41TE 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: Identifying Solenoid/Pressure Switch Assembly & Gasket

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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 the solenoid/pressure switch assembly-to-case bolts.
Remove solenoid/pressure switch assembly and gasket (2).

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

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

Fig 3: Removing/Installing Oil Pan

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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/Installing Oil Filter
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1 - OIL FILTER

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

Fig 5: Removing/Installing Valve Body Bolts
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1 - VALVE BODY ATTACHING BOLTS (18)

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

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

Fig 6: Pushing Park Rod Rollers From Guide Bracket

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1 - PARK SPRAG ROLLERS

2 - SCREWDRIVER

3 - PARK SPRAG GUIDE BRACKET

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

Fig 7: Removing/Installing Valve Body
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1 - VALVE BODY

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

Remove valve body assembly (1).

Fig 8: Removing Underdrive and Overdrive Accumulators

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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/Installing Low/Reverse Accumulator Snap Ring
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1 - SNAP RING

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

Fig 10: Removing Low/Reverse Accumulator Plug (Cover)
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1 - ADJUSTABLE PLIERS

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

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

Remove low/reverse accumulator piston (1) using suitable pliers. See Fig 11.

Fig 12: Exploded View Of Low/Reverse Accumulator

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1 - ACCUMULATOR PISTON

2 - SEAL RINGS

3 - RETURN SPRINGS

4 - (NOTE NOTCH)

Remove low/reverse accumulator return springs (3). See Fig 12.

Fig 13: Measuring Input Shaft End Play Using End Play Set 8266

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1 - END PLAY SOCKET SET 8266-8

2 - DIAL INDICATOR C-3339

Measure input shaft end play. Place transaxle so input shaft is vertical. Set up End Play Socket Set and dial indicator (2,3). See 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 14: Removing/Installing Pump Bolts
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1 - PUMP ATTACHING BOLTS

2 - PUMP HOUSING
Remove oil pump-to-case bolts (1). See Fig 14.

Fig 15: Installing Tool C-3752
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1 - OIL PUMP PULLERS C-3752

2 - PUMP

CAUTION: Be sure input speed sensor is removed before removing oil pump.
Install oil pump puller C-3752 (1). See Fig 15.

Fig 16: Removing Oil Pump
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1 - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP
Remove oil pump assembly (1). See Fig 16.

Fig 17: Removing/Installing Oil Pump Gasket
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1 - PUMP GASKET
Remove oil pump gasket (1). See Fig 17.

Fig 18: Removing/Installing Bypass Valve
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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/Installing Caged Needle Bearing
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1 - #1 CAGED NEEDLE BEARING

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

Fig 20: Removing/Installing Input Clutch Assembly
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1 - INPUT CLUTCH ASSEMBLY

2 - #4 THRUST WASHER

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

Fig 21: Identifying 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 #4 thrust plate (2). See Fig 21.

Fig 22: View Of Front Sun Gear Assembly And #4 Thrust Washer
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1 - FRONT SUN GEAR ASSEMBLY

2 - #4 THRUST WASHER (FOUR TABS)

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

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

Fig 24: Identifying Rear Sun Gear & No. 7 Needle Bearing
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1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

Remove rear sun gear (2) and #7 needle bearing (1). See Fig 24.

Fig 25: Identifying Rear Sun Gear & No. 7 Needle Bearing

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1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

NOTE: The number 7 needle bearing (1) 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 (2). A small amount of petrolatum can be used to hold the bearing to the rear sun gear. See Fig 25.

Fig 26: Removing/Installing 2/4 Clutch Retainer Snap Ring

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1 - COMPRESSING TOOL 5058-A

2 - SCREWDRIVER

3 - SNAP RING

4 - 2/4 CLUTCH RETAINER

Setup compressing tool 5058 (1), Compress 2/4 clutch return spring (4) (just enough to remove snap ring) and remove snap ring (3). See Fig 26.
NOTE: Verify that Compressing 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: Identifying 2/4 Clutch Retainer
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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
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1 - 2/4 CLUTCH RETURN SPRING
Remove 2/4 clutch return spring (1). See Fig 28.

Fig 29: Identifying 2/4 Clutch Pack
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1 - CLUTCH PLATE (4)

2 - CLUTCH DISC (4)

Remove 2/4 clutch pack (1,2). See Fig 29. Tag 2/4 clutch pack for reassembly identification.

Fig 30: Removing 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 tapered snap ring (3). See Fig 30.

Fig 31: Removing/Installing Low/Reverse Reaction Plate
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1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Remove low/reverse reaction plate (1). See Fig 31.

Fig 32: Removing/Installing One Disc
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1 - ONE DISC FROM LOW/REVERSE CLUTCH

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

Fig 33: Removing/Installing 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 reaction plate snap ring (2). See Fig 33.

Fig 34: Identifying Low/Reverse Clutch Pack
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1 - CLUTCH PLATES (5)

2 - CLUTCH DISCS (5)

Remove low/reverse clutch pack (1,2). See Fig 34.

Fig 35: Removing/Installing Rear Cover Bolts

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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/Installing Rear Cover
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1 - REAR COVER

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

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

Fig 37: Removing Transfer Shaft Gear Nut

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1 - TRANSFER SHAFT GEAR

2 - OUTPUT GEAR

3 - HOLDER 6259

Install holder 6259 (3). See Fig 37.

Fig 38: Identifying Transfer Shaft Gear Nut & Coned Washer
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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

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1 -GEAR PULLER L-4407 A

2 - TRANSFER SHAFT GEAR

Using Gear Puller L-4407 A,(3) remove transfer shaft gear (2). See Fig 39.

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

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1 - TRANSFER SHAFT GEAR

2 - BEARING CUP RETAINER

3 - SHIM (SELECT)

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

Fig 41: Removing/Installing Bearing Cup Retainer
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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

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1 - WRENCHES

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

3 - TRANSFER SHAFT GEAR

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

Fig 43: Removing Transfer Shaft Bearing Cup

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1 - WRENCHES

2 - REMOVER 6062

3 - TRANSFER SHAFT BEARING CUP RETAINER

Remove transfer shaft bearing cup from retainer (3) using Remover 6062- A (2). See Fig 43.

Fig 44: Removing/Installing Transfer Shaft Bearing Snap Ring

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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/Installing Transfer Shaft

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1 - REMOVER/INSTALLER 5049-A

2 - TRANSFER SHAFT

3 - OUTPUT GEAR

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

Fig 46: Identifying Shaft Components

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1 - BEARING CUP

2 - BEARING CONE

3 - TRANSFER SHAFT

4 - OIL BAFFLE

5 - O-RING

Slip bearing cup retainer (1) and oil baffle (4) off of shaft. See Fig 46.

Fig 47: Removing Transfer Shaft Bearing Cone

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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/Installing Strap Bolts

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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

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1 - OUTPUT GEAR BOLT

2 - RETAINING STRAP

3 - STIRRUP

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

Fig 50: Removing Output Gear Bolt
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1 - OUTPUT GEAR

2 - HOLDING TOOL 6259

Using Holding Tool 6259 (2). See Fig 50.

Fig 51: Removing/Installing Output Gear Bolt & Washer

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1 - OUTPUT GEAR

2 - BOLT

3 - CONED LOCK WASHER

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

Fig 52: Removing Output Gear

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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

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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

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1 - PULLER SET 5048 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.

Fig 55: Removing/Installing Rear Carrier Assembly
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1 - REAR CARRIER ASSEMBLY

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

Fig 56: Removing Rear Carrier Bearing Cone

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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.

Fig 57: Identifying Low/Reverse Spring Compressor Tool

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1 - DISC 6057

2 - COMPRESSOR 5059

3 - COMPRESSOR BAR 5058-3

Install Disk 6057 (1), compressor 5059 (2) and compressor bar 5058-3 (3). See Fig 57.

Fig 58: View Of Compressor Tool In Use

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1 - LOW/REVERSE CLUTCH RETURN SPRING

2 - SNAP RING (INSTALL AS SHOWN)

3 - DISC 6057

4 - COMPRESSOR 5059

5 - COMPRESSOR BAR 5058-3

Install low/reverse spring compressor. See Fig 58.

Fig 59: Removing/Installing Snap Ring

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

2 - SNAP RING PLIERS

3 - DISC 6057

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

Fig 60: Identifying Low/Reverse Piston Return Spring
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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/Installing Anchor Shaft & Plug

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1 - GUIDE BRACKET ANCHOR SHAFT

2 - PIVOT SHAFT

3 - ANCHOR SHAFT PLUG

Using a suitable punch, drive out park guide bracket pivot shaft plug (3). See Fig 61.

Fig 62: Identifying Pivot Shaft & Guide Bracket

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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: Exploded View Of Guide Bracket

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1 - ANTI-RATCHET SPRING

2 - GUIDE BRACKET

3 - SPLIT SLEEVE

4 - SPACER

5 - PAWL

6 - STEPPED SPACER

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

Fig 64: Removing/Installing Low/Reverse Clutch Piston

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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/Installing Piston Retainer Attaching Screws

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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/Installing Piston Retainer
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1 - LOW/REVERSE CLUTCH PISTON RETAINER

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

Fig 67: Removing/Installing Piston Retainer Gasket
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1 - GASKET HOLES MUST LINE UP

2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET

Remove low/reverse piston retainer-to-case gasket (2), gasket holes must line up (1). See Fig 67.

Fig 68: Removing Output Bearing Inner Cup

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