Dodge Journey: Assembly

Automatic Transmission 41TE
Fig. 257: Installing Input Shaft

  1. - INPUT SHAFT
  2. - ARBOR PRESS
  3. - INPUT SHAFT HUB ASSEMBLY

Use petrolatum on all seals to ease assembly of components.

1. Using an arbor press (2), install input shaft (1) to input shaft hub (3) .

Automatic Transmission 41TE
Fig. 258: Installing Input Shaft Snap Ring

  1. - INPUT SHAFT
  2. - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)
  3. - SNAP RING
  4. - O-RINGS
  5. - SEALS

2. Install input shaft snap ring (3) .

Automatic Transmission 41TE
Fig. 259: Identifying OD/Reverse Piston, Return Spring, & Snap Ring

  1. - OD/REVERSE PISTON
  2. - RETURN SPRING
  3. - SNAP RING
  4. - O-RING

3. Place OD/Reverse piston (1) return spring (2) and snap ring (3) into position.

Automatic Transmission 41TE
Fig. 260: Installing OD/Reverse Piston, Return Spring, & Snap Ring

  1. - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING)
  2. - SCREWDRIVER
  3. - SNAP RING
  4. - Disk 6057
  5. - OD/REVERSE PISTON
  6. - RETURN SPRING

4. Using an arbor press (1) and Disk 6057 (4), install OD/Reverse piston (5) return spring (6) and snap ring (3).

Automatic Transmission 41TE
Fig. 261: Installing OD/Reverse Piston

  1. - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON
  2. - INPUT CLUTCHES RETAINER

5. Install the OD/Reverse piston assembly (1) to the input clutch retainer (2)

Automatic Transmission 41TE
Fig. 262: Installing Input Shaft Hub Assembly

  1. - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY (ROTATE TO ALIGN SPLINES)
  2. - OD/REV. PISTON

6. Install the input hub/shaft assembly (rotate to align splines) (1) to the OD/Reverse piston/clutch retainer assembly (2)

Automatic Transmission 41TE
Fig. 263: Identifying Input Clutch Hub, Retainer, & OD/Reverse Piston

  1. - SNAP RING (INPUT SHAFT)
  2. - SNAP RING
  3. - CLUTCH RETAINER
  4. - SEAL, OUTER
  5. - SEAL, INNER
  6. - OD/REVERSE PISTON
  7. - SEAL, INPUT SHAFT
  8. - SHAFT, INPUT
  9. - HUB
  10. - SEAL
  11. - SNAP RING
  12. - BELLEVILLE SPRING

7. Refer to Fig. 263 as necessary when performing the following steps .

Automatic Transmission 41TE
Fig. 264: Installing Input Hub Tapered Snap Ring

  1. - INPUT SHAFT
  2. - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN CAVITY)
  3. - SNAP RING PLIERS

8. Install input hub tapered snap ring (tapered side up with tabs in cavity) (2) .

Automatic Transmission 41TE
Fig. 265: Installing Underdrive Clutch Piston

  1. - PISTON

9. Install UD clutch piston (1) .

Automatic Transmission 41TE
Fig. 266: Installing UD Piston Return Spring & Installer 5067

  1. - PISTON RETURN SPRING
  2. - INSTALLER 5067
  3. - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY

10. Install UD piston return spring (1) and Installer 5067 (2).

Automatic Transmission 41TE
Fig. 267: Removing/Installing Underdrive Clutch Piston, Spring & Retainer

  1. - SNAP RING
  2. - SPRING RETAINER
  3. - SPRING
  4. - UD CLUTCH PISTON
  5. - SEAL, OUTER
  6. - SEAL, INNER
  7. - INPUT CLUTCH ASSEMBLY

11. Refer to Fig. 267 as necessary when performing the following steps.

Automatic Transmission 41TE
Fig. 268: Identifying UD Spring Retainer & Snap Ring

  1. - UNDERDRIVE SPRING RETAINER
  2. - SNAP RING
  3. - SEAL
  4. - PISTON RETURN SPRING

12. Place the UD spring retainer (1) and snap ring (2) into position.

Automatic Transmission 41TE
Fig. 269: Installing UD Spring Retainer and Snap Ring

  1. - ARBOR PRESS RAM
  2. - SNAP RING PLIERS
  3. - SNAP RING
  4. - OD/REVERSE PISTON
  5. - INSTALLER 5067
  6. - COMPRESSOR 5059-A

13. Using Compressor 5059-A (6) and an arbor press (1), Install the UD spring retainer and snap ring (3) Compress just enough to install snap ring (3)

CAUTION: Compress return spring just enough to install snap ring.

Automatic Transmission 41TE
Fig. 270: Installing Underdrive UD Clutch Pack

  1. - CLUTCH PLATE
  2. - ONE UD CLUTCH DISC
  3. - CLUTCH DISC

14. Install the UD clutch pack (1,3) . Leave out upper disc (2), until snap ring is installed.

Automatic Transmission 41TE
Fig. 271: Installing UD Clutch Flat Snap Ring

  1. - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
  2. - SCREWDRIVER

15. Install the UD clutch flat snap ring (1)

Automatic Transmission 41TE
Fig. 272: Installing Last UD Clutch Disc

  1. - ONE UNDERDRIVE CLUTCH DISC

16. Install the last UD clutch disc (1) .

Automatic Transmission 41TE
Fig. 273: Installing OD/UD Clutches Reaction Plate

  1. - OD/UD CLUTCH REACTION PLATE (TAPERED STEP SIDE UP)

17. Place the OD/UD clutch reaction plate (1) and snap ring into position. The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up.

Automatic Transmission 41TE
Fig. 274: Installing Snap Ring

  1. - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING
  2. - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)

18. Install the snap ring (1) using a screwdriver (2).

NOTE: Snap ring ends must be located within one finger of the input clutch hub.

Be sure that snap ring is fully seated, by pushing with screwdriver, into snap ring groove all the way around.

Automatic Transmission 41TE
Fig. 275: Removing/Installing OD/UD Reaction Plate Tapered Snap Ring, Clutch Plate, & First Clutch Disc

  1. - SNAP RING (TAPERED)
  2. - OD/UD REACTION PLATE
  3. - CLUTCH DISC
  4. - SNAP RING (FLAT)
  5. - CLUTCH PLATE
  6. - INPUT CLUTCH ASSEMBLY

19. Refer to Fig. 275 as necessary when performing the following steps .

Automatic Transmission 41TE
Fig. 276: Seating Tapered Snap Ring

  1. - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING
  2. - SCREWDRIVER

20. Seat tapered snap ring (1) to ensure proper installation.

Automatic Transmission 41TE
Fig. 277: Installing Input Clutch Assembly

  1. - INPUT CLUTCH ASSEMBLY
  2. - INPUT CLUTCH PRESSURE FIXTURE 8391

21. Install input clutch assembly (1) to the Input Clutch Pressure Fixture 8391 (2) .

Automatic Transmission 41TE
Fig. 278: Identifying Dial Indicator & UD Clutch Pack

  1. - DIAL INDICATOR
  2. - UNDERDRIVE CLUTCH

22. Set up dial indicator (1) on the UD clutch pack (2) .

Automatic Transmission 41TE
Fig. 279: Measuring UD Clutch Pack Clearance

  1. - DIAL INDICATOR
  2. - UNDERDRIVE CLUTCH

23. Using moderate pressure, press down and hold (near indicator) the UD clutch pack (2) with screwdriver or suitable tool and zero dial indicator . When releasing pressure on clutch pack, indicator reading should advance 0.005-0.010.

CAUTION: Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack.

24. Apply 30 psi (206 kPa) to the underdrive hose on Input Clutch Pressure Fixture 8391 and measure UD clutch clearance. Measure and record UD clutch pack measurement in four places, 90º apart.

25. Take average of four measurements and compare with UD clutch pack (2) clearance specification.

Underdrive clutch pack clearance must be 0.94-1.50 mm (0.037-0.059 in.).

26. If necessary, select the proper reaction plate to achieve specifications:

Automatic Transmission 41TE
Fig. 280: Installing OD Clutch Pack

  1. - OVERDRIVE CLUTCH PACK

27. Install the OD clutch pack (four frictions/three steels) (1) .

Automatic Transmission 41TE
Fig. 281: Installing Waved Snap Ring

  1. - OVERDRIVE PRESSURE PLATE WAVED SNAP RING
  2. - SCREWDRIVER

28. Install OD pressure plate waved snap ring (1) .

Automatic Transmission 41TE
Fig. 282: Installing OD/Reverse Pressure Plate

  1. - OVERDRIVE/REVERSE PRESSURE PLATE
  2. - (STEP SIDE DOWN)

29. Install the OD/Reverse pressure plate (1) with large step down (towards OD clutch pack) (2) .

Automatic Transmission 41TE
Fig. 283: Removing/Installing OD/Reverse Pressure Plate Snap Ring

  1. - SNAP RING
  2. - OD/REVERSE PRESSURE PLATE
  3. - SNAP RING (WAVE)
  4. - CLUTCH DISC (4)
  5. - CLUTCH STEEL (3)
  6. - INPUT CLUTCH ASSEMBLY

30. Refer to Fig. 283 as necessary when performing the following steps .

Automatic Transmission 41TE
Fig. 284: Installing Flat Snap Ring

  1. - ARBOR PRESS RAM
  2. - COMPRESSOR 5059-A
  3. - FLAT SNAP RING

31. Install OD pressure plate flat snap ring (3) .

Automatic Transmission 41TE
Fig. 285: Measuring OD Clutch Pack Clearance

  1. - DIAL INDICATOR
  2. - OD/REVERSE REACTION PLATE

32. Measure OD clutch pack clearance. Set up dial indicator (1) on top of the OD/Reverse pressure plate.

33. Zero dial indicator and apply 30 psi (206 kPa) air pressure to the overdrive clutch hose on Tool 8391.

Measure and record OD clutch pack measurement in four places, 90º apart.

34. Take average of four measurements and compare with OD clutch pack clearance specification. The overdrive (OD) clutch pack clearance is 1.07-3.25 mm (0.042-0.128 in.).

If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance.

35. Install reverse clutch pack (two frictions/one steel) (1,2) .

Automatic Transmission 41TE
Fig. 286: Installing Reverse Clutch Reaction Plate

  1. - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)

36. Install reverse clutch reaction plate with the flat side down towards reverse clutch .

Automatic Transmission 41TE
Fig. 287: Removing/Installing Reverse Clutch Pack

  1. - SNAP RING
  2. - REACTION PLATE
  3. - CLUTCH DISC (2)
  4. - CLUTCH PLATE (1)
  5. - INPUT CLUTCH ASSEMBLY

37. Refer to Fig. 287 as necessary when performing the following steps .

Automatic Transmission 41TE
Fig. 288: Installing Reverse Clutch Snap Ring

  1. - REVERSE CLUTCH SNAP RING (SELECT)
  2. - SCREWDRIVER
  3. - REVERSE CLUTCH REACTION PLATE

38. Tap reaction plate (3) down to allow installation of the reverse clutch snap ring (1) Install reverse clutch snap ring (1).

Automatic Transmission 41TE
Fig. 289: Prying Up Reaction Plate To Seat Against Snap Ring

  1. - SCREWDRIVER
  2. - SNAP RING
  3. - SCREWDRIVER
  4. - MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP RING

39. Pry up reverse reaction plate (4) to seat against snap ring (2).

Automatic Transmission 41TE
Fig. 290: Identifying Dial Indicator & Reverse Clutch Pack

  1. - DIAL INDICATOR
  2. - REVERSE CLUTCH

40. Set up a dial indicator (1) on the reverse clutch pack (2).

Automatic Transmission 41TE
Fig. 291: Measuring Reverse Clutch Pack Clearance

  1. - DIAL INDICATOR
  2. - REVERSE CLUTCH

41. Using moderate pressure, press down and hold (near indicator) reverse clutch disc (2) with screwdriver or suitable tool and zero dial indicator (1). When releasing pressure, indicator should advance 0.005-0.010. as clutch pack relaxes.

42. Apply 30 psi (206 kPa) air pressure to the reverse clutch hose on Input Clutch Pressure Fixture 8391.

Measure and record reverse clutch pack measurement in four places, 90º apart.

43. Take average of four measurements and compare with reverse clutch pack clearance specification. The reverse clutch pack clearance is 0.89-1.37 mm (0.035-0.054 in.). Select the proper reverse clutch snap ring to achieve specifications:

44. To complete the assembly, reverse clutch and overdrive clutch must be removed.

45. Install the #2 needle bearing (note 3 small tabs up) (1) .

Automatic Transmission 41TE
Fig. 292: Installing Underdrive Shaft Assembly

  1. - UNDERDRIVE SHAFT ASSEMBLY
  2. - #2 NEEDLE BEARING

46. Install the underdrive shaft assembly (1) .

Automatic Transmission 41TE
Fig. 293: Installing No. 3 Thrust Washer

  1. - #3 THRUST WASHER (NOTE 5 TABS)
  2. - UNDERDRIVE SHAFT ASSEMBLY

47. Install the #3 thrust washer (1) to the underdrive shaft assembly (2). Be sure five tabs are seated properly.

Automatic Transmission 41TE
Fig. 294: Installing No. 3 Thrust Plate

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

48. Install the #3 thrust plate (3) (note 3 tabs) to the bottom of the overdrive shaft assembly (1). Retain with petrolatum or transmission assembly gel (2).

Automatic Transmission 41TE
Fig. 295: Removing/Installing OD & UD Shafts, Thrust Washer & Plate, & #2 Needle Bearing

  1. - OVERDRIVE SHAFT
  2. - #3 THRUST PLATE (3 TABS)
  3. - #3 THRUST WASHER (5 TABS)
  4. - UNDERDRIVE SHAFT
  5. - #2 NEEDLE BEARING (3 TABS)
  6. - INPUT CLUTCH ASSEMBLY

49. Refer to Fig. 295 as necessary when performing the following steps .

Automatic Transmission 41TE
Fig. 296: Installing Overdrive Shaft Assembly

  1. - OVERDRIVE SHAFT ASSEMBLY
  2. - #3 THRUST PLATE
  3. - #3 THRUST WASHER

50. Install the overdrive shaft assembly (1) .

51. Reinstall overdrive and reverse clutch as shown in Fig. 296. Rechecking these clutch clearances is not necessary.

    Disassembly
    Fig. 241: Tapping Down Reverse Clutch Reaction Plate - #4 THRUST PLATE (SELECT) - TAP DOWN REVERSE CLUTCH REACTION PLATE TO REMOVE OR INSTALL SNAP RING - INPUT SHAFT CLUTCHES RETAINER ASSEMB ...

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