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41TE Automatic Transaxle: Disassembly

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.
  1. Remove input and output speed sensors.
  2. Remove three (3) solenoid/pressure switch assembly-to-case bolts.
  3. Remove solenoid/pressure switch assembly and gasket (Fig 1).
    Fig 1: Identifying Solenoid/Pressure Switch Assembly And Gasket
    G03633945Courtesy of DAIMLERCHRYSLER CORP.
  4. Remove oil pan-to-case bolts (Fig 2).
    Fig 2: Removing Oil Pan Bolts
    G03633946Courtesy of DAIMLERCHRYSLER CORP.
  5. Remove oil pan (Fig 3).
    Fig 3: Removing Oil Pan
    G03633947Courtesy of DAIMLERCHRYSLER CORP.
  6. Remove oil filter (Fig 4).
    Fig 4: Removing Oil Filter
    G03633948Courtesy of DAIMLERCHRYSLER CORP.
  7. Turn manual valve fully clock-wise to get park rod into position for removal.
  8. Remove valve body-to-case bolts (Fig 5).
    Fig 5: Removing Valve Body Attaching Bolts
    G03633949Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: Do not handle the valve body assembly from the manual valve. Damage can result.
  9. Using a screwdriver, push park rod rollers away from guide bracket (Fig 6) and remove valve body assembly (Fig 7).
    Fig 6: Pushing Park Rod Rollers From Guide Bracket
    G03633950Courtesy of DAIMLERCHRYSLER CORP.
    Fig 7: Removing Valve Body
    G03633951Courtesy of DAIMLERCHRYSLER CORP.
    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.
  10. Remove underdrive and overdrive accumulators (Fig 8) (Fig 9) (Fig 10).
    Fig 8: Removing Underdrive and Overdrive Accumulators
    G03633952Courtesy of DAIMLERCHRYSLER CORP.
    Fig 9: Identifying Accumulator (Underdrive)
    G03633953Courtesy of DAIMLERCHRYSLER CORP.
    Fig 10: Identifying Accumulator (Overdrive)
    G03633954Courtesy of DAIMLERCHRYSLER CORP.
  11. Remove low/reverse accumulator snap ring (Fig 11).
    Fig 11: Removing Low/Reverse Accumulator Snap Ring
    G03633955Courtesy of DAIMLERCHRYSLER CORP.
  12. Remove low/reverse accumulator plug (Fig 12).
    Fig 12: Removing Low/Reverse Accumulator Plug (Cover)
    G03633956Courtesy of DAIMLERCHRYSLER CORP.
  13. Remove low/reverse accumulator piston using petrolatum and a suitable tool (Fig 13).
    Fig 13: Removing Low/Reverse Accumulator Piston
    G03633957Courtesy of DAIMLERCHRYSLER CORP.
  14. Remove low/reverse accumulator (Fig 14).
    Fig 14: Removing Low/Reverse Accumulator
    G03633958Courtesy of DAIMLERCHRYSLER CORP.
  15. Measure input shaft end play. Place transaxle so input shaft is vertical. Set up end play set and dial indicator as shown in (Fig 15). 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 15: Measuring Input Shaft End Play Using End Play Set 8266
    G03633959Courtesy of DAIMLERCHRYSLER CORP.
  16. Remove oil pump-to-case bolts (Fig 16).
    Fig 16: Removing Pump Attaching Bolts
    G03633960Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: Be sure input speed sensor is removed before removing oil pump.
  17. Install pullers Tool C-3752 as shown in (Fig 17).
    Fig 17: Installing Tool C-3752
    G03633961Courtesy of DAIMLERCHRYSLER CORP.
  18. Remove oil pump assembly (Fig 18) (Fig 19).
    Fig 18: Removing Oil Pump
    G03633962Courtesy of DAIMLERCHRYSLER CORP.
    Fig 19: Removing Oil Pump
    G03633963Courtesy of DAIMLERCHRYSLER CORP.
  19. Remove oil pump gasket (Fig 20).
    Fig 20: Removing Oil Pump Gasket
    G03633964Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt to clean valve.
  20. Remove cooler bypass valve (Fig 21).
    Fig 21: Removing Bypass Valve
    G03633965Courtesy of DAIMLERCHRYSLER CORP.
  21. Remove #1 needle bearing (Fig 22).
    Fig 22: Removing Caged Needle Bearing
    G03633966Courtesy of DAIMLERCHRYSLER CORP.
  22. Remove input clutch assembly (Fig 23).
    Fig 23: Removing Input Clutch Assembly
    G03633967Courtesy of DAIMLERCHRYSLER CORP.
  23. Remove #4 thrust plate (Fig 24).
    Fig 24: No. 4 Thrust Plate
    G03633968Courtesy of DAIMLERCHRYSLER CORP.
  24. Remove front sun gear assembly and #4 thrust washer (Fig 25).
    Fig 25: Removing Front Sun Gear Assembly
    G03633969Courtesy of DAIMLERCHRYSLER CORP.
  25. Remove front carrier/rear annulus assembly and #6 needle bearing (Fig 26).
    Fig 26: Removing Front Carrier and Rear Annulus Assembly
    G03633970Courtesy of DAIMLERCHRYSLER CORP.
  26. Remove rear sun gear and #7 needle bearing (Fig 27).
    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 (Fig 28). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
    Fig 27: Removing Rear Sun Gear
    G03633971Courtesy of DAIMLERCHRYSLER CORP.
    Fig 28: Identifying Number 7 Bearing
    G03633972Courtesy of DAIMLERCHRYSLER CORP.
  27. Setup tool 5058 as shown in (Fig 29). 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 29: Removing 2/4 Clutch Retainer Snap Ring
    G03633973Courtesy of DAIMLERCHRYSLER CORP.
  28. Remove 2/4 clutch retainer (Fig 30).
    Fig 30: Identifying 2/4 Clutch Retainer
    G03633974Courtesy of DAIMLERCHRYSLER CORP.
  29. Remove 2/4 clutch return spring (Fig 31).
    Fig 31: Removing 2/4 Clutch Return Spring
    G03633975Courtesy of DAIMLERCHRYSLER CORP.
  30. Remove 2/4 clutch pack (Fig 32). Tag 2/4 clutch pack for reassembly identification. 
    Fig 32: Removing 2/4 Clutch Pack
    G03633976Courtesy of DAIMLERCHRYSLER CORP.
  31. Remove tapered snap ring (Fig 33).
    Fig 33: Removing Tapered Snap Ring
    G03633977Courtesy of DAIMLERCHRYSLER CORP.
  32. Remove low/reverse reaction plate (Fig 34).
    Fig 34: Removing Low/Reverse Reaction Plate
    G03633978Courtesy of DAIMLERCHRYSLER CORP.
  33. Remove one low/reverse clutch disc (Fig 35).
    Fig 35: Removing One Disc
    G03633979Courtesy of DAIMLERCHRYSLER CORP.
  34. Remove low/reverse reaction plate snap ring (Fig 36).
    Fig 36: Removing Low/Reverse Reaction Plate Snap Ring
    G03633980Courtesy of DAIMLERCHRYSLER CORP.
  35. Remove low/reverse clutch pack (Fig 37).
    Fig 37: Removing Low/Reverse Clutch Pack
    G03633981Courtesy of DAIMLERCHRYSLER CORP.
  36. Remove transfer gear cover-to-case bolts (Fig 38).
    Fig 38: Removing Rear Cover Bolts
    G03633982Courtesy of DAIMLERCHRYSLER CORP.
  37. Remove transfer gear cover (Fig 39).
    Fig 39: Removing Rear Cover
    G03633983Courtesy of DAIMLERCHRYSLER CORP.
  38. Using Tool 6259, remove transfer shaft gear-to-shaft nut and coned washer (Fig 40) (Fig 41).
    Fig 40: Removing Transfer Shaft Gear Nut
    G03633984Courtesy of DAIMLERCHRYSLER CORP.
    Fig 41: Identifying Transfer Shaft Gear Nut And Coned Washer
    G03633985Courtesy of DAIMLERCHRYSLER CORP.
  39. Using tool L-4407A, remove transfer shaft gear (Fig 42).
    Fig 42: Removing Transfer Shaft Gear
    G03633986Courtesy of DAIMLERCHRYSLER CORP.
  40. Remove transfer gear shim (select) (Fig 43).
    Fig 43: Removing Transfer Shaft Gear And (Select) Shim
    G03633987Courtesy of DAIMLERCHRYSLER CORP.
  41. Remove bearing cup retainer (Fig 44).
    Fig 44: Removing Bearing Cup Retainer
    G03633988Courtesy of DAIMLERCHRYSLER CORP.
  42. Remove transfer gear bearing cone using setup shown in (Fig 45).
    Fig 45: Removing Transfer Gear Bearing Cone
    G03633989Courtesy of DAIMLERCHRYSLER CORP.
  43. Remove transfer shaft bearing cup from retainer using Tool 6062 (Fig 46).
    Fig 46: Removing Transfer Shaft Bearing Cup
    G03633990Courtesy of DAIMLERCHRYSLER CORP.
  44. Using Tool 6051, remove transfer shaft bearing snap ring (Fig 47).
    Fig 47: Removing Transfer Shaft Bearing Snap Ring
    G03633991Courtesy of DAIMLERCHRYSLER CORP.
  45. Using tool 5049A, remove transfer shaft from transaxle (Fig 48).
    Fig 48: Removing Transfer Shaft
    G03633992Courtesy of DAIMLERCHRYSLER CORP.
  46. Slip bearing cup retainer and oil baffle off of shaft (Fig 49).
    Fig 49: Identifying Bearing Cup
    G03633993Courtesy of DAIMLERCHRYSLER CORP.
  47. Using tool P-334, press transfer shaft bearing cone off of shaft (Fig 50).
    Fig 50: Removing Transfer Shaft Bearing Cone
    G03633994Courtesy of DAIMLERCHRYSLER CORP.
  48. Bend output gear retaining strap ears flat to allow bolt removal.
  49. Remove output shaft stirrup strap bolts (Fig 51).
    Fig 51: Removing Strap Bolts
    G03633995Courtesy of DAIMLERCHRYSLER CORP.
  50. Remove stirrup and strap (Fig 52).
    Fig 52: Removing Stirrup Strap
    G03633996Courtesy of DAIMLERCHRYSLER CORP.
  51. Using Tool 6259 (Fig 53), remove output shaft gear-to-shaft bolt and washer (Fig 54).
    Fig 53: Removing Output Gear Bolt
    G03633997Courtesy of DAIMLERCHRYSLER CORP.
    Fig 54: Identifying Output Gear Bolt And Washer
    G03633998Courtesy of DAIMLERCHRYSLER CORP.
  52. Using Tool L4407A, and button 6055, remove output gear from shaft (Fig 55).
    Fig 55: Removing Output Gear
    G03633999Courtesy of DAIMLERCHRYSLER CORP.
  53. Remove output gear bearing shim (select) (Fig 56).
    Fig 56: Output Gear And (Select) Shim
    G03634000Courtesy of DAIMLERCHRYSLER CORP.
  54. Using setup as shown in (Fig 57), remove output gear bearing cone.
    Fig 57: Removing Bearing Cone
    G03634001Courtesy of DAIMLERCHRYSLER CORP.
  55. Remove rear carrier assembly from transaxle (Fig 58).
    Fig 58: Removing Rear Carrier Assembly
    G03634002Courtesy of DAIMLERCHRYSLER CORP.
  56. Remove rear carrier assembly bearing cone using setup shown in (Fig 59).
    Fig 59: Removing Rear Carrier Bearing Cone
    G03634003Courtesy of DAIMLERCHRYSLER CORP.
  57. Install low/reverse spring compressor tool as shown in (Fig 60) (Fig 61).
    Fig 60: Installing Low/Reverse Spring Compressor Tool
    G03634004Courtesy of DAIMLERCHRYSLER CORP.
    Fig 61: Identifying Compressor Tool
    G03634005Courtesy of DAIMLERCHRYSLER CORP.
  58. Compress low/reverse piston return spring and remove snap ring (Fig 62).
    Fig 62: Removing Snap Ring
    G03634006Courtesy of DAIMLERCHRYSLER CORP.
  59. Remove low/reverse spring compressor tool and low reverse piston return spring (Fig 63).
    Fig 63: Low/Reverse Piston Return Spring
    G03634007Courtesy of DAIMLERCHRYSLER CORP.
  60. Using a suitable punch, drive out park guide bracket pivot shaft plug (Fig 64).
    Fig 64: Removing Anchor Shaft and Plug
    G03634008Courtesy of DAIMLERCHRYSLER CORP.
  61. Using ordinary pliers, remove pivot shaft and guide bracket assembly (Fig 65).
    Fig 65: Identifying Pivot Shaft And Guide Bracket
    G03634009Courtesy of DAIMLERCHRYSLER CORP.
  62. Inspect guide bracket components for excessive wear and replace if necessary (Fig 66).
    Fig 66: Disconnecting Guide Bracket
    G03634010Courtesy of DAIMLERCHRYSLER CORP.
  63. Remove low/reverse clutch piston (Fig 67).
    Fig 67: Removing Low/Reverse Clutch Piston
    G03634011Courtesy of DAIMLERCHRYSLER CORP.
  64. Remove low/reverse piston retainer-to-case screws (Fig 68).
    Fig 68: Removing Piston Retainer Attaching Screws
    G03634012Courtesy of DAIMLERCHRYSLER CORP.
  65. Remove low/reverse piston retainer (Fig 69).
    Fig 69: Removing Piston Retainer
    G03634013Courtesy of DAIMLERCHRYSLER CORP.
  66. Remove low/reverse piston retainer-to-case gasket (Fig 70).
    Fig 70: Removing Piston Retainer Gasket
    G03634014Courtesy of DAIMLERCHRYSLER CORP.
  67. Using a hammer and suitable drift, drive out inner output bearing cup (Fig 71).
    Fig 71: Removing Output Bearing Inner Cup
    G03634015Courtesy of DAIMLERCHRYSLER CORP.
  68. Using tool 6062, remove outer output bearing cup (Fig 72).
    Fig 72: Removing Output Bearing Outer Cup
    G03634016Courtesy of DAIMLERCHRYSLER CORP.
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