40TE Automatic Transaxle: Disassembly

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.

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 STANDARD PROCEDURE )

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

Remove input and output speed sensors.
Remove three (3) solenoid/pressure switch assembly-to-case bolts.
Remove solenoid/pressure switch assembly and gasket. See Fig 1.

Fig 1: Solenoid/Pressure Switch Assembly and Gasket
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1 - SOLENOID/PRESSURE SWITCH ASSEMBLY

2 - GASKET
Remove oil pan-to-case bolts. See Fig 2.

Fig 2: Remove Oil Pan Bolts
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1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)

Remove oil pan. See Fig 3.

Fig 3: Remove Oil Pan

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1 - OIL PAN

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

3 - OIL FILTER

Remove oil filter. See Fig 4.

Fig 4: Remove Filter and O-Ring
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1 - OIL FILTER

2 - O-RING
Turn manual valve fully clock-wise to get park rod into position for removal.
Remove valve body-to-case bolts. See Fig 5.

Fig 5: Remove Valve Body-to-Case Bolts
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1 - VALVE BODY ATTACHING BOLTS (18)

2 - VALVE BODY

CAUTION: Do not handle the valve body assembly from the manual valve. Damage can result.

Using a screwdriver, push park rod rollers away from guide bracket and remove valve body assembly. See Fig 6 and Fig 7.

Fig 6: Push Park Rod Rollers from Guide Bracket

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1 - PARK SPRAG ROLLERS

2 - SCREWDRIVER

3 - PARK SPRAG GUIDE BRACKET

Fig 7: Valve Body Removal/Installation

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1 - VALVE BODY

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.

Remove underdrive and overdrive accumulators. See Fig 8.

Fig 8: Underdrive and Overdrive Accumulators
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1 - OVERDRIVE PISTON AND SPRING

2 - UNDERDRIVE PISTON AND SPRING
Remove low/reverse accumulator snap ring. See Fig 9.

Fig 9: Remove Low/Reverse Accumulator Snap Ring
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1 - SNAP RING

2 - PLUG
Remove low/reverse accumulator plug. See Fig 10.

Fig 10: Remove Low/Reverse Accumulator Plug
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1 - ADJUSTABLE PLIERS

2 - PLUG
Remove low/reverse accumulator piston using suitable pliers. See Fig 11. Remove piston and springs. See Fig 12.

Fig 11: Low/Reverse Accumulator Piston
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1 - ACCUMULATOR PISTON

Fig 12: Low/Reverse Accumulator
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1 - PISTON

2 - RETURN SPRINGS

Measure input shaft end play. Place transaxle so input shaft is vertical. Set up end play set and dial indicator as shown in Fig 13. 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 13: Measure Input Shaft End Play Using Tool 8266 - Typical

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1 - TOOL 8266-8

2 - TOOL 8266-2

3 - TOOL C-3339

Remove oil pump-to-case bolts. See Fig 14.

Fig 14: Remove Oil Pump-to-Case Bolts
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1 - PUMP ATTACHING BOLTS

2 - PUMP HOUSING

CAUTION: Be sure input speed sensor is removed before removing oil pump.
Install pullers Tool C-3752 as shown in Fig 15.

Fig 15: Install Tool C-3752
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1 - PULLERS TOOL C-3752

2 - PUMP
Remove oil pump assembly. See Fig 16. See Fig 17.

Fig 16: Remove Oil Pump
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1 - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP

Fig 17: Oil Pump Removed
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1 - OIL PUMP

2 - GASKET
Remove oil pump gasket. See Fig 18.

Fig 18: Remove Oil Pump Gasket
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1 - PUMP GASKET

CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt to clean valve.
Remove cooler bypass valve. See Fig 19.

Fig 19: Remove Bypass Valve
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1 - COOLER BYPASS VALVE
Remove #1 needle bearing. See Fig 20.

Fig 20: Remove No. 1 Caged Needle Bearing
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1 - #1 CAGED NEEDLE BEARING

2 - NOTE: TANGED SIDE OUT
Remove input clutch assembly. See Fig 21.

Fig 21: Remove Input Clutch Assembly
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1 - INPUT CLUTCH ASSEMBLY

2 - #4 THRUST WASHER

Remove #4 thrust plate. See Fig 22.

Fig 22: No. 4 Thrust Plate

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1 - OVERDRIVE SHAFT ASSEMBLY

2 - #4 THRUST PLATE (SELECT)

3 - 3 DABS OF PETROLATUM FOR RETENTION

Remove front sun gear assembly and #4 thrust washer. See Fig 23.

Fig 23: Remove Front Sun Gear Assembly
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1 - FRONT SUN GEAR ASSEMBLY

2 - #4 THRUST WASHER (FOUR TABS)

Remove front carrier/rear annulus assembly and #6 needle bearing. See Fig 24.

Fig 24: Remove Front Carrier/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).

Remove rear sun gear and #7 needle bearing. See Fig 25.
NOTE: The number 7 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. See Fig 26. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.

Fig 25: Remove Rear Sun Gear
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1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

Fig 26: Number 7 Bearing
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1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

Setup tool 5058 as shown in Fig 27. Compress 2/4 clutch return spring (just enough to remove snap ring) and remove snap ring.

NOTE: Verify that Tool 5058 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.

Fig 27: Remove 2/4 Clutch Retainer Snap Ring

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1 - TOOL 5058

2 - SCREWDRIVER

3 - SNAP RING

4 - 2/4 CLUTCH RETAINER

NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

Remove 2/4 clutch retainer. See Fig 28.

Fig 28: 2/4 Clutch Retainer
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1 - 2/4 CLUTCH RETAINER

2 - 2/4 CLUTCH RETURN SPRING
Remove 2/4 clutch return spring. See Fig 29.

Fig 29: Remove 2/4 Clutch Return Spring
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1 - 2/4 CLUTCH RETURN SPRING
Remove 2/4 clutch pack. See Fig 30. Tag 2/4 clutch pack for reassembly identification.

Fig 30: Removing/Installing 2/4 Clutch
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1 - CLUTCH DISC

2 - CLUTCH PLATE

Remove tapered snap ring. See Fig 31.

Fig 31: 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

Remove low/reverse reaction plate. See Fig 32.

Fig 32: Remove Low/Reverse Reaction Plate
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1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Remove one low/reverse clutch disc. See Fig 33.

Fig 33: Remove One Disc
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1 - ONE DISC FROM LOW/REVERSE CLUTCH

Remove low/reverse reaction plate snap ring. See Fig 34.

Fig 34: 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

Remove low/reverse clutch pack. See Fig 35.

Fig 35: Removing/Installing Low/Reverse Clutch
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1 - CLUTCH PLATE

2 - CLUTCH DISC

Remove transfer gear cover-to-case bolts. See Fig 36.

Fig 36: Remove Rear Cover Bolts

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1 - REAR COVER BOLTS

2 - REAR COVER

3 - USE SEALANT ON BOLTS

Remove transfer gear cover. See Fig 37.

Fig 37: Remove Rear Cover
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1 - REAR COVER

2 - 1/8 INCH BEAD OF MOPAR(R) ATF RTV (MS-GF41) AS SHOWN

Using Tool 6259, remove transfer shaft gear-to-shaft nut and coned washer. See Fig 38. See Fig 39.

Fig 38: Remove Transfer Shaft Gear Nut

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1 - TRANSFER SHAFT GEAR

2 - OUTPUT GEAR

3 - SPECIAL TOOL 6259

Fig 39: Transfer Shaft Gear Nut and Coned Washer

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1 - TRANSFER SHAFT

2 - LOCK WASHER

3 - NUT

Using tool L-4407A, remove transfer shaft gear. See Fig 40.

Fig 40: Remove Transfer Shaft Gear

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1 - SPECIAL TOOL L4407-6

2 - TRANSFER SHAFT GEAR

3 - SPECIAL TOOL L4407A

Remove transfer gear shim (select). See Fig 41.

Fig 41: Remove Transfer Shaft Gear and (Select) Shim

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1 - TRANSFER SHAFT GEAR

2 - BEARING CUP RETAINER

3 - SHIM (SELECT)

Remove bearing cup retainer. See Fig 42.

Fig 42: Remove Bearing Cup Retainer
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1 - ALIGN INDEXING TAB TO SLOT

2 - BEARING CUP RETAINER

Remove transfer gear bearing cone using setup shown in Fig 43.

Fig 43: Remove Transfer Gear Bearing Cone

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1 - WRENCHES

2 - TOOL 5048 WITH JAWS TOOL 5048-4 AND BUTTON TOOL L-4539-2

3 - TRANSFER SHAFT GEAR

Remove transfer shaft bearing cup from retainer using Tool 6062. See Fig 44.

Fig 44: Remove Transfer Shaft Bearing Cup

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1 - WRENCHES

2 - TOOL 6062

3 - TRANSFER SHAFT BEARING CUP RETAINER

Using Tool 6051, remove transfer shaft bearing snap ring. See Fig 45.

Fig 45: Remove Transfer Shaft Bearing Snap Ring

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1 - SNAP RING PLIERS TOOL 6051

2 - TRANSFER SHAFT BEARING SNAP RING

3 - TRANSFER SHAFT

Using tool 5049A, remove transfer shaft from transaxle. See Fig 46.

Fig 46: Remove Transfer Shaft

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1 - SPECIAL TOOL 5049-A

2 - TRANSFER SHAFT

3 - OUTPUT GEAR

Slip bearing cup retainer and oil baffle off of shaft. See Fig 47.

Fig 47: Bearing Cup Removed

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1 - BEARING CUP

2 - BEARING CONE

3 - TRANSFER SHAFT

4 - OIL BAFFLE

5 - O-RING

Using tool P-334, press transfer shaft bearing cone off of shaft. See Fig 48.

Fig 48: Remove Transfer Shaft Bearing Cone

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1 - ARBOR PRESS RAM

2 - TRANSFER SHAFT

3 - TOOL P-334

4 - BEARING CONE

Bend output gear retaining strap ears flat to allow bolt removal.

Remove output shaft stirrup strap bolts. See Fig 49.

Fig 49: Remove Strap Bolts

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1 - RETAINING STRAP

2 - STIRRUP

3 - RETAINING STRAP BOLTS

Remove stirrup and strap. See Fig 50.

Fig 50: Remove Stirrup Strap

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1 - OUTPUT GEARBOLT

2 - RETAINING STRAP

3 - STIRRUP

Using Tool 6259, remove output shaft gear-to-shaft bolt and washer. See Fig 51 and Fig 52.

Fig 51: Remove Output Gear Bolt

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1 - OUTPUT GEAR

2 - TOOL 6259

Fig 52: Output Gear Bolt and Washer

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1 - OUTPUT GEAR

2 - BOLT

3 - CONED LOCK WASHER

Using Tool L4407A, and button 6055, remove output gear from shaft. See Fig 53.

Fig 53: Remove Output Gear

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1 - OUTPUT GEAR

2 - BUTTON TOOL 6055

3 - WRENCHES

4 - TOOL L4407A

5 - BOLTS TOOL L4407-6

Remove output gear bearing shim (select). See Fig 54.

Fig 54: Output Gear and (Select) Shim

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1 - REAR CARRIER ASSEMBLY

2 - SHIM (SELECT)

3 - OUTPUT GEAR

Using setup as shown in Fig 55, remove output gear bearing cone.

Fig 55: Remove Bearing Cone

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1 - TOOL 5048 WITH JAWS 5048-5 AND BUTTON L-4539-2

2 - WRENCHES

3 - OUTPUT GEAR

Remove rear carrier assembly from transaxle. See Fig 56.

Fig 56: Remove Rear Carrier Assembly
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1 - REAR CARRIER ASSEMBLY

Remove rear carrier assembly bearing cone using setup shown in Fig 57.

Fig 57: Remove Rear Carrier Bearing Cone

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1 - TOOL 5048 WITH JAWS 5048-3 AND BUTTON 6055

2 - WRENCHES

3 - REAR CARRIER ASSEMBLY

Install low/reverse spring compressor tool as shown in Fig 58. See Fig 59.

Fig 58: Low/Reverse Spring Compressor Tool

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1 - TOOL 6057

2 - TOOL 5059

3 - TOOL 5058-3

Fig 59: Compressor Tool in Use

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1 - LOW/REVERSE CLUTCH RETURN SPRING

2 - SNAP RING (INSTALL AS SHOWN)

3 - TOOL 6057

4 - TOOL 5059

5 - TOOL 5058-3

Compress low/reverse piston return spring and remove snap ring. See Fig 60.

Fig 60: Install Snap Ring

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

2 - SNAP RING PLIERS

3 - TOOL 6057

Remove low/reverse spring compressor tool and low reverse piston return spring. See Fig 61.

Fig 61: Low/Reverse Piston
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1 - LOW/REVERSE PISTON RETURN SPRING

2 - PISTON

Using a suitable punch , drive out park guide bracket pivot shaft plug. See Fig 62.

Fig 62: Remove Anchor Shaft and Plug

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1 - GUIDE BRACKET ANCHOR SHAFT

2 - PIVOT SHAFT

3 - ANCHOR SHAFT PLUG

Using ordinary pliers, remove pivot shaft and guide bracket assembly. See Fig 63.

Fig 63: Pivot Shaft and Guide Bracket

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1 - ANTIRACHET SPRING

2 - GUIDE BRACKET

3 - PIVOT SHAFT

4 - PAWL

Inspect guide bracket components for excessive wear and replace if necessary. See Fig 64.

Fig 64: Guide Bracket Disassembled

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1 - ANTIRATCHET SPRING

2 - GUIDE BRACKET

3 - SPLIT SLEEVE

4 - SPACER

5 - PAWL

6 - STEPPED SPACER

NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

Remove low/reverse clutch piston. See Fig 65.

Fig 65: Remove Low/Reverse Clutch Piston

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1 - LOW/REVERSE CLUTCH PISTON

2 - BONDED SEAL

3 - BONDED SEAL

Remove low/reverse piston retainer-to-case screws. See Fig 66.

Fig 66: Remove Piston Retainer-to-Case Screws

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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - SCREWDRIVER

3 - TORX-LOC SCREWS

Remove low/reverse piston retainer. See Fig 67.

Fig 67: Remove Piston Retainer
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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - GASKET
Remove low/reverse piston retainer-to-case gasket. See Fig 68.

Fig 68: Remove Piston Retainer Gasket
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1 - GASKET HOLES MUST LINE UP

2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET

Using a hammer and suitable drift, drive out inner output bearing cup. See Fig 69.

Fig 69: Remove Output Bearing Inner Cup

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1 - OUTPUT BEARING CUPS (REPLACE IN PAIRS)

2 - HAMMER

3 - BRASS DRIFT

Using tool 6062, remove outer output bearing cup. See Fig 70.

Fig 70: Remove Output Bearing Outer

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1 - TOOL 6062