Dodge Journey: Disassembly

Automatic Transmission 41TE
Fig. 28: Identifying Solenoid/Pressure Switch Assembly & Gasket

  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.

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

1. Remove input and output speed sensors.

2. Remove the solenoid/pressure switch assembly-to-case bolts.

3. Remove solenoid/pressure switch assembly and gasket (2).

Automatic Transmission 41TE
Fig. 29: Identifying Oil Pan Bolts

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

4. Remove oil pan-to-case bolts (1) .

Automatic Transmission 41TE
Fig. 30: Removing/Installing Oil Pan

  1. - OIL PAN
  2. - 1/8 INCH BEAD OF MOPAR ATF RTV (MS-GF41)
  3. - OIL FILTER

5. Remove oil pan (1) .

Automatic Transmission 41TE
Fig. 31: Removing/Installing Oil Filter

  1. - OIL FILTER
  2. - O-RING

6. Remove oil filter (1) .

Automatic Transmission 41TE
Fig. 32: Removing/Installing Valve Body-To-Case Bolts

  1. - VALVE BODY ATTACHING BOLTS (18)
  2. - VALVE BODY

7. Turn manual valve fully clockwise to get park rod into position for removal.

8. Remove valve body-to-case bolts (1) .

Automatic Transmission 41TE
Fig. 33: Identifying Push Park Rod Rollers & Guide Bracket

  1. - PARK SPRAG ROLLERS
  2. - SCREWDRIVER
  3. - PARK SPRAG GUIDE BRACKET

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

Automatic Transmission 41TE
Fig. 34: Removing/Installing Valve Body Assembly

  1. - VALVE BODY

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

Damage can result.

10. Remove valve body assembly (1).

Automatic Transmission 41TE
Fig. 35: Removing/Installing Underdrive & Overdrive Accumulators

  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.

11. Remove underdrive (2) and overdrive (4) accumulators.

Automatic Transmission 41TE
Fig. 36: Removing/Installing Low/Reverse Accumulator Snap Ring

  1. - SNAP RING
  2. - PLUG

12. Remove low/reverse accumulator snap ring (1) .

Automatic Transmission 41TE
Fig. 37: Removing/Installing Low/Reverse Accumulator Plug

  1. - ADJUSTABLE PLIERS
  2. - PLUG

13. Remove low/reverse accumulator plug (2) .

Automatic Transmission 41TE
Fig. 38: Removing/Installing Low/Reverse Accumulator Piston

  1. - ACCUMULATOR PISTON

14. Remove low/reverse accumulator piston (1) using suitable pliers.

Automatic Transmission 41TE
Fig. 39: Removing/Installing Low/Reverse Accumulator Return Springs

  1. - ACCUMULATOR PISTON
  2. - SEAL RINGS
  3. - RETURN SPRINGS
  4. - (NOTE NOTCH)

15. Remove low/reverse accumulator return springs (3) .

Automatic Transmission 41TE
Fig. 40: Measuring Input Shaft End Play Using End Play Fixtures 8266 & Dial Indicator C-3339A

  1. - END PLAY FIXTURES 8266A
  2. - DIAL INDICATOR C-3339A

16. Measure input shaft end play. Place transaxle so input shaft is vertical. Set up End Play fixture and dial indicator (2,3) . 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.

Automatic Transmission 41TE
Fig. 41: Removing/Installing Oil Pump-To-Case Bolts

  1. - PUMP ATTACHING BOLTS
  2. - PUMP HOUSING

17. Remove oil pump-to-case bolts (1) .

Automatic Transmission 41TE
Fig. 42: Identifying Slide Hammers C-3752 & Oil Pump

  1. - SLIDE HAMMERS C-3752
  2. - PUMP

CAUTION: Be sure input speed sensor is removed before removing oil pump.

18. Install slide hammers C-3752 (1) .

Automatic Transmission 41TE
Fig. 43: Removing/Installing Oil Pump Assembly

  1. - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP

19. Remove oil pump assembly (1) .

Automatic Transmission 41TE
Fig. 44: Removing/Installing Oil Pump Gasket

  1. - PUMP GASKET

20. Remove oil pump gasket (1) .

Automatic Transmission 41TE
Fig. 45: Removing/Installing Cooler Bypass Valve

  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.

21. Remove cooler bypass valve (1) .

Automatic Transmission 41TE
Fig. 46: Removing/Installing #1 Caged Needle Bearing

  1. - #1 CAGED NEEDLE BEARING
  2. - NOTE: TANGED SIDE OUT

22. Remove #1 needle bearing (1) .

Automatic Transmission 41TE
Fig. 47: Removing/Installing Input Clutch Assembly

  1. - INPUT CLUTCH ASSEMBLY
  2. - #4 THRUST WASHER

23. Remove input clutch assembly (1) .

Automatic Transmission 41TE
Fig. 48: Removing/Installing #4 Thrust Plate

  1. - OVERDRIVE SHAFT ASSEMBLY
  2. - #4 THRUST PLATE (SELECT)
  3. - 3 DABS OF PETROLATUM FOR RETENTION

24. Remove #4 thrust plate (2) .

Automatic Transmission 41TE
Fig. 49: Removing/Installing Front Sun Gear Assembly

  1. - FRONT SUN GEAR ASSEMBLY
  2. - #4 THRUST WASHER (FOUR TABS)

25. Remove front sun gear assembly (1) and #4 thrust washer (2).

Automatic Transmission 41TE
Fig. 50: Removing/Installing Front Carrier/Rear Annulus Assembly

  1. - #6 NEEDLE BEARING
  2. - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).

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

Automatic Transmission 41TE
Fig. 51: Removing/Installing Rear Sun Gear

  1. - #7 NEEDLE BEARING
  2. - REAR SUN GEAR

27. Remove rear sun gear (2) and #7 needle bearing (1)

Automatic Transmission 41TE
Fig. 52: Removing/Installing #7 Needle Bearing

  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.

Automatic Transmission 41TE
Fig. 53: Removing/Installing Snap Ring

  1. - SPRING COMPRESSOR 5058A
  2. - SCREWDRIVER
  3. - SNAP RING
  4. - 2/4 CLUTCH RETAINER

28. Setup spring compressor 5058A (1) , Compress 2/4 clutch return spring (4) (just enough to remove snap ring) and remove snap ring (3).

NOTE: Verify that spring compressor 5058A is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the 5058A bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.

Automatic Transmission 41TE
Fig. 54: Removing/Installing 2/4 Clutch Retainer

  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.

29. Remove 2/4 clutch retainer (1) .

Automatic Transmission 41TE
Fig. 55: Removing/Installing 2/4 Clutch Return Spring

  1. - 2/4 CLUTCH RETURN SPRING

30. Remove 2/4 clutch return spring (1) .

Automatic Transmission 41TE
Fig. 56: Removing/Installing 2/4 Clutch Pack

  1. - CLUTCH PLATE (4)
  2. - CLUTCH DISC (4)

31. Remove 2/4 clutch pack (1,2) . Tag 2/4 clutch pack for reassembly identification.

Automatic Transmission 41TE
Fig. 57: Removing/Installing Tapered Snap Ring

  1. - LOW/REVERSE CLUTCH REACTION PLATE
  2. - SCREWDRIVER
  3. - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)
  4. - OIL PAN FACE
  5. - LONG TAB

32. Remove tapered snap ring (3) .

Automatic Transmission 41TE
Fig. 58: Removing/Installing Low/Reverse Reaction Plate

  1. - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)

33. Remove low/reverse reaction plate (1) .

Automatic Transmission 41TE
Fig. 59: Removing/Installing Low/Reverse Clutch Disc

  1. - ONE DISC FROM LOW/REVERSE CLUTCH

34. Remove one low/reverse clutch disc (1) .

Automatic Transmission 41TE
Fig. 60: Removing/Installing Low/Reverse Reaction Plate Snap Ring

  1. - SCREWDRIVER
  2. - LOW/REVERSE REACTION PLATE FLAT SNAP RING
  3. - DO NOT SCRATCH CLUTCH PLATE

35. Remove low/reverse reaction plate snap ring (2) .

Automatic Transmission 41TE
Fig. 61: Removing/Installing Low/Reverse Clutch Pack

  1. - CLUTCH PLATES (5)
  2. - CLUTCH DISCS (5)

36. Remove low/reverse clutch pack (1,2) .

Automatic Transmission 41TE
Fig. 62: Removing/Installing Transfer Gear Cover-To-Case Bolts

  1. - REAR COVER BOLTS
  2. - REAR COVER
  3. - USE SEALANT ON BOLTS

37. Remove transfer gear cover-to-case bolts (1) .

Automatic Transmission 41TE
Fig. 63: Removing/Installing Transfer Gear Cover

  1. - REAR COVER
  2. - 1/8 INCH BEAD OF MOPAR ATF RTV (MS-GF41)

38. Remove transfer gear cover (1) .

Automatic Transmission 41TE
Fig. 64: Identifying Holder 6259

  1. - TRANSFER SHAFT GEAR
  2. - OUTPUT GEAR
  3. - HOLDER 6259

39. Install holder 6259 (3) .

Automatic Transmission 41TE
Fig. 65: Removing/Installing Transfer Shaft Gear Nut & Coned Washer

  1. - TRANSFER SHAFT
  2. - LOCK WASHER
  3. - NUT

40. Remove transfer shaft gear-to-shaft nut (3) and coned washer (2).

Automatic Transmission 41TE
Fig. 66: Removing/Installing Transfer Shaft Gear

  1. - GEAR PULLER L-4407A
  2. - TRANSFER SHAFT GEAR

41. Using Gear Puller L-4407A (3) remove transfer shaft gear (2).

Automatic Transmission 41TE
Fig. 67: Removing/Installing Transfer Gear Shim (Select)

  1. - TRANSFER SHAFT GEAR
  2. - BEARING CUP RETAINER
  3. - SHIM (SELECT)

42. Remove transfer gear shim (select) (3) .

Automatic Transmission 41TE
Fig. 68: Removing/Installing Bearing Cup Retainer

  1. - ALIGN INDEXING TAB TO SLOT
  2. - BEARING CUP RETAINER

43. Remove bearing cup retainer (2) .

Automatic Transmission 41TE
Fig. 69: Removing Transfer Gear Bearing Cone

  1. - WRENCHES
  2. - BEARING PULLER 5048 WITH JAWS 5048-4 AND THRUST PAD L-4539-2
  3. - TRANSFER SHAFT GEAR

44. Remove transfer gear bearing cone using setup using bearing puller 5048 with jaws 5048-4 and thrust pad L-4539-2 (2) .

Automatic Transmission 41TE
Fig. 70: Removing Transfer Shaft Bearing Cup

  1. - WRENCHES
  2. - BEARING CUP PULLER 6062A
  3. - TRANSFER SHAFT BEARING CUP RETAINER

45. Remove transfer shaft bearing cup from retainer (3) using bearing cup puller 6062A (2).

Automatic Transmission 41TE
Fig. 71: Removing/Installing Transfer Shaft Bearing Snap Ring

  1. - SNAP RING PLIERS 6051A
  2. - TRANSFER SHAFT BEARING SNAP RING
  3. - TRANSFER SHAFT

46. Using Snap Ring Pliers 6051A (1) remove transfer shaft bearing snap ring (2).

Automatic Transmission 41TE
Fig. 72: Removing/Installing Transfer Shaft

  1. - REMOVER/INSTALLER 5049-A
  2. - TRANSFER SHAFT
  3. - OUTPUT GEAR

47. Using the Remover/Installer 5049-A (1) remove transfer shaft (2) from transaxle.

Automatic Transmission 41TE
Fig. 73: Identifying Bearing Cup Retainer & Oil Baffle

  1. - BEARING CUP
  2. - BEARING CONE
  3. - TRANSFER SHAFT
  4. - OIL BAFFLE
  5. - O-RING

48. Slip bearing cup retainer (1) and oil baffle (4) off of shaft.

Automatic Transmission 41TE
Fig. 74: Identifying Bearing Splitter P-334, Transfer Shaft Bearing Cone, & Transfer Shaft

  1. - ARBOR PRESS RAM
  2. - TRANSFER SHAFT
  3. - BEARING SPLITTER P-334
  4. - BEARING CONE

49. Using Bearing Splitter P-334 (3) press transfer shaft bearing cone (4) off of shaft (2).

Automatic Transmission 41TE
Fig. 75: Removing/Installing Retaining Strap Bolts

  1. - RETAINING STRAP
  2. - STIRRUP
  3. - RETAINING STRAP BOLTS

50. Bend output gear retaining strap (1) ears flat to allow bolt removal.

51. Remove output shaft stirrup strap bolts (3)

Automatic Transmission 41TE
Fig. 76: Removing/Installing Stirrup & Strap

  1. - OUTPUT GEAR BOLT
  2. - RETAINING STRAP
  3. - STIRRUP

52. Remove stirrup (3) and strap (2).

Automatic Transmission 41TE
Fig. 77: Identifying Holder 6259

  1. - OUTPUT GEAR
  2. - HOLDER 6259

53. Install Holder 6259 (2).

Automatic Transmission 41TE
Fig. 78: Removing/Installing Output Gear Bolt & Washer

  1. - OUTPUT GEAR
  2. - BOLT
  3. - CONED LOCK WASHER

54. Remove output shaft gear-to-shaft bolt (2) and washer (3)

Automatic Transmission 41TE
Fig. 79: Removing Output Gear

  1. - OUTPUT GEAR
  2. - THRUST BUTTON 6055
  3. - WRENCHES
  4. - GEAR PULLER L4407A
  5. - BOLTS L4407-6

55. Using Gear Puller L4407A (4) and thrust button 6055 (2), remove output gear (1) from shaft.

Automatic Transmission 41TE
Fig. 80: Removing Output Gear Bearing Shim (Select)

  1. - REAR CARRIER ASSEMBLY
  2. - SHIM (SELECT)
  3. - OUTPUT GEAR

56. Remove output gear bearing shim (select) (2)

Automatic Transmission 41TE
Fig. 81: Removing Output Gear Bearing Cone

  1. - BEARING PULLER 5048 WITH JAWS 5048-5 AND THRUST PAD L-4539-2
  2. - WRENCHES
  3. - OUTPUT GEAR

57. Using bearing puller 5048 with jaws 5048-5 and thrust pad L-4539-2 (1) Remove output gear bearing cone.

Automatic Transmission 41TE
Fig. 82: Removing/Installing Rear Carrier Assembly

  1. - REAR CARRIER ASSEMBLY

58. Remove rear carrier assembly (1) from transaxle.

Automatic Transmission 41TE
Fig. 83: Removing Rear Carrier Assembly Bearing Cone

  1. - BEARING PULLER 5048 WITH JAWS 5048-3 AND THRUST BUTTON 6055
  2. - WRENCHES
  3. - REAR CARRIER ASSEMBLY

59. Remove rear carrier assembly (3) bearing cone using bearing puller 5048 with jaws 5048-3 and thrust button 6055.

Automatic Transmission 41TE
Fig. 84: Identifying Spring Compressor 5059-A, Spring Compressor Disc 6057, & Forcing Screw 5058A-3

  1. - SPRING COMPRESSOR DISC 6057
  2. - SPRING COMPRESSOR 5059-A
  3. - FORCING SCREW 5058A-3

60. Install disk 6057 (1) , spring compressor 5059-A (2) and forcing screw 5058A-3 (3).

Automatic Transmission 41TE
Fig. 85: Removing/Installing Low/Reverse Spring Compressor

  1. - LOW/REVERSE CLUTCH RETURN SPRING
  2. - SNAP RING (INSTALL AS SHOWN IN ILLUSTRATION)
  3. - SPRING COMPRESSOR DISC 6057
  4. - SPRING COMPRESSOR 5059-A
  5. - FORCING SCREW 5058A-3

61. Install low/reverse spring compressor .

Automatic Transmission 41TE
Fig. 86: Removing/Installing Remove Snap Ring

  1. - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN IN ILLUSTRATION)
  2. - SNAP RING PLIERS
  3. - SPRING COMPRESSOR DISC 6057

62. Compress low/reverse piston return spring and remove snap ring (1) .

Automatic Transmission 41TE
Fig. 87: Removing/Installing Low/Reverse Piston Return Spring

  1. - LOW/REVERSE PISTON RETURN SPRING
  2. - PISTON

63. Remove low/reverse spring compressor tool and low reverse piston return spring (1)

Automatic Transmission 41TE
Fig. 88: Driving Out Park Guide Bracket Pivot Shaft Plug

  1. - GUIDE BRACKET ANCHOR SHAFT
  2. - PIVOT SHAFT
  3. - ANCHOR SHAFT PLUG

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

Automatic Transmission 41TE
Fig. 89: Removing/Installing Pivot Shaft & Guide Bracket Assembly

  1. - ANTIRACHET SPRING
  2. - GUIDE BRACKET
  3. - PIVOT SHAFT
  4. - PAWL

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

Automatic Transmission 41TE
Fig. 90: Identifying Guide Bracket Components

66. Inspect guide bracket components for excessive wear and replace Anti-ratching spring (1), guide bracket (2), Split sleeve (3), spacer (4), pawl (5) and stepped spacer (6) if necessary.

Automatic Transmission 41TE
Fig. 91: Identifying Low/Reverse Clutch Piston & Bonded Seals

  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.

67. Remove low/reverse clutch piston (1) .

Automatic Transmission 41TE
Fig. 92: Removing/Installing Low/Reverse Piston Retainer-To-Case Screws

  1. - LOW/REVERSE CLUTCH PISTON RET
  2. - SCREWDRIVER
  3. - TORX-LOC SCREWS

68. Remove low/reverse piston retainer-to-case screws (3)

Automatic Transmission 41TE
Fig. 93: Removing/Installing Low/Reverse Piston Retainer

  1. - LOW/REVERSE CLUTCH PISTON RETAINER
  2. - GASKET

69. Remove low/reverse piston retainer (1) .

Automatic Transmission 41TE
Fig. 94: Removing/Installing Low/Reverse Piston Retainer-To-Case Gasket

  1. - GASKET HOLES MUST LINE UP
  2. - LOW/REVERSE CLUTCH PISTON RETAINER GASKET

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

Automatic Transmission 41TE
Fig. 95: Removing Inner Output Bearing Cup

  1. - OUTPUT BEARING CUPS (REPLACE IN PAIRS)
  2. - HAMMER
  3. - BRASS DRIFT

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

Automatic Transmission 41TE
Fig. 96: Removing Outer Output Bearing Cup

  1. - BEARING CUP PULLER 6062A

72. Using bearing cup puller 6062A (1) , remove outer output bearing cup.

    Removal
    Fig. 10: Identifying Battery Cables NOTE: If transaxle assembly is being replaced or overhauled (clutch and/or seal replacement), it is necessary to perform the "Quick-Learn" Proc ...

    Assembly
    Fig. 97: Installing Output Bearing Cups - OUTPUT BEARING CUPS - WRENCHES - INSTALLER - 5050A CAUTION: The cooler bypass valve must be replaced if transaxle failure has occur ...

    See also:

    Removal
    1. Release the parking brake. 2. Manually release the parking brake cable tension. 3. Raise and support the vehicle. Fig. 206: TIRE AND WHEEL MOUNTING 4. Remove wheel mounting nuts (3), t ...

    Switch, remote radio
    DESCRIPTION Remote radio control switches are rocker-type switch units are mounted in the upper spoke covers of the rear (instrument panel side) steering wheel trim cover. The switch unit on the l ...

    Removal
    FRONT 1. Raise and support the vehicle. Fig. 163: TIRE AND WHEEL MOUNTING 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE: In some cases, it may be necessary ...

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