41TE Automatic Transmision - Service Information: Overhaul Dodge Journey I

ASSEMBLY

Note. Use Mopar® Silicone Rubber Adhesive Sealant, or equivalent, on retainer and extension housing/adapter plate to seal to transaxle case.

Scheme 390

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Scheme 395

1. Position differential case to ring gear. Install ring gear-to-differential case bolts (1) and draw ring gear into position. Torque bolts to 95 N.m (70 ft. lbs.). 1 - SIDE GEAR THRUST WASHER
2. Install side gear thrust washers (1) . 1 - SIDE GEAR
3. Install differential side gears (1) . 1 - WASHER 2 - PINION GEAR
4. Install pinion gears (2) and thrust washers (1) 180° apart. 1 - ANTI-ROTATE TAB 2 - POCKET
5. Rotate pinion gears into position, ensuring the anti-rotate tabs (1) are located into the differential case (2). 1 - PINION SHAFT
6. Install pinion shaft (1) . 1 - PINION SHAFT RETAINER
7. Install pinion shaft retainer (1) . 1 - PINION SHAFT RETAINER
8. Install pinion shaft retainer/ring (1) gear-to-differential case bolts and torque to 95 N.m (70 ft. lbs.). 1 - DIFFERENTIAL ASSEMBLY 2 - DIFFERENTIAL BEARING
9. Position differential side bearing cone (2) onto differential. 1 - HANDLE C-4171 2 - INSTALLER 5052
10. Using Installer 5052 (2) and Handle C-4171 (1), install differential bearing to differential (ring gear side). 1 - HANDLE C-4171 2 - BEARING INSTALLER L-4410
11. Using Bearing Installer L-4410 (2) and Handle C-4171 (1), install differential bearing to differential (ring gear side). 1 - DIFFERENTIAL BEARING CUP 2 - DIFFERENTIAL BEARING RETAINER
12. Using Installer 6061 and Handle C-4171, install differential bearing race to bearing retainer (2) . 1 - DIFFERENTIAL RETAINER BOLTS
13. Using Installer L-4520 and Handle C-4171, install differential bearing cup to extension housing.
14. Measure and adjust differential bearing preload. See «Transmission and Transfer Case/Automatic - 41TE/DRIVE, Final - Adjustments»(ref-353617-S18860419612010011200000) .
15. Install differential assembly to case. Install extension housing/adapter plate and bearing retainer.
16. Install bearing retainer with a bead of Mopar® Silicone Rubber Adhesive Sealant and torque bolts (1) to 28 N.m (250 in. lbs.). 1 - DIFFERENTIAL ASSEMBLY 2 - DIFFERENTIAL COVER
17. Install extension housing/adapter plate with a bead of Mopar® Silicone Rubber Adhesive Sealant and torque bolts to 28 N.m (250 in. lbs.).
18. Install differential cover (2) with a bead of Mopar® Silicone Rubber Adhesive Sealant and torque bolts to 28 N.m (250 in. lbs.).

Scheme 396

Note. Perform all differential bearing preload measurements with the transfer shaft and gear removed.

Scheme 397

1. Position the transaxle assembly vertically on the support stand, differential bearing retainer (3) side up.
2. Install Differential Tool L-4436-A (1) into the differential and onto the pinion mate shaft. 1 - DIFFERENTIAL TOOL L-4436-A 2 - TORQUE WRENCH
3. Rotate the differential at least one full revolution to ensure the tapered roller bearings are fully seated.
4. Using Differential Tool L-4436-A (1) and an Inch-Pound Torque Wrench (2), check the turning torque of the differential. The turning torque should be between 5 and 18 inch-pounds.
5. If the turning torque is within specifications, remove tools. Setup is complete.
6. If turning torque is not within specifications, proceed with the following steps. Remove differential bearing retainer from the transaxle case. Remove the bearing cup from the differential bearing retainer using Remover 6062A. Remove the existing shim from under the cup. Measure the existing shim. If the turning torque was too high when measured, install a 0.05 mm (0.002 inch) thinner shim. If the turning torque is was too low, install a 0.05 mm (0.002 inch) thicker shim. Repeat until 5 to 18 inch-pounds turning torque is obtained. Oil baffle is not required to be installed when making shim selection. Install the proper shim under the bearing cup. Make sure the oil baffle is installed properly in the bearing retainer, below the bearing shim and cup. Install the differential bearing retainer using Installer 5052 and Handle C-4171. Seal the retainer to the housing with MOPAR® Adhesive Sealant and torque bolts to 28 N.m (250 in. lbs.).
7. Using Differential Tool L-4436-A and an Inch-Pound Torque Wrench, recheck the turning torque of the differential. The turning torque should be between 5 and 18 inch-pounds.

Shim thickness need be determined only if any of the following parts are replaced

1. Transaxle case
2. Differential carrier
3. Differential bearing retainer
4. Extension housing
5. Differential bearing cups and cones

DIFFERENTIAL BEARING SHIM CHART

DISASSEMBLY

Note. Cleanliness through entire disassembly and assembly of the valve body cannot be overemphasized. When disassembling, each part should be washed in a suitable solvent, then dried by compressed air. Do not wipe parts with shop towels. All mating surfaces in the valve body are accurately machined; therefore, careful handling of all parts must be exercised to avoid nicks or burrs.

Note. If valve body assembly is being reconditioned, the PCM/TCM Quick Learn Procedure must be performed. Refer to Electrical/Electronic Control Modules/MODULE, Powertrain Control - Standard Procedure .

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Scheme 408

1. Remove manual shaft seal (1). 1 - TRANSMISSION RANGE SENSOR 2 - MANUAL VALVE CONTROL PIN 3 - RETAINING SCREW
2. Remove Transmission Range Sensor retaining screw (3). 1 - TRANSMISSION RANGE SENSOR 2 - MANUAL SHAFT / ROOSTER COMB 3 - ROOSTER COMB
3. Remove Manual Shaft/Rooster Comb (3) and Transmission Range Sensor (1). 1 - 2-4 ACCUMULATOR RETAINING PLATE 2 - DETENT SPRING
4. Remove 2/4 Accumulator Retaining Plate (1). 1 - VALVE BODY 2 - RETAINER PLATE 3 - DETENT SPRING 4 - SPRINGS 5 - SEALS 6 - PISTON
5. Remove 2/4 Accumulator components (2,3,4,5 and 6). 1 - SCREW (24) 2 - TRANSFER PLATE 3 - VALVE BODY
6. Remove Valve Body (3) to Transfer Plate (2) screws (1). 1 - TRANSFER PLATE
7. Invert assembly and remove Transfer Plate (1). Beware of loose check balls.
8. Remove oil screen (1). 1 - SEPARATOR PLATE 2 - VALVE BODY
9. Remove separator plate (1). 1 - (#4) REVERSE CHECK BALL 2 - (#3 ) L/R CHECK BALL
10. Remove valve body check balls (1 and 2). Note their location for assembly ease. 1 - REMOVER/INSTALLER 6301 2 - RETAINER NOTE: Tag all valve/spring assemblies for reassembly identification.
11. Remove dual retainer plate (2) using Remover/Installer 6301(1). 1 - REMOVER/INSTALLER 6302 2 - RETAINER
12. Remove regulator valve spring retainer (2) using Remover/Installer 6302 (1). 1 - RETAINER 2 - RETAINER
13. Remove retainers (1and 2). 1 - VALVE BODY 5 - MANUAL VALVE 2 - T/C REGULATOR VALVE 6 - CONVERTER CLUTCH SWITCH VALVE 3 - L/R SWITCH VALVE 7 - SOLENOID SWITCH VALVE 4 - CONVERTER CLUTCH CONTROL VALVE 8 - REGULATOR VALVE
14. Remove valves and springs.

Note. Cleanliness through entire disassembly and assembly of the valve body cannot be overemphasized. When disassembling, each part should be washed in a suitable solvent, then dried by compressed air. Do not wipe parts with shop towels. All mating surfaces in the valve body are accurately machined; therefore, careful handling of all parts must be exercised to avoid nicks or burrs.

Note. If valve body assembly is reconditioned, the PCM/TCM Quick Learn Procedure must be performed. Refer to Electrical/Electronic Control Modules/MODULE, Powertrain Control - Standard Procedure .

1. Install valves and springs. 1 - REMOVER/INSTALLER 6302 2 - RETAINER
2. Install regulator valve spring retainer (2) using remover/installer 6302 (1). 1 - REMOVER/INSTALLER 6301 2 - RETAINER
3. Install dual retainer plate (2) using remover/installer 6301 (1). 1 - RETAINER 2 - RETAINER
4. Verify that all retainers are installed (1,2). Retainers should be flush or below valve body surface. 1 - (#4) REVERSE CHECK BALL 2 - (#5) (#3 ) L/R CHECK BALL
5. Install check balls (1 and 2) into position as shown. If necessary, secure them with petrolatum or transmission assembly gel for assembly ease. 1 - SEPARATOR PLATE 2 - VALVE BODY
6. Install separator plate (1) to valve body (2).
7. Install oil screen (1) to separator plate. 1 - TRANSFER PLATE
8. Install transfer plate (1) to valve body and separator plate. 1 - SCREW (24) 2 - TRANSFER PLATE 3 - VALVE BODY
9. Install twenty-four transfer plate to valve body screws (1) and torque to 5 N.m (45 in. lbs.). 1 - VALVE BODY 2 - RETAINER PLATE 3 - DETENT SPRING 4 - SPRINGS 5 - SEALS 6 - PISTON
10. Install 2/4 Accumulator components (2,3,4,5 and 6). 1 - 2-4 ACCUMULATOR RETAINING PLATE 2 - DETENT SPRING
11. Torque 2/4 Accumulator retainer (1) to 5 N.m (45 in. lbs.). 1 - TRANSMISSION RANGE SENSOR 2 - MANUAL SHAFT / ROOSTER COMB 3 - ROOSTER COMB
12. Install Manual Shaft/Rooster Comb (3) and Transmission Range Sensor (1). 1 - TRANSMISSION RANGE SENSOR 2 - MANUAL VALVE CONTROL PIN 3 - RETAINING SCREW
13. Make sure Manual Valve control pin (2) is contained within the rooster comb slot. Install Transmission Range Sensor retaining screw (3) and torque to 5 N.m (45 in. lbs.). 1 - SEAL 2 - MANUAL SHAFT
14. Install manual shaft seal (1).