove speed sensor drive gear from speed
sensor.
INSTALLATION
(1) Install pinion gear to speed sensor (Fig. 279).
(2) Using a NEW o-ring, install the speed sensor
to the transaxle (Fig. 279).
(3) Install the bolt and torque to 7 N·m (60 in.
lbs.).
(4) Connect speed sensor connector (Fig. 279).
(5) Lower vehicle and road test to verify proper
speedometer operation.
Fig. 278 1/2 Synchronizer Assembly
1 - SLEEVE
2 - REACTOR RING (2)
3 - HUB
4 - BLOCKER RING (2)
5 - SLEEVE
6 - FRICTION CONE (2)
7 - SPRING (3)
8 - KEY (3)
9 - BALL (3)
Fig. 279 Speed Sensor and Pinion Removal/
Installation—Typical
1 - CONNECTOR
2 - SENSOR
3 - O-RING
4 - GEAR
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T850 MANUAL TRANSAXLE
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SYNCHRONIZER (Continued)
41TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page
page
41TE AUTOMATIC TRANSAXLE
. . . . . . . . . . . . . . . . . . . . . . . . 117
. . . . . . . . . . . . . . . . . . . . . . . . . . 119
TRANSAXLE GENERAL DIAGNOSIS . . . . . . 119
DIAGNOSIS AND TESTING - ROAD TEST
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS . . . . . . . . . . . . . . . . . . . 120
DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS . . . . . . . . . . . . . . . . . . . 122
DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE . . 123
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
. . . . . . . . . . . . . . . . . . . . . . . . 125
. . . . . . . . . . . . . . . . . . . . . . . . . . . 144
. . . . . . . . . . . . . . . . . . . . . . . . 166
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . 169
SPECIFICATIONS - 41TE TRANSAXLE
ACCUMULATOR
. . . . . . . . . . . . . . . . . . . . . . . . 188
. . . . . . . . . . . . . . . . . . . . . . . . . . 189
AUTOSTICK SWITCH
. . . . . . . . . . . . . . . . . . . . . . . . 189
. . . . . . . . . . . . . . . . . . . . . . . . . . 189
DRIVING CLUTCHES
. . . . . . . . . . . . . . . . . . . . . . . . 190
. . . . . . . . . . . . . . . . . . . . . . . . . . 190
FINAL DRIVE
. . . . . . . . . . . . . . . . . . . . . . . . 190
. . . . . . . . . . . . . . . . . . . . . . . . . . . 195
ADJUSTMENT - DIFFERENTIAL BEARING
PRELOAD . . . . . . . . . . . . . . . . . . . . . . . . . . 199
FLUID
FLUID LEVEL AND CONDITION CHECK
STANDARD PROCEDURE - FLUID AND
FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . 203
GEAR SHIFT CABLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
. . . . . . . . . . . . . . . . . . . . . . . . 205
HOLDING CLUTCHES
. . . . . . . . . . . . . . . . . . . . . . . . 207
. . . . . . . . . . . . . . . . . . . . . . . . . . 207
INPUT CLUTCH ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . 208
. . . . . . . . . . . . . . . . . . . . . . . . . . . 216
OIL PUMP
. . . . . . . . . . . . . . . . . . . . . . . . 230
. . . . . . . . . . . . . . . . . . . . . . . . . . 230
. . . . . . . . . . . . . . . . . . . . . . . . 230
. . . . . . . . . . . . . . . . . . . . . . . . . . . 232
PLANETARY GEARTRAIN
. . . . . . . . . . . . . . . . . . . . . . . . 232
. . . . . . . . . . . . . . . . . . . . . . . . . . 232
SEAL - OIL PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
. . . . . . . . . . . . . . . . . . . . . . . . 233
SHIFT INTERLOCK SOLENOID
. . . . . . . . . . . . . . . . . . . . . . . . 233
. . . . . . . . . . . . . . . . . . . . . . . . . . 233
DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK
SOLENOID
. . . . . . . . . . . . . . . . . . . . . . . . . . 235
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
. . . . . . . . . . . . . . . . . . . . . . . . 236
SOLENOID/PRESSURE SWITCH ASSY
. . . . . . . . . . . . . . . . . . . . . . . . 237
. . . . . . . . . . . . . . . . . . . . . . . . . . 237
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
. . . . . . . . . . . . . . . . . . . . . . . . 239
SPEED SENSOR - INPUT
. . . . . . . . . . . . . . . . . . . . . . . . 239
. . . . . . . . . . . . . . . . . . . . . . . . . . 240
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
. . . . . . . . . . . . . . . . . . . . . . . . 240
SPEED SENSOR - OUTPUT
. . . . . . . . . . . . . . . . . . . . . . . . 241
. . . . . . . . . . . . . . . . . . . . . . . . . . 241
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
. . . . . . . . . . . . . . . . . . . . . . . . 242
TORQUE CONVERTER
. . . . . . . . . . . . . . . . . . . . . . . . 242
. . . . . . . . . . . . . . . . . . . . . . . . . . 245
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
. . . . . . . . . . . . . . . . . . . . . . . . 247
TRANSMISSION CONTROL RELAY
. . . . . . . . . . . . . . . . . . . . . . . . 247
. . . . . . . . . . . . . . . . . . . . . . . . . . 248
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41TE AUTOMATIC TRANSAXLE
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TRANSMISSION RANGE SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . 248
. . . . . . . . . . . . . . . . . . . . . . . . . . 248
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
. . . . . . . . . . . . . . . . . . . . . . . . 249
TRD LINK
. . . . . . . . . . . . . . . . . . . . . . . . 249
. . . . . . . . . . . . . . . . . . . . . . . . . . 249
VALVE BODY
. . . . . . . . . . . . . . . . . . . . . . . . 250
. . . . . . . . . . . . . . . . . . . . . . . . . . 250
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
. . . . . . . . . . . . . . . . . . . . . . . . 252
. . . . . . . . . . . . . . . . . . . . . . . . . . . 257
. . . . . . . . . . . . . . . . . . . . . . . . 262
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.
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41TE AUTOMATIC TRANSAXLE
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