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41TE Automatic Transaxle: Disassembly

CAUTION: If transaxle failure has occurred, it is necessary to flush the transaxle oil cooler and lines to remove debris and particles that could contaminate and/or fail a new or rebuilt unit. (Refer to STANDARD PROCEDURE - FLUSHING COOLERS AND TUB under COOLING SYSTEM).
NOTE: If transaxle is being overhauled (clutch and/or seal replacement) or replaced, it is necessary to perform the TCM Quick Learn Procedure. Refer to DIAGNOSIS - 41TE article.
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: Removing Solenoid/Pressure Switch Assembly & Gasket
    G01030912Courtesy of DAIMLERCHRYSLER CORP.
  4. Remove oil pan-to-case bolts. (Fig 2).
    Fig 2: Removing Oil Pan Bolts
    G01030913Courtesy of DAIMLERCHRYSLER CORP.
  5. Remove oil pan. (Fig 3).
    Fig 3: Removing Oil Pan
    G01030914Courtesy of DAIMLERCHRYSLER CORP.
  6. Remove oil filter. (Fig 4).
    Fig 4: Removing Oil Filter
    G01030915Courtesy of DAIMLERCHRYSLER CORP.
  7. Turn manual valve fully clockwise to get park rod into position for removal.
  8. Remove valve body-to-case bolts. (Fig 5).
    Fig 5: Removing Valve Body Attaching Bolts
    G01030916Courtesy 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: Removing Push Park Rod Rollers From Guide Bracket
    G01030917Courtesy of DAIMLERCHRYSLER CORP.
    Fig 7: Removing Valve Body
    G01030918Courtesy 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 and Fig 10 ).
    Fig 8: Removing Underdrive & Overdrive Accumulators
    G01030919Courtesy of DAIMLERCHRYSLER CORP.
    Fig 9: Identifying Accumulator Components (Underdrive)
    G01030920Courtesy of DAIMLERCHRYSLER CORP.
    Fig 10: Identifying Accumulator Components (Overdrive)
    G01030921Courtesy of DAIMLERCHRYSLER CORP.
  11. Remove low/reverse accumulator snap ring. (Fig 11).
    Fig 11: Removing Low/Reverse Accumulator Snap Ring
    G01030922Courtesy of DAIMLERCHRYSLER CORP.
  12. Remove low/reverse accumulator plug. (Fig 12).
    Fig 12: Removing Low/Reverse Accumulator Plug (Cover)
    G01030923Courtesy of DAIMLERCHRYSLER CORP.
  13. Remove low/reverse accumulator piston using petrolatum and a suitable tool. (Fig 13).
    Fig 13: Removing Low/Reverse Accumulator Piston
    G01030924Courtesy of DAIMLERCHRYSLER CORP.
  14. Remove low/reverse accumulator. (Fig 14).
    Fig 14: Removing Low/Reverse Accumulator
    G01030925Courtesy 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
    G01030926Courtesy of DAIMLERCHRYSLER CORP.
  16. Remove oil pump-to-case bolts. (Fig 16).
    Fig 16: Removing Oil Pump Attaching Bolts
    G01030927Courtesy 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
    G01030928Courtesy of DAIMLERCHRYSLER CORP.
  18. Remove oil pump assembly. (Fig 18). (Fig 19).
    Fig 18: Positioning Pullers On Oil Pump
    G01030929Courtesy of DAIMLERCHRYSLER CORP.
    Fig 19: Removing Oil Pump
    G01030930Courtesy of DAIMLERCHRYSLER CORP.
  19. Remove oil pump gasket. (Fig 20).
    CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. DO NOT reuse or attempt to clean valve.
    Fig 20: Removing Oil Pump Gasket
    G01030931Courtesy of DAIMLERCHRYSLER CORP.
  20. Remove cooler bypass valve. (Fig 21).
    Fig 21: Removing Bypass Valve
    G01030932Courtesy of DAIMLERCHRYSLER CORP.
  21. Remove #1 needle bearing. (Fig 22).
    Fig 22: Removing Caged Needle Bearing
    G01030933Courtesy of DAIMLERCHRYSLER CORP.
  22. Remove input clutch assembly. (Fig 23).
    Fig 23: Removing Input Clutch Assembly
    G01030934Courtesy of DAIMLERCHRYSLER CORP.
  23. Remove #4 thrust plate. (Fig 24).
    Fig 24: Removing No. 4 Thrust Plate
    G01030935Courtesy of DAIMLERCHRYSLER CORP.
  24. Remove front sun gear assembly and #4 thrust washer. (Fig 25).
    Fig 25: Removing Front Sun Gear Assembly
    G01030936Courtesy of DAIMLERCHRYSLER CORP.
  25. Remove front carrier/rear annulus assembly and #6 needle bearing. (Fig 26).
    Fig 26: Removing Front Carrier & Rear Annulus Assembly
    G01030937Courtesy of DAIMLERCHRYSLER CORP.
  26. Remove rear sun gear and #7 needle bearing. (Fig 27).
    NOTE: The number 7 needle bearing has three anti-reversal tables 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
    G01030938Courtesy of DAIMLERCHRYSLER CORP.
    Fig 28: Removing No. 7 Needle Bearing
    G01030939Courtesy 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
    G01030940Courtesy of DAIMLERCHRYSLER CORP.
  28. Remove 2/4 clutch retainer. (Fig 30).
    Fig 30: Removing 2/4 Clutch Retainer
    G01030941Courtesy of DAIMLERCHRYSLER CORP.
  29. Remove 2/4 clutch return spring. (Fig 31).
    Fig 31: Removing 2/4 Clutch Return Spring
    G01030942Courtesy 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
    G01030943Courtesy of DAIMLERCHRYSLER CORP.
  31. Remove tapered snap ring. (Fig 33).
    Fig 33: Removing Tapered Snap Ring
    G01030944Courtesy of DAIMLERCHRYSLER CORP.
  32. Remove low/reverse reaction plate. (Fig 34).
    Fig 34: Removing Low/Reverse Reaction Plate
    G01030945Courtesy of DAIMLERCHRYSLER CORP.
  33. Remove one low/reverse clutch disc. (Fig 35).
    Fig 35: Removing One Low/Reverse Clutch Disc
    G01030946Courtesy of DAIMLERCHRYSLER CORP.
  34. Remove low/reverse reaction plate snap ring. (Fig 36).
    Fig 36: Removing Low/Reverse Reaction Plate Snap Ring
    G01030947Courtesy of DAIMLERCHRYSLER CORP.
  35. Remove low/reverse clutch pack. (Fig 37).
    Fig 37: Removing Low/Reverse Clutch Pack
    G01030948Courtesy of DAIMLERCHRYSLER CORP.
  36. Remove transfer rear cover-to-case bolts. (Fig 38).
    Fig 38: Removing Rear Cover Bolts
    G01030949Courtesy of DAIMLERCHRYSLER CORP.
  37. Remove transfer rear cover. (Fig 39).
    Fig 39: Removing Rear Cover
    G01030950Courtesy of DAIMLERCHRYSLER CORP.
  38. Using Tool 6259, remove transfer shaft gear-to-shaft nut and coned washer. (Fig 40 and Fig 41 ).
    Fig 40: Removing Transfer Shaft Gear Nut
    G01030951Courtesy of DAIMLERCHRYSLER CORP.
    Fig 41: Identifying Transfer Shaft Gear Nut & Coned Washer
    G01030952Courtesy of DAIMLERCHRYSLER CORP.
  39. Using tool L-4407A, remove transfer shaft gear. (Fig 42).
    Fig 42: Removing Transfer Shaft Gear
    G01030953Courtesy of DAIMLERCHRYSLER CORP.
  40. Remove transfer gear shim (select). (Fig 43).
    Fig 43: Identifying Transfer Shaft Gear & (Select) Shim
    G01030954Courtesy of DAIMLERCHRYSLER CORP.
  41. Remove bearing cup retainer. (Fig 44).
    Fig 44: Removing Bearing Cup Retainer
    G01030955Courtesy of DAIMLERCHRYSLER CORP.
  42. Remove transfer gear bearing cone using setup shown in (Fig 45).
    Fig 45: Removing Transfer Gear Bearing Cone
    G01030956Courtesy of DAIMLERCHRYSLER CORP.
  43. Remove transfer shaft bearing cup from retainer using Tool 6062. (Fig 46).
    Fig 46: Removing Transfer Shaft Bearing Cup
    G01030957Courtesy of DAIMLERCHRYSLER CORP.
  44. Using Tool 6051, remove transfer shaft bearing snap ring. (Fig 47).
    Fig 47: Removing Transfer Shaft Bearing Snap Ring
    G01030958Courtesy of DAIMLERCHRYSLER CORP.
  45. Using tool 5049A, remove transfer shaft from transaxle. (Fig 48).
    Fig 48: Removing Transfer Shaft
    G01030959Courtesy of DAIMLERCHRYSLER CORP.
  46. Slip bearing cup retainer and oil baffle off of shaft. (Fig 49).
    Fig 49: Identifying Transfer Shaft Components
    G01030960Courtesy 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
    G01030961Courtesy 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
    G01030962Courtesy of DAIMLERCHRYSLER CORP.
  50. Remove stirrup and strap (Fig 52).
    Fig 52: Removing Stirrup & Strap
    G01030963Courtesy 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
    G01030964Courtesy of DAIMLERCHRYSLER CORP.
    Fig 54: Identifying Output Gear Bolt & Washer
    G01030965Courtesy of DAIMLERCHRYSLER CORP.
  52. Using Tool L4407A, and button 6055, remove output gear from shaft. (Fig 55).
    Fig 55: Removing Output Gear
    G01030966Courtesy of DAIMLERCHRYSLER CORP.
  53. Remove output gear bearing shim (select). (Fig 56).
    Fig 56: Identifying Output Gear & (Select) Shim
    G01030967Courtesy of DAIMLERCHRYSLER CORP.
  54. Using setup as shown in (Fig 57), remove output gear bearing cone.
    Fig 57: Removing Bearing Cone
    G01030968Courtesy of DAIMLERCHRYSLER CORP.
  55. Remove rear carrier assembly from transaxle. (Fig 58).
    Fig 58: Removing Rear Carrier Assembly
    G01030969Courtesy of DAIMLERCHRYSLER CORP.
  56. Remove rear carrier assembly bearing cone using setup shown in (Fig 59).
    Fig 59: Removing Rear Carrier Bearing Cone
    G01030970Courtesy of DAIMLERCHRYSLER CORP.
  57. Install low/reverse spring compressor tool as shown in (Fig 60 and Fig 61 ).
    Fig 60: Identifying Low/Reverse Spring Compressor Tool
    G01030971Courtesy of DAIMLERCHRYSLER CORP.
    Fig 61: Using Compressor Tool
    G01030972Courtesy of DAIMLERCHRYSLER CORP.
  58. Compress low/reverse piston return spring and remove snap ring. (Fig 62).
    Fig 62: Removing Snap Ring
    G01030973Courtesy of DAIMLERCHRYSLER CORP.
  59. Remove low/reverse spring compressor tool and low reverse piston return spring. (Fig 63).
    Fig 63: Removing Low/Reverse Piston Return Spring
    G01030974Courtesy of DAIMLERCHRYSLER CORP.
  60. Using a suitable punch, drive out park guide bracket pivot shaft plug. (Fig 64).
    Fig 64: Removing Anchor Shaft & Plug
    G01030975Courtesy of DAIMLERCHRYSLER CORP.
  61. Using ordinary pliers, remove pivot shaft and guide bracket assembly. (Fig 65).
    Fig 65: Removing Pivot Shaft & Guide Bracket
    G01030976Courtesy of DAIMLERCHRYSLER CORP.
  62. Inspect guide bracket components for excessive wear and replace if necessary. (Fig 66).
    Fig 66: Inspecting Guide Bracket (Disassembled)
    G01030977Courtesy of DAIMLERCHRYSLER CORP.
  63. Remove low/reverse clutch piston. (Fig 67).
    Fig 67: Removing Low/Reverse Clutch Piston
    G01030978Courtesy of DAIMLERCHRYSLER CORP.
  64. Remove low/reverse piston retainer-to-case screws. (Fig 68).
    Fig 68: Removing Piston Retainer Attaching Screws
    G01030979Courtesy of DAIMLERCHRYSLER CORP.
  65. Remove low/reverse piston retainer. (Fig 69).
    Fig 69: Removing Piston Retainer
    G01030980Courtesy of DAIMLERCHRYSLER CORP.
  66. Remove low/reverse piston retainer-to-case gasket. (Fig 70).
    Fig 70: Removing Piston Retainer Gasket
    G01030981Courtesy 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
    G01030982Courtesy of DAIMLERCHRYSLER CORP.
  68. Using tool 6062, remove outer output bearing cup. (Fig 72).
    Fig 72: Removing Output Bearing Outer Cup
    G01030983Courtesy of DAIMLERCHRYSLER CORP.
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