40TE Transaxle

WARNING: This page is about a different car, the 2007 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Solenoid/Pressure Switch Assembly & Gasket

Courtesy of CHRYSLER LLC

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 STANDARD PROCEDURE .

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

Remove input and output speed sensors.
Remove three solenoid/pressure switch assembly-to-case bolts.
Remove solenoid/pressure switch assembly (1) and gasket (2). See Fig 1.

Fig 2: Removing Oil Pan Bolts
Courtesy of CHRYSLER LLC

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

Remove oil pan-to-case bolts (1). See Fig 2.

Fig 3: Removing Oil Pan

Courtesy of CHRYSLER LLC

1 - OIL PAN

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

3 - OIL FILTER

Remove oil pan (1). See Fig 3.

Fig 4: Removing Filter & O-Ring
Courtesy of CHRYSLER LLC

1 - OIL FILTER

2 - O-RING
Remove oil filter (1). See Fig 4.

Fig 5: Removing Valve Body-to-Case Bolts
Courtesy of CHRYSLER LLC

1 - VALVE BODY ATTACHING BOLTS (18)

2 - VALVE BODY
Turn manual valve fully clockwise to get park rod into position for removal.

Remove valve body-to-case bolts (1). See Fig 5.

Fig 6: Identifying Push Park Rod Rollers from Guide Bracket

Courtesy of CHRYSLER LLC

1 - PARK SPRAG ROLLERS

2 - SCREWDRIVER

3 - PARK SPRAG GUIDE BRACKET

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

Using a screwdriver (2), push park rod rollers (1) away from guide bracket (3). See Fig 6.

Fig 7: Removing/Installing Valve Body
Courtesy of CHRYSLER LLC

1 - VALVE BODY

Remove valve body assembly (1). See Fig 7.

Fig 8: Underdrive And Overdrive Accumulators

Courtesy of CHRYSLER LLC

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.

Remove underdrive (2) and overdrive (4) accumulators. See Fig 8.

Fig 9: Removing Low/Reverse Accumulator Snap Ring
Courtesy of CHRYSLER LLC

1 - SNAP RING

2 - PLUG
Remove low/reverse accumulator snap ring (1). See Fig 9.

Fig 10: Removing Low/Reverse Accumulator Plug
Courtesy of CHRYSLER LLC

1 - ADJUSTABLE PLIERS

2 - PLUG

Remove low/reverse accumulator plug (2). See Fig 10.

Fig 11: Exploded View Of Low/Reverse Accumulator

Courtesy of CHRYSLER LLC

1 - ACCUMULATOR PISTON

2 - SEAL RINGS

3 - RETURN SPRINGS

4 - (NOTE NOTCH)

Remove low/reverse accumulator (1) and springs (3). See Fig 11.

Fig 12: Measuring Input Shaft End Play Using Tool 8266 - Typical
Courtesy of CHRYSLER LLC

1 - END PLAY SOCKET SET 8266

2 - DIAL INDICATOR C-3339
Measure input shaft end play using End Play Socket Set 8266-8 (1) and C-3339 (3). Place transaxle so input shaft is vertical. Set up End Play Socket set and Dial Indicator. See Fig 12.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: Removing Oil Pump-to-Case Bolts
Courtesy of CHRYSLER LLC

1 - PUMP ATTACHING BOLTS

2 - PUMP HOUSING
Remove oil pump-to-case bolts (1). See Fig 13.

Fig 14: Installing Tool C-3752
Courtesy of CHRYSLER LLC

1 - PULLERS C-3752

2 - PUMP

CAUTION: Be sure input speed sensor is removed before removing oil pump.
Install Pullers C-3752 (1). See Fig 14.

Fig 15: Removing Oil Pump
Courtesy of CHRYSLER LLC

1 - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP
"Push in" on input shaft while removing pump (1). See Fig 15.

Fig 16: View Of Oil Pump Removed
Courtesy of CHRYSLER LLC

1 - OIL PUMP

2 - GASKET
Remove oil pump assembly (1). See Fig 16.

Fig 17: Removing Oil Pump Gasket
Courtesy of CHRYSLER LLC

1 - PUMP GASKET
Remove oil pump gasket (1). See Fig 17.

Fig 18: Removing Bypass Valve
Courtesy of CHRYSLER LLC

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.
Remove cooler bypass valve (1). See Fig 18.

Fig 19: Removing No. 1 Caged Needle Bearing
Courtesy of CHRYSLER LLC

1 - #1 CAGED NEEDLE BEARING

2 - NOTE: TANGED SIDE OUT
Remove #1 needle bearing (1). See Fig 19.

Fig 20: Removing Input Clutch Assembly
Courtesy of CHRYSLER LLC

1 - INPUT CLUTCH ASSEMBLY

2 - #4 THRUST WASHER

Remove input clutch assembly (1). See Fig 20.

Fig 21: Identifying No. 4 Thrust Plate

Courtesy of CHRYSLER LLC

1 - OVERDRIVE SHAFT ASSEMBLY

2 - #4 THRUST PLATE (SELECT)

3 - 3 DABS OF PETROLATUM FOR RETENTION

Remove #4 thrust plate (2). See Fig 21.

Fig 22: Removing Front Sun Gear Assembly
Courtesy of CHRYSLER LLC

1 - FRONT SUN GEAR ASSEMBLY

2 - #4 THRUST WASHER (FOUR TABS)

Remove front sun gear assembly (1). See Fig 22and #4 thrust washer (2).

Fig 23: Removing Front Carrier/Rear Annulus Assembly

Courtesy of CHRYSLER LLC

1 - #6 NEEDLE BEARING

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

Remove front carrier/rear annulus assembly (2) and #6 needle bearing (1). See Fig 23.

Fig 24: Removing Rear Sun Gear
Courtesy of CHRYSLER LLC

1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR
Remove rear sun gear (2). See Fig 24.

Fig 25: Identifying Number 7 Bearing
Courtesy of CHRYSLER LLC

1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

Remove needle bearing (1). 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. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.

Fig 26: Removing 2/4 Clutch Retainer Snap Ring

Courtesy of CHRYSLER LLC

1 - COMPRESSOR 5058

2 - SCREWDRIVER

3 - SNAP RING

4 - 2/4 CLUTCH RETAINER

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

Fig 27: Identifying 2/4 Clutch Retainer
Courtesy of CHRYSLER LLC

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.
Remove 2/4 clutch retainer (1). See Fig 27.

Fig 28: Removing 2/4 Clutch Return Spring
Courtesy of CHRYSLER LLC

1 - 2/4 CLUTCH RETURN SPRING
Remove 2/4 clutch return spring (1). See Fig 28.

Fig 29: Removing/Installing 2/4 Clutch
Courtesy of CHRYSLER LLC

1 - CLUTCH DISC

2 - CLUTCH PLATE

Remove 2/4 clutch pack. See Fig 29. Tag 2/4 clutch pack for reassembly identification.

Fig 30: Removing Tapered Snap Ring

Courtesy of CHRYSLER LLC

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 tapered snap ring (3). See Fig 30.

Fig 31: Removing Low/Reverse Reaction Plate
Courtesy of CHRYSLER LLC

1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Remove low/reverse reaction plate (1). See Fig 31.

Fig 32: Removing One Disc
Courtesy of CHRYSLER LLC

1 - ONE DISC FROM LOW/REVERSE CLUTCH

Remove one low/reverse clutch disc (1). See Fig 32.

Fig 33: Removing Low/Reverse Reaction Plate Snap Ring

Courtesy of CHRYSLER LLC

1 - SCREWDRIVER

2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING

3 - DO NOT SCRATCH CLUTCH PLATE

Remove low/reverse reaction plate snap ring (2). See Fig 33.

Fig 34: Removing/Installing Low/Reverse Clutch
Courtesy of CHRYSLER LLC

1 - CLUTCH PLATE

2 - CLUTCH DISC

Remove low/reverse clutch pack. See Fig 34.

Fig 35: Removing Rear Cover Bolts

Courtesy of CHRYSLER LLC

1 - REAR COVER BOLTS

2 - REAR COVER

3 - USE SEALANT ON BOLTS

Remove transfer gear cover-to-case bolts (1). See Fig 35.

Fig 36: Removing Rear Cover
Courtesy of CHRYSLER LLC

1 - REAR COVER

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

Remove transfer gear cover (1). See Fig 36.

Fig 37: Removing Transfer Shaft Gear Nut

Courtesy of CHRYSLER LLC

1 - TRANSFER SHAFT GEAR

2 - OUTPUT GEAR

3 - HOLDER 6259

Using Holder 6259(3). See Fig 37.

Fig 38: Identifying Transfer Shaft Gear Nut & Coned Washer
Courtesy of CHRYSLER LLC

1 - TRANSFER SHAFT

2 - LOCK WASHER

3 - NUT

Remove transfer shaft gear-to-shaft nut (3) and coned washer (2). See Fig 38.

Fig 39: Removing Transfer Shaft Gear

Courtesy of CHRYSLER LLC

1 - SPECIAL TOOL L4407-6

2 - TRANSFER SHAFT GEAR

3 - GEAR PULLERL4407A

Using Gear Puller L-4407A (3), remove transfer shaft gear. See Fig 39.

Fig 40: Removing Transfer Shaft Gear & (Select) Shim

Courtesy of CHRYSLER LLC

1 - TRANSFER SHAFT GEAR

2 - BEARING CUP RETAINER

3 - SHIM (SELECT)

Remove transfer gear shim (select) (3). See Fig 40.

Fig 41: Removing Bearing Cup Retainer
Courtesy of CHRYSLER LLC

1 - ALIGN INDEXING TAB TO SLOT

2 - BEARING CUP RETAINER

Remove bearing cup retainer (2). See Fig 41.

Fig 42: Removing Transfer Gear Bearing Cone

Courtesy of CHRYSLER LLC

1 - WRENCHES

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

3 - TRANSFER SHAFT GEAR

Remove transfer gear bearing cone using Puller Set 5048 with jaws 5048-4 and button -4539-2. See Fig 42.

Fig 43: Removing Transfer Shaft Bearing Cup

Courtesy of CHRYSLER LLC

1 - WRENCHES

2 - REMOVER 6062

3 - TRANSFER SHAFT BEARING CUP RETAINER

Remove transfer shaft bearing cup from retainer using Remover 6062 (2). See Fig 43.

Fig 44: Removing Transfer Shaft Bearing Snap Ring

Courtesy of CHRYSLER LLC

1 - SNAP RING PLIERS 6051

2 - TRANSFER SHAFT BEARING SNAP RING

3 - TRANSFER SHAFT

Using Snap Ring Pliers 6051(1), remove transfer shaft bearing snap ring (2). See Fig 44.

Fig 45: Removing Transfer Shaft

Courtesy of CHRYSLER LLC

1 -REMOVER/INSTALLER 5049-A

2 - TRANSFER SHAFT

3 - OUTPUT GEAR

Using Remover/Installer 5049A (1), remove transfer shaft (2) from transaxle. See Fig 45.

Fig 46: View Of Bearing Cup Removed

Courtesy of CHRYSLER LLC

1 - BEARING CUP

2 - BEARING CONE

3 - TRANSFER SHAFT

4 - OIL BAFFLE

5 - O-RING

Slip bearing cup retainer and oil baffle off of shaft. See Fig 46.

Fig 47: Removing Transfer Shaft Bearing Cone

Courtesy of CHRYSLER LLC

1 - ARBOR PRESS RAM

2 - TRANSFER SHAFT

3 - BEARING SPLITTER P-334

4 - BEARING CONE

Using Bearing Splitter P-334(3), press transfer shaft bearing cone (4) off of shaft (2). See Fig 47.

Fig 48: Removing Strap Bolts

Courtesy of CHRYSLER LLC

1 - RETAINING STRAP

2 - STIRRUP

3 - RETAINING STRAP BOLTS

Bend output gear retaining strap (1) ears flat to allow bolt removal. See Fig 48.

Remove output shaft stirrup strap bolts (3).

Fig 49: Removing Stirrup Strap

Courtesy of CHRYSLER LLC

1 - OUTPUT GEARBOLT

2 - RETAINING STRAP

3 - STIRRUP

Remove stirrup (3) and strap (2). See Fig 49.

Fig 50: Removing Output Gear Bolt
Courtesy of CHRYSLER LLC

1 - OUTPUT GEAR

2 - HOLDER 6259

Using Holder 6259 (2). See Fig 50.

Fig 51: Identifying Output Gear Bolt & Washer

Courtesy of CHRYSLER LLC

1 - OUTPUT GEAR

2 - BOLT

3 - CONED LOCK WASHER

Remove output shaft gear-to-shaft bolt (2) and washer (3). See Fig 51.

Fig 52: Removing Output Gear

Courtesy of CHRYSLER LLC

1 - OUTPUT GEAR

2 - BUTTON 6055

3 - WRENCHES

4 - GEAR PULLER L4407A

5 - BOLTS L4407-6

Using Gear Puller L4407A (4), and button 6055 (2), remove output gear (1) from shaft. See Fig 52.

Fig 53: Identifying Output Gear & (Select) Shim

Courtesy of CHRYSLER LLC

1 - REAR CARRIER ASSEMBLY

2 - SHIM (SELECT)

3 - OUTPUT GEAR

Remove output gear bearing shim (select) (2). See Fig 53.

Fig 54: Removing Bearing Cone

Courtesy of CHRYSLER LLC

1 - PULLER SET5048 WITH JAWS 5048-5 AND BUTTON L-4539-2

2 - WRENCHES

3 - OUTPUT GEAR

Using Puller Set 5048 with jaws 5048-5 and button L-4539-2(1), remove output gear bearing cone. See Fig 54.

Fig 55: Removing Rear Carrier Assembly
Courtesy of CHRYSLER LLC

1 - REAR CARRIER ASSEMBLY

Remove rear carrier assembly (1) from transaxle. See Fig 55.

Fig 56: Removing Rear Carrier Bearing Cone

Courtesy of CHRYSLER LLC

1 - PULLER SET 5048 WITH JAWS 5048-3 AND BUTTON 6055

2 - WRENCHES

3 - REAR CARRIER ASSEMBLY

Remove rear carrier assembly (3) bearing cone using Puller Set 5048 with jaws 5048-3 and button 6055. See Fig 56.

Fig 57: View Of Low/Reverse Spring Compressor Tool

Courtesy of CHRYSLER LLC

1 - DISK 6057

2 - COMPRESSOR 5059

3 - COMPRESSOR 5058-3

Low/reverse spring compressor Disk 6057(1), Compressor 5059 (2) and Compressor 5058-3 (3). See Fig 57.

Fig 58: View Of Compressor Tool in Use

Courtesy of CHRYSLER LLC

1 - LOW/REVERSE CLUTCH RETURN SPRING

2 - SNAP RING (INSTALL AS SHOWN)

3 - TOOL 6057

4 - COMPRESSOR 5059

5 - COMPRESSOR 5058-3

Install low/reverse spring compressor 6057 (1), compressor 5059 (2) and compressor 5058-3 (3). See Fig 58.

Fig 59: Installing Snap Ring

Courtesy of CHRYSLER LLC

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

2 - SNAP RING PLIERS

3 - TOOL 6057

Compress low/reverse piston return spring and remove snap ring (1). See Fig 59.

Fig 60: Identifying Low/Reverse Piston
Courtesy of CHRYSLER LLC

1 - LOW/REVERSE PISTON RETURN SPRING

2 - PISTON

Remove low/reverse spring compressor tool and low reverse piston return spring (1). See Fig 60.

Fig 61: Removing Anchor Shaft & Plug

Courtesy of CHRYSLER LLC

1 - GUIDE BRACKET ANCHOR SHAFT

2 - PIVOT SHAFT

3 - ANCHOR SHAFT PLUG

Using a suitable punch, drive out park guide bracket pivot shaft (2) plug. See Fig 61.

Fig 62: Identifying Pivot Shaft & Guide Bracket

Courtesy of CHRYSLER LLC

1 - ANTIRACHET SPRING

2 - GUIDE BRACKET

3 - PIVOT SHAFT

4 - PAWL

Using ordinary pliers, remove pivot shaft (3) and guide bracket assembly (2). See Fig 62.

Fig 63: View Of Guide Bracket Disassembled

Courtesy of CHRYSLER LLC

1 - ANTIRATCHET SPRING

2 - GUIDE BRACKET

3 - SPLIT SLEEVE

4 - SPACER

5 - PAWL

6 - STEPPED SPACER

Inspect guide bracket (2) components for excessive wear and replace if necessary. See Fig 63.

Fig 64: Removing Low/Reverse Clutch Piston

Courtesy of CHRYSLER LLC

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.

Remove low/reverse clutch piston (1). See Fig 64.

Fig 65: Removing Piston Retainer-to-Case Screws

Courtesy of CHRYSLER LLC

1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - SCREWDRIVER

3 - TORX-LOC SCREWS

Remove low/reverse piston retainer-to-case screws (3). See Fig 65.

Fig 66: Removing Piston Retainer
Courtesy of CHRYSLER LLC

1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - GASKET
Remove low/reverse piston retainer (1). See Fig 66.

Fig 67: Removing Piston Retainer Gasket
Courtesy of CHRYSLER LLC

1 - GASKET HOLES MUST LINE UP

2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET

Remove low/reverse piston retainer-to-case gasket (2). See Fig 67.

Fig 68: Removing Output Bearing Inner Cup

Courtesy of CHRYSLER LLC

1 - OUTPUT BEARING CUPS (REPLACE IN PAIRS)

2 - HAMMER

3 - BRASS DRIFT

Using a hammer (2) and suitable drift (3), drive out inner output bearing cup (1). See Fig 68.

Fig 69: Removing Output Bearing Outer
Courtesy of CHRYSLER LLC

1 - REMOVER 6062
Using Remover 6062 (1), remove outer output bearing cup. See Fig 69.