2008 Dodge Avenger SXT

2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

ASSEMBLY

41TE TRANSAXLE

Fig. 82: Installing Both Output Bearing Cups

Courtesy of CHRYSLER LLC

1 - OUTPUT BEARING CUPS

2 - WRENCHES
3 - INSTALLER - 5050

CAUTION: The cooler bypass valve must be replaced if transaxle failure has
occurred. Do not attempt to reuse or clean old valve.

NOTE: If transaxle is being overhauled (clutch and/or seal replacement), the TCM/PCM
Quick Learn procedure must be performed. Refer to STANDARD PROCEDURE .

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 2008 Dodge Avenger SXT
2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

1. Install both output bearing cups (1) using Installer 5050 (3). See Fig. 82.

Fig. 83: Removing/Installing Piston Retainer Gasket

Courtesy of CHRYSLER LLC

1 - GASKET HOLES MUST LINE UP

2 - LOW/REVERSE CLUTCH PISTON RETAINER
GASKET

2. Install low/reverse piston retainer gasket (2). See Fig. 83. Make sure gasket holes line up with case (1).

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Fig. 84: Removing/Installing Piston Retainer

Courtesy of CHRYSLER LLC

1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - GASKET

3. Install low/reverse piston retainer (1). See Fig. 84.

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2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 85: Removing/Installing Piston Retainer Attaching Screws

Courtesy of CHRYSLER LLC

1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - SCREWDRIVER
3 - TORX-LOC SCREWS

4. Install low/reverse piston retainer-to-case screws (3). See Fig. 85and torque to 5 N.m (45 in. lbs.).

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 2008 Dodge Avenger SXT
2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 86: Removing/Installing Low/Reverse Clutch Piston

Courtesy of CHRYSLER LLC

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.

5. Install low/reverse clutch piston (1). See Fig. 86.

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2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 87: Exploded View Of Guide Bracket

Courtesy of CHRYSLER LLC

1 - ANTI-RATCHET SPRING
2 - GUIDE BRACKET
3 - SPLIT SLEEVE
4 - SPACER
5 - PAWL
6 - STEPPED SPACER

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 2008 Dodge Avenger SXT
2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

6. Use figure as a reference while assembling park guide bracket assembly. See Fig. 87.

Fig. 88: Guide Bracket

Courtesy of CHRYSLER LLC

1 - GUIDE BRACKET
2 - ANTI-RATCHET SPRING (MUST BE ASSEMBLED
AS SHOWN)
3 - PAWL

7. Assemble park guide bracket assembly. See Fig. 88.

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 2008 Dodge Avenger SXT
2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 89: Pivot Shaft & Guide Bracket

Courtesy of CHRYSLER LLC

1 - ANTI-RACHET SPRING
2 - GUIDE BRACKET
3 - PIVOT SHAFT
4 - PAWL

8. Install guide bracket (2) into position and insert pivot shaft (3). See Fig. 89.

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 2008 Dodge Avenger SXT
2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 90: Removing/Installing Anchor Shaft & Plug

Courtesy of CHRYSLER LLC

1 - GUIDE BRACKET ANCHOR SHAFT

2 - PIVOT SHAFT
3 - ANCHOR SHAFT PLUG

9. Install anchor shaft (1) and plug (3). Make sure guide bracket and split sleeve are in contact with the rear
of the transaxle case. See Fig. 90.

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 2008 Dodge Avenger SXT
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Fig. 91: Identifying Low/Reverse Piston Return Spring

Courtesy of CHRYSLER LLC

1 - LOW/REVERSE PISTON RETURN SPRING

2 - PISTON

10. Install low/reverse piston return spring (1). See Fig. 91.

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 2008 Dodge Avenger SXT
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Fig. 92: Compressor Tool In Use

Courtesy of CHRYSLER LLC

1 - LOW/REVERSE CLUTCH RETURN SPRING

2 - SNAP RING (INSTALL AS SHOWN)
3 - DISC 6057
4 - COMPRESSOR 5059
5 - COMPRESSOR BAR 5058-3

11. Install low/reverse spring compressor into position. See Fig. 92.

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 2008 Dodge Avenger SXT
2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 93: Removing/Installing Snap Ring

Courtesy of CHRYSLER LLC

1 - SNAP RING OPENING MUST BE BETWEEN SPRING

LEVERS (AS SHOWN)
2 - SNAP RING PLIERS
3 - DISC 6057

12. Compress low/reverse piston and install snap ring (1). See Fig. 93.

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 2008 Dodge Avenger SXT
2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 94: Installing Rear Carrier Bearing Cone

Courtesy of CHRYSLER LLC

1 - ARBOR PRESS RAM

2 - INSTALLER 6053
3 - NEW BEARING CONE
4 - REAR CARRIER ASSEMBLY

13. Install rear carrier bearing cone (3) using Installer 6053 (1). See Fig. 94.

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 2008 Dodge Avenger SXT
2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 95: Removing/Installing Rear Carrier Assembly

Courtesy of CHRYSLER LLC

1 - REAR CARRIER ASSEMBLY

14. Install rear carrier assembly (1) to transaxle case. See Fig. 95.

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 2008 Dodge Avenger SXT
2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 96: Installing Output Gear Bearing Cone

Courtesy of CHRYSLER LLC

1 - ARBOR PRESS RAM

2 - HANDLE C-4171
3 - INSTALLER 5052
4 - OUTPUT GEAR

15. Install output gear bearing cone using Installer 5052 (3). See Fig. 96.

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 2008 Dodge Avenger SXT
2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 97: Checking Output Gear Bearings End Play

Courtesy of CHRYSLER LLC

1 - GEAR CHECKING PLATE L-4432

2 - DIAL INDICATOR
3 - SPECIAL SCREWS 6260
4 - OUTPUT GEAR

16. OUTPUT GEAR BEARING ADJUSTMENT:

 With output gear removed, install a 4.50 mm (0.177 in.) gauging shim on the rear carrier assembly
hub, using grease to hold the shim in place.
 Using Holder 6259, install output gear and bearing assembly. Torque to 271 N.m (200 ft. lbs.).

 Measure bearing end play. Attach Gear Checking Plate L-4432 (1) to the gear. See Fig. 97.

 Push and pull the gear while rotating back and forth to ensure seating of bearing rollers.

 Using a dial indicator mounted to the transaxle case, measure output gear end play.

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 2008 Dodge Avenger SXT
2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

 Refer to the output gear bearing shim chart for the required shim to obtain proper bearing setting.
 Use Holder 6259 to remove the output gear retaining bolt and washer. To remove the output gear,
use Gear Puller L4407A.
 Remove the gauging shim and install the proper shim determined by the chart. Use grease to hold
the shim in place.

OUTPUT GEAR BEARING SHIM CHART

Part Shim Part
End Play Shim Needed End Play
Number Needed Number
0.05mm 4.42mm 0.53mm 3.94mm
4412830AB 4412818AB
(0.002 in.) (0.174 in.) (0.021 in.) (0.155 in.)
0.08mm 4.38mm 0.56mm 3.90mm
4412829AB 4412817AB
(0.003 in.) (0.172 in.) (0.022 in.) (0.154 in.)
0.10mm 4.38mm 0.58mm 3.90mm
4412829AB 4412817AB
(0.004 in.) (0.172 in.) (0.023 in.) (0.154 in.)
0.13mm 4.34mm 0.61mm 3.86mm
4412828AB 4412816AB
(0.005 in.) (0.171 in.) (0.024 in.) (0.152 in.)
0.15mm 4.30mm 0.64mm 3.82mm
4412827AB 4412815AB
(0.006 in.) (0.169 in.) (0.025 in.) (0.150 in.)
0.18mm 4.30mm 0.66mm 3.82mm
4412827AB 4412815AB
(0.007 in.) (0.169 in.) (0.026 in.) (0.150 in.)
0.20mm 4.26mm 0.69mm 3.78mm
4412826AB 4412814AB
(0.008 in.) (0.168 in.) (0.027 in.) (0.149 in.)
0.23mm 4.22mm 0.71mm 3.74mm
4412825AB 4412813AB
(0.009 in.) (0.166 in.) (0.028 in.) (0.147 in.)
0.25mm 4.22mm 0.74mm 3.74mm
4412825AB 4412813AB
(0.010 in.) (0.166 in.) (0.029 in.) (0.147 in.)
0.28mm 4.18mm 0.76mm 3.70mm
4412824AB 4412812AB
(0.011 in.) (0.165 in.) (0.030 in.) (0.146 in.)
0.30mm 4.14mm 0.79mm 3.66mm
4412823AB 4412811AB
(0.012 in.) (0.163 in.) (0.031 in.) (0.144 in.)
0.33mm 4.14mm 0.81mm 3.66mm
4412823AB 4412811AB
(0.013 in.) (0.163 in.) (0.032 in.) (0.144 in.)
0.36mm 4.10mm 0.84mm 3.62mm
4412822AB 4412810AB
(0.014 in.) (0.161 in.) (0.033 in.) (0.143 in.)
0.38mm 4.10mm 0.86mm 3.62mm
4412822AB 4412810AB
(0.015 in.) (0.161 in.) (0.034 in.) (0.143 in.)
0.41mm 4.06mm 0.89mm 3.58mm
4412821AB 4412809AB
(0.016 in.) (0.160 in.) (0.035 in.) (0.141)
0.43mm 4.02mm 0.91mm 3.54mm
4412820AB 4412808AB
(0.017 in.) (0.158 in.) (0.036in.) (0.139 in.)
0.46mm 4.02mm 0.94mm 3.54mm
4412820AB 4412808AB
(0.018 in.) (0.158 in.) (0.037 in.) (0.139 in.)
0.48mm 3.98mm 4412819AB 0.97mm 3.50mm 4412807AB

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(0.019 in.) (0.157 in.) (0.038 in.) (0.138 in.)

0.51mm 3.94mm
4412818AB - - -
(0.020 in.) (0.155 in.)

Fig. 98: Installing Output Gear

Courtesy of CHRYSLER LLC

1 - WRENCHES
2 - INSTALLER 6261 WITH STUD
3 - OUTPUT GEAR

17. Install the output gear (3) and bearing assembly using Installer 6261 (2). See Fig. 98.

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2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 99: Removing/Installing Output Gear Bolt & Washer

Courtesy of CHRYSLER LLC

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

18. Install NEW output gear retaining bolt (2) and washer (3). See Fig. 99.

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 2008 Dodge Avenger SXT
2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 100: Tighten Output Gear to 271 N.m (200 ft. lbs.)
Courtesy of CHRYSLER LLC

1 - OUTPUT GEAR
2 - TORQUE WRENCH
3 - 200 FT. LBS.
4 - HOLDER 6259

19. Using Holder 6259 (4), torque output gear (1) retaining bolt to 271 N.m (200 ft. lbs.). See Fig. 100.

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2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 101: Check Output Gear Bearings Turning Torque

Courtesy of CHRYSLER LLC

1 - INCH-POUND TORQUE WRENCH

2 - OUTPUT GEAR

20. Using an inch pound torque wrench (1), check output shaft turning torque. See Fig. 101.Output shaft
turning torque should be within 3-8 in. lbs. If the turning torque is too high, install a 0.04 mm (0.0016
in.) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until
the proper turning torque of 3-8 in. lbs. is obtained.

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Fig. 102: Installing Stirrup

Courtesy of CHRYSLER LLC

1 - STIRRUP
2 - OUTPUT GEAR RETAINING BOLT

21. Install output gear stirrup (1) with serrated side out. See Fig. 102.

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Fig. 103: Removing/Installing Strap Bolts

Courtesy of CHRYSLER LLC

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

22. Install retaining strap (1). See Fig. 103.

23. Install strap bolts (3) but do not tighten at this time.

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Fig. 104: Turn Stirrup Clockwise Against Bolt Flats

Courtesy of CHRYSLER LLC

1 - RETAINING STRAP
2 - STIRRUP

24. Rotate stirrup (2) clockwise against flats of retaining bolt. See Fig. 104.

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Fig. 105: Tighten Stirrup Strap Bolts to 23 N.m (200 in. lbs.)
Courtesy of CHRYSLER LLC

1 - RETAINING STRAP
2 - STIRRUP

25. Torque stirrup strap bolts to 23 N.m (204 in. lbs.). See Fig. 105.

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Fig. 106: Bend Tabs on Strap up Against Flats of Bolts

Courtesy of CHRYSLER LLC

1 - RETAINING STRAP TABS

2 - RETAINING STRAP
3 - STIRRUP

26. Bend tabs (1) on strap up against flats of bolts. See Fig. 106.

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2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 107: Installing Transfer Shaft Bearing Cone

Courtesy of CHRYSLER LLC

1 - INSTALLER 6052
2 - NEW BEARING CONE
3 - TRANSFER SHAFT
4 - ARBOR PRESS RAM

27. Install new transfer shaft bearing cone (2) using Installer 6052 (1). See Fig. 107.

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Fig. 108: Removing/Installing Transfer Shaft

Courtesy of CHRYSLER LLC

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

28. Using Remover/Installer 5049A (1), install transfer shaft (2). See Fig. 108.

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Fig. 109: Removing/Installing Transfer Shaft Bearing Snap Ring

Courtesy of CHRYSLER LLC

1 - SNAP RING PLIERS 6051

2 - TRANSFER SHAFT BEARING SNAP RING
3 - TRANSFER SHAFT

29. Using Snap Ring Pliers 6051 (1), install transfer shaft bearing snap ring (2). See Fig. 109.

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Fig. 110: Installing Transfer Shaft Bearing Cup Into Retainer

Courtesy of CHRYSLER LLC

1 - ARBOR PRESS RAM

2 - HANDLE C-4171
3 - INSTALLER 6061
4 - TRANSFER SHAFT BEARING CUP RETAINER
5 - USE REMOVED BEARING CUP TO SUPPORT

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RETAINER

30. Using an arbor press (1) install transfer shaft bearing cup into retainer using Installer 6061(3). Use
removed bearing cup to support retainer (4). See Fig. 110.

Fig. 111: Removing/Installing Bearing Cup Retainer

Courtesy of CHRYSLER LLC

1 - ALIGN INDEXING TAB TO SLOT

2 - BEARING CUP RETAINER

31. Install bearing cup retainer (2) to transaxle. See Fig. 111.

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Fig. 112: Installing Transfer Gear Bearing Cone

Courtesy of CHRYSLER LLC

1 - ARBOR PRESS RAM

2 - HANDLE C-4171
3 - NEW BEARING CONE
4 - TRANSFER SHAFT GEAR
5 - INSTALLER 5052

32. Install new transfer gear bearing cone (3) to transfer gear (4) using Installer 5052 (5). See Fig. 112.

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Fig. 113: Removing/Installing Transfer Shaft Gear & (Select) Shim

Courtesy of CHRYSLER LLC

1 - TRANSFER SHAFT GEAR

2 - BEARING CUP RETAINER
3 - SHIM (SELECT)

33. TRANSFER GEAR BEARING ADJUSTMENT:

 Install a 4.66 mm (0.183 in.) gauging shim on the transfer shaft. See Fig. 113.

 Install transfer shaft gear using Installer 6261. Using Holder 6259, install transfer shaft gear
retaining nut to 271 N.m (200 ft. lbs.).
 Measure end play. Attach Gear Checking Plate L4432 to the transfer gear.

 Mount a steel ball with grease into the end of the transfer shaft.

 Push and pull the gear while rotating back and forth to ensure seating of the bearing rollers.

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 Using a dial indicator, measure transfer shaft end play.

 Refer to the transfer shaft bearing shim chart for the required shim combination to obtain the proper
bearing setting.
 Use Holder 6259 to remove the retaining nut and washer. Remove the transfer shaft gear using
Gear Puller L4407A.
 Remove the gauging shim and install the proper shim indicated by the chart.

TRANSFER SHAFT BEARING SHIM CHART

Shim Part Shim Part
End Play End Play
Needed Number Needed Number
0.05mm 4.66mm 0.76mm 3.94mm
4505588AB 4412818AB
(0.002 in.) (0.183 in.) (0.030 in.) (0.155 in.)
0.08mm 4.62mm 0.79mm 3.90mm
4412835AB 4412817AB
(0.003 in.) (0.182 in.) (0.031 in.) (0.154 in.)
0.10mm 4.58mm 0.81mm 3.90mm
4412834AB 4412817AB
(0.004 in.) (0.180 in.) (0.032 in.) (0.154 in.)
0.13mm 4.58mm 0.84mm 3.86mm
4412834AB 4412816AB
(0.005 in.) (0.180 in.) (0.033 in.) (0.152 in.)
0.15mm 4.54mm 0.86mm 3.82mm
4412833AB 4412815AB
(0.006 in.) (0.178 in.) (0.034 in.) (0.150 in.)
0.18mm 4.50mm 0.89mm 3.82mm
4412832AB 4412815AB
(0.007 in.) (0.177 in.) (0.035 in.) (0.150 in.)
0.20mm 4.50mm 0.91mm 3.78mm
4412832AB 4412814AB
(0.008 in.) (0.177 in.) (0.036 in.) (0.149 in.)
0.23mm 4.46mm 0.94mm 3.74mm
4412831AB 4412813AB
(0.009 in.) (0.175 in.) (0.037 in.) (0.147 in.)
0.25mm 4.46mm 0.97mm 3.74mm
4412831AB 4412813AB
(0.010 in.) (0.175 in.) (0.038 in.) (0.147 in.)
0.28mm 4.42mm 0.99mm 3.70mm
4412830AB 4412812AB
(0.011 in.) (0.174 in.) (0.039 in.) (0.146 in.)
0.30mm 4.38mm 1.02mm 3.66mm
4412829AB 4412811AB
(0.012 in.) (0.172 in.) (0.040 in.) (0.144 in.)
0.33mm 4.38mm 1.04mm 3.66mm
4412829AB 4412811AB
(0.013 in.) (0.172 in.) (0.041 in.) (0.144 in.)
0.36mm 4.34mm 1.07mm 3.62mm
4412828AB 4412810AB
(0.014 in.) (0.171 in.) (0.042 in.) (0.143 in.)
0.38mm 4.30mm 1.08mm 3.62mm
4412827AB 4412810AB
(0.015 in.) (0.169 in.) (0.043 in.) (0.143 in.)
0.41mm 4.30mm 1.12mm 3.58mm
4412827AB 4412809AB
(0.016 in.) (0.169 in.) (0.044 in.) (0.141)
0.43mm 4.26mm 1.14mm 3.54mm
4412826AB 4412808AB
(0.017 in.) (0.168 in.) (0.045 in.) (0.139 in.)
0.46mm 4.22mm 1.17mm 3.54mm
4412825AB 4412808AB
(0.018 in.) (0.166 in.) (0.046 in.) (0.139 in.)

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0.48mm 4.22mm 1.19mm 3.50mm

4412825AB 4412807AB
(0.019 in.) (0.166 in.) (0.047 in.) (0.138 in.)
0.50mm 4.18mm 1.22mm 3.46mm
4412824AB 4412806AB
(0.020 in.) (0.165 in.) (0.048 in.) (0.136 in.)
0.53mm 4.18mm 1.24mm 3.46mm
4412824AB 4412806AB
(0.021 in.) (0.165 in.) (0.049 in.) (0.136 in.)
0.56mm 4.14mm 1.27mm 3.42mm
4412823AB 4412805AB
(0.022 in.) (0.163 in.) (0.050 in.) (0.135 in.)
0.58mm 4.10mm 1.30mm 3.38mm
4412822AB 4412804AB
(0.023 in.) (0.161 in.) (0.051 in.) (0.133 in.)
0.61mm 4.10mm 1.32mm 3.38mm
4412822AB 4412804AB
(0.024 in.) (0.161 in.) (0.052 in.) (0.133 in.)
0.64mm 4.06mm 1.35mm 3.34mm
4412821AB 4412803AB
(0.025 in.) (0.160 in.) (0.053 in.) (0.132 in.)
0.66mm 4.02mm 1.37mm 3.34mm
4412820AB 4412803AB
(0.026 in.) (0.158 in.) (0.054 in.) (0.132 in.)
0.69mm 4.02mm 1.40mm 3.30mm
4412820AB 4412802AB
(0.027 in.) (0.158 in.) (0.055 in.) (0.130 in.)
0.71mm 3.98mm 1.45mm 3.26mm
4412819AB 4412801AB
(0.028 in.) (0.157 in.) (0.057 in (0.128 in.)
0.74mm 3.94mm 1.47mm 2.22mm
4412818AB 4505570AB
(0.029 in.) (0.155 in.) (0.058 in.) (0.127 in.)

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Fig. 114: Installing Transfer Shaft Gear

Courtesy of CHRYSLER LLC

1 - WRENCHES
2 - INSTALLER 6261
3 - OUTPUT GEAR
4 - TRANSFER SHAFT GEAR

34. Install the transfer shaft gear (4) using Installer 6261 (2). See Fig. 114.

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Fig. 115: Tighten Transfer Gear Nut to 271 N.m (200 ft. lbs.)
Courtesy of CHRYSLER LLC

1 - TRANSFER SHAFT GEAR

2 - 200 FT. LBS.
3 - TORQUE WRENCH
4 - HOLDER 6259

CAUTION: Install a NEW retaining nut, as the original nut MUST NOT be reused.

35. Install the new retaining nut and washer.

36. Using Holder 6259 (4), torque transfer gear retaining nut to 271 N.m (200 ft. lbs.). See Fig. 115.

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Fig. 116: Rear Cover Sealant Application

Courtesy of CHRYSLER LLC

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

37. Measure transfer shaft end play. Transfer shaft end play should be within 0.05-0.10 mm (0.002-0.004
in.). If the end play is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the end play is too low,
install a 0.04 mm (0.0016 in.) thinner shim. Repeat until 0.05-0.10 mm (0.002-0.004 in.) end play is
obtained.
38. Install a bead of Mopar® ATF RTV (MS-GF41) (2) to transfer gear cover (1). See Fig. 116.

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Fig. 117: Removing/Installing Rear Cover Bolts

Courtesy of CHRYSLER LLC

1 - REAR COVER BOLTS

2 - REAR COVER
3 - USE SEALANT ON BOLTS

39. Use sealant on bolts (3), install transfer gear cover-to-case bolts (1) and torque to 20 N.m (175 in. lbs.)
torque. See Fig. 117.

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 2008 Dodge Avenger SXT
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Fig. 118: Identifying Low/Reverse Clutch Pack

Courtesy of CHRYSLER LLC

1 - CLUTCH PLATES (5)

2 - CLUTCH DISCS (5)

40. Install low/reverse clutch pack (1,2). See Fig. 118. Leave uppermost disc out until snap ring is installed.

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 2008 Dodge Avenger SXT
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Fig. 119: Removing/Installing Low/Reverse Reaction Plate Snap Ring

Courtesy of CHRYSLER LLC

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

41. Install low/reverse reaction plate flat snap ring (2) insure you do not scratch clutch plate (3). See Fig. 119.

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 2008 Dodge Avenger SXT
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Fig. 120: Removing/Installing One Disc

Courtesy of CHRYSLER LLC

1 - ONE DISC FROM LOW/REVERSE CLUTCH

42. Install remaining low/reverse clutch disc (1). See Fig. 120.

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 2008 Dodge Avenger SXT
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Fig. 121: Removing/Installing Low/Reverse Reaction Plate

Courtesy of CHRYSLER LLC

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

43. Install low/reverse reaction plate with flat side up (1). See Fig. 121.

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Fig. 122: Tapered Snap Ring Instructions

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 2008 Dodge Avenger SXT
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Courtesy of CHRYSLER LLC

44. Use as a reference while installing tapered snap ring. See Fig. 122.

Fig. 123: Installing Snap Ring

Courtesy of CHRYSLER LLC

1 - SCREWDRIVER
2 - TAPERED SNAP RING (INSTALL AS SHOWN)

45. Install tapered snap ring (with tapered side up) (2). See Fig. 123.

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Fig. 124: Check Low/Reverse Clutch Clearance

Courtesy of CHRYSLER LLC

1 - DIAL INDICATOR
2 - DIAL INDICATOR TIP TOOL 6268
3 - HOOK TOOL

46. Set up dial indicator (1) to measure low/reverse clutch clearance. Press down on clutch pack with finger
and zero dial indicator. See Fig. 124.Low/Reverse clutch pack clearance is 0.89-1.47 mm (0.035-0.058
in.) . Set up indicator and record measurement in four places. Take average of readings and select the
proper low/reverse reaction plate to achieve specifications.

LOW/REVERSE REACTION PLATE CHART

PART NUMBER THICKNESS
4799846AA 5.88 mm (0.232 in.)

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4799847AA 6.14 mm (0.242 in.)

4799848AA 6.40 mm (0.252 in.)
4799849AA 6.66 mm (0.262 in.)
4799855AA 6.92 mm (0.273 in.)

Fig. 125: Identifying 2/4 Clutch Pack

Courtesy of CHRYSLER LLC

1 - CLUTCH PLATE (4)

2 - CLUTCH DISC (4)

47. Install 2/4 clutch pack (1, 2). See Fig. 125.

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Fig. 126: View Of Proper Orientation Of 2/4 Clutch Retainer & Spring
Courtesy of CHRYSLER LLC

1 - NOTE POSITION
2 - RETURN SPRING
3 - 2/4 CLUTCH RETAINER

NOTE: The 2/4 Clutch Piston has bonded seals which are not individually
serviceable. Seal replacement requires replacement of the piston
assembly.

48. Orient 2/4 clutch return spring to retainer (3). See Fig. 126.

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Fig. 127: 2/4 Clutch Retainer

Courtesy of CHRYSLER LLC

1 - 2/4 CLUTCH RETAINER

2 - 2/4 CLUTCH RETURN SPRING

49. Install 2/4 clutch retainer to transaxle (1, 2). See Fig. 127.

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Fig. 128: Removing/Installing 2/4 Clutch Retainer Snap Ring

Courtesy of CHRYSLER LLC

1 - COMPRESSING TOOL 5058-A

2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER

50. Using Compressing Tool 5058-A (1), compress 2/4 clutch return spring just enough to install snap ring
(3). See Fig. 128.
51. Install snap ring.

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Fig. 129: Check 2/4 Clutch Clearance

Courtesy of CHRYSLER LLC

1 - DIAL INDICATOR
2 - HOOK TOOL
3 - DIAL INDICATOR TIP 6268

52. Set up dial indicator (1) and measure 2/4 clutch clearance. Press down on clutch pack with finger and
zero dial indicator. See Fig. 129.2/4 clutch pack clearance is 0.76-2.64 mm (0.030-0.104 in.). Set up
indicator and record measurement in four (4) places. Take average of readings. If clearance is outside this
range, the clutch is assembled improperly. There is no adjustment for 2/4 clutch clearance.

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 2008 Dodge Avenger SXT
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Fig. 130: Identifying Rear Sun Gear & No. 7 Needle Bearing
Courtesy of CHRYSLER LLC

1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR

NOTE: The number seven needle (1) 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. A small
amount of petrolatum can be used to hold the bearing to the rear sun gear
(2). See Fig. 130.

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Fig. 131: Identifying Rear Sun Gear & No. 7 Needle Bearing
Courtesy of CHRYSLER LLC

1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR

53. Install rear sun gear (2) and #7 needle bearing (1). See Fig. 131.

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Fig. 132: Removing/Installing Front Carrier & Rear Annulus Assembly

Courtesy of CHRYSLER LLC

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

54. Install front carrier/rear annulus assembly (2) and #6 needle bearing (1). See Fig. 132.

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Fig. 133: Removing/Installing Front Sun Gear Assembly And #4 Thrust Washer
Courtesy of CHRYSLER LLC

1 - FRONT SUN GEAR ASSEMBLY

2 - #4 THRUST WASHER (FOUR TABS)

55. Install front sun gear assembly (1) and #4 thrust washer (2). See Fig. 133.

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Fig. 134: Identifying No. 4 Thrust Plate

Courtesy of CHRYSLER LLC

1 - OVERDRIVE SHAFT ASSEMBLY

2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION

56. Select the thinnest #4 thrust plate thickness (2) and install to input clutch assembly. Use petrolatum to
retain (3). See Fig. 134.

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 2008 Dodge Avenger SXT
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Fig. 135: View Through Input Speed Sensor Hole

Courtesy of CHRYSLER LLC

1 - INPUT CLUTCH RETAINER

2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS

57. Install input clutch assembly into position and verify that it is completely seated by viewing through input
speed sensor hole (2). See Fig. 135. If view through input speed sensor hole is not as shown in the below
view, the input clutch assembly is not seated properly.

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Fig. 136: Removing/Installing Oil Pump O-Ring

Courtesy of CHRYSLER LLC

1 - OIL PUMP ASSEMBLY

2 - O-RING

58. Remove oil pump O-ring (2). See Fig. 136. Be sure to reinstall oil pump O-ring after selecting the
proper #4 thrust plate.
59. Install pump and gasket to transmission. Install and torque bolts.

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 2008 Dodge Avenger SXT
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Fig. 137: Measuring Input Shaft End Play Using End Play Set 8266
Courtesy of CHRYSLER LLC

1 - END PLAY SOCKET SET 8266

2 - DIAL INDICATOR C-3339

60. Set up input shaft for measurement with Indicator Set C3339 (3) and End Play Set 8266 (1). See Fig. 137.

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61. Measure the input shaft end play with the transaxle in the vertical position. Input shaft end play must be
within 0.005 to 0.025 inch. For example, if end play reading is 0.055 inch, select No. 4 Thrust Plate
which is 0.071 to 0.074 thick. This should provide an input shaft end play reading of 0.020 inch which is
within specifications.
62. Refer to the No. 4 thrust plate chart NO. 4 THRUST PLATE CHART to select the proper No. 4 thrust
plate.

NO. 4 THRUST PLATE CHART

PART NUMBER THICKNESS
4431665AB 1.60mm (0.063 in.)
3836237AB 1.73mm (0.068 in.)
4431666AB 1.80mm (0.071 in.)
3836238AB 1.96mm (0.077 in.)
4431667AB 2.03mm (0.080 in.)
3836239AB 2.16mm (0.085 in.)
4431668AB 2.24mm (0.088 in.)
3836240AB 2.39mm (0.094 in.)
4431669AB 2.46mm (0.097 in.)
3836241AB 2.62mm (0.103 in.)
4446670AB 2.67mm (0.105 in.)
4446671AB 2.90mm (0.114 in.)

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Fig. 138: Removing/Installing Input Clutch Assembly

Courtesy of CHRYSLER LLC

1 - INPUT CLUTCH ASSEMBLY

2 - #4 THRUST WASHER

63. Install input clutch assembly (1). See Fig. 138.

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Fig. 139: Removing/Installing Caged Needle Bearing

Courtesy of CHRYSLER LLC

1 - #1 CAGED NEEDLE BEARING

2 - NOTE: TANGED SIDE OUT

64. Install #1 caged needle bearing (1) note: tanged side out (2). See Fig. 139.

CAUTION: The cooler bypass valve must be replaced if transaxle failure has
occurred. Do not attempt to reuse or clean old valve.

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 2008 Dodge Avenger SXT
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Fig. 140: Removing/Installing Bypass Valve

Courtesy of CHRYSLER LLC

1 - COOLER BYPASS VALVE

65. Install cooler bypass valve (1) with O-ring end towards rear of case. See Fig. 140.

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Fig. 141: Removing/Installing Oil Pump Gasket

Courtesy of CHRYSLER LLC

1 - PUMP GASKET

66. Install oil pump gasket (1). See Fig. 141.

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Fig. 142: Removing/Installing Oil Pump

Courtesy of CHRYSLER LLC

1 - OIL PUMP
2 - GASKET

67. Install oil pump (1). See Fig. 142.

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 2008 Dodge Avenger SXT
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Fig. 143: Removing/Installing Pump Bolts

Courtesy of CHRYSLER LLC

1 - PUMP ATTACHING BOLTS

2 - PUMP HOUSING

68. Install oil pump-to-case bolts (1) and torque to 27 N.m (20 ft. lbs.). See Fig. 143.

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 2008 Dodge Avenger SXT
2008 AUTOMATIC TRANSMISSION 41TE - Service Information - Avenger & Sebring

Fig. 144: Installing Low/Reverse Accumulator

Courtesy of CHRYSLER LLC

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

69. Install low/reverse accumulator (1). See Fig. 144.

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Fig. 145: Removing Low/Reverse Accumulator Plug (Cover)

Courtesy of CHRYSLER LLC

1 - ADJUSTABLE PLIERS
2 - PLUG

70. Install low/reverse accumulator plug (2). See Fig. 145.

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Fig. 146: Removing/Installing Low/Reverse Accumulator Snap Ring

Courtesy of CHRYSLER LLC

1 - SNAP RING
2 - PLUG

71. Install low/reverse accumulator snap ring (1). See Fig. 146.

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 2008 Dodge Avenger SXT
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Fig. 147: Identifying Underdrive & Overdrive Accumulators

Courtesy of CHRYSLER LLC

1 - OVERDRIVE PISTON AND SPRING

2 - UNDERDRIVE PISTON AND SPRING

NOTE: Depending on engine application, some accumulators will have two

springs, and others will have one spring. The springs are color-coded for
application and year.

72. Install underdrive and overdrive accumulators (1, 2). See Fig. 147.

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Fig. 148: Removing/Installing Valve Body

Courtesy of CHRYSLER LLC

1 - VALVE BODY

73. Install valve body (1) to transaxle. Rotate manual valve shaft fully clockwise to ease installation. Make
sure park rod rollers are positioned within park guide bracket. See Fig. 148.

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Fig. 149: Removing/Installing Valve Body Bolts

Courtesy of CHRYSLER LLC

1 - VALVE BODY ATTACHING BOLTS (18)

2 - VALVE BODY

74. Install and torque valve body-to-case bolts (1) to 12 N.m (105 in. lbs.). See Fig. 149.

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 2008 Dodge Avenger SXT
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Fig. 150: Removing/Installing Oil Filter

Courtesy of CHRYSLER LLC

1 - OIL FILTER
2 - O-RING

75. Install oil filter (1) and new O-ring (2). See Fig. 150.

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 2008 Dodge Avenger SXT
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Fig. 151: Oil Pan Sealant Application

Courtesy of CHRYSLER LLC

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

76. Apply an 1/8" bead of Mopar® ATF RTV (MS-GF41) (2). See Fig. 151to oil pan (1) and immediately
install to case.

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Fig. 152: Identifying Solenoid/Pressure Switch Assembly & Gasket

Courtesy of CHRYSLER LLC

1 - SOLENOID/PRESSURE SWITCH ASSEMBLY

2 - GASKET

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77. Install oil pan-to-case bolts and torque to 19 N.m (165 in. lbs.).
78. Install solenoid/pressure switch assembly (1) and gasket (2) to case. See Fig. 152.

Fig. 153: Identifying Solenoid Pack-To-Transaxle Bolts

Courtesy of CHRYSLER LLC

1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY

79. Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts (1) to 12 N.m (110 in. lbs.).
See Fig. 153.

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80. Install and torque input and output speed sensors to case to 27 N.m (20 ft. lbs.).

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