TownAndCountry 2008

Transaxle Removal & Installation

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4-Speed Transaxle (41TE)-3.3L Engine



Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the battery cables.
  4.  
  5. Remove the battery hold down bolt and remove the battery.
  6.  
  7. Remove the clips holding the harness and ground cable to the battery tray.
  8.  
  9. Remove the battery tray hold down bolts and remove the battery tray.
  10.  
  11. Remove the bolts at the left mount (1, 2).

    Click image to see an enlarged view

    Fig. Remove the bolts at left mount-3.3L engine

  12.  
  13. Remove the bolt at the transaxle fluid level indicator/tube assembly.
  14.  
  15. Remove the fluid level indicator/tube assembly. Plug the opening to prevent debris from entering the transaxle.
  16.  
  17. Disconnect the oil cooler lines from the transaxle using Disconnect Tool 8875A.
  18.  
  19. Disconnect the electrical connectors at the transaxle.
  20.  
  21. Disconnect the gear shift cable from the manual valve lever and cable bracket.
  22.  
  23. Remove the heater tube bolt at the bellhousing.
  24.  
  25. Move the heater tube out of the way to gain access to the bellhousing bolts.
  26.  
  27. Remove the rear mount bracket-to-transaxle case bolts.
  28.  
  29. Raise and safely support the vehicle.
  30.  
  31. Remove the transaxle oil pan and drain the fluid into suitable a container.
  32.  
  33. Remove the front wheel/tire assemblies.
  34.  
  35. Remove the left and right halfshaft assemblies. Refer to Front Drive Axle, Halfshafts, removal & installation.
  36.  
  37. Support the engine with a screw jack and the transaxle with a transmission jack.
  38.  
  39. Remove the bolts at the crossmember (2, 3).
  40.  
  41. Remove the crossmember (1).

    Click image to see an enlarged view

    Fig. Remove the crossmember-3.3L engine

  42.  
  43. Remove the rear mount side bolt.
  44.  
  45. Remove the bolt (2) holding the ground cable (1) and the heater tube bracket (3) to the front mount (4).

    Click image to see an enlarged view

    Fig. Remove the bolt holding the ground cable and the heater tube bracket to the front mount-3.3L engine

  46.  
  47. Remove the bolts at the front mount.
  48.  
  49. Remove the front mount.
  50.  
  51. Remove the starter motor. Refer to Starting System, Starter, removal & installation.
  52.  
  53. Remove the inspection cover bolts.
  54.  
  55. Remove the inspection cover.
  56.  
  57. Remove the torque converter-to-flexplate bolts.
  58.  
  59. Lower the engine and transaxle enough to gain access to the left mount to block bolts.
  60.  
  61. Remove the left mount to block bolts.
  62.  
  63. Remove the left mount.
  64.  
  65. Unplug the electrical connector at the Crankshaft Position (CKP) sensor.
  66.  
  67. Remove the bolt at the CKP sensor.
  68.  
  69. Remove the CKP sensor.
  70.  
  71. Remove the bellhousing upper (1) and lower bolts (2) from the transaxle.
  72.  
  73. Remove the transaxle assembly from the vehicle.

    Click image to see an enlarged view

    Fig. Remove the bellhousing upper (1) and lower bolts (2) from the transaxle-3.3L engine

  74.  

To install:

  1. Install the transaxle assembly into the vehicle.
  2.  
  3. Install the bellhousing upper (1) and lower bolts (2) and tighten to 55 ft. lbs. (75 Nm).
  4.  
  5. Install and connect the CKP sensor. Tighten the bolt to 106 inch lbs. (12 Nm).
  6.  
  7. Install the left mount bracket assembly (1) to the transaxle. Tighten the bolts (2) to 40 ft. lbs. (54 Nm).

    Click image to see an enlarged view

    Fig. Install the left mount bracket assembly to the transaxle-3.3L engine

  8.  
  9. Raise the engine/transaxle assembly into position.
  10.  
  11. Install the torque converter-to-flexplate bolts and tighten to 65 ft. lbs. (88 Nm).
  12.  
  13. Install the inspection cover.
  14.  
  15. Install the inspection cover (1) and tighten the larger fastener (3) to 70 ft. lbs. (95 Nm) and the smaller fasteners (2) to 70 ft. lbs. (12 Nm)

    Click image to see an enlarged view

    Fig. Install the inspection cover-3.3L engine

  16.  
  17. Install the front mount to the transaxle.
  18.  
  19. Install the front mount bolts and tighten to 70 ft. lbs. (95 Nm).
  20.  
  21. Install the starter motor. Refer to Starting System, Starter, removal & installation.
  22.  
  23. Install the bolt holding the ground cable and the heater tube bracket to the front mount.
  24.  
  25. Install the crossmember.
  26.  
  27. Install the bolts at the crossmember and tighten to 30 ft. lbs. (40 Nm).
  28.  
  29. Remove the transmission jack and screw jack at the engine.
  30.  
  31. Lower the vehicle.
  32.  
  33. Install the left and right halfshaft assemblies. Refer to Front Drive Axle, Halfshafts, removal & installation.
  34.  
  35. Install the front wheel/tire assemblies.
  36.  
  37. Install the rear mount bracket-to-transaxle case bolts and tighten to 55 ft. lbs. (75 Nm).
  38.  
  39. Install the heater tube bolt at the bellhousing and tighten to 44 inch lbs. (5 Nm).
  40.  
  41. Insure that the shift cable bracket is in place.
  42.  
  43. Install the bolts at the left mount and tighten to 70 ft. lbs. (95 Nm).
  44.  
  45. Connect the gear shift cable to the manual valve lever and the shift cable bracket.
  46.  
  47. Connect the electrical connectors at the transaxle.
  48.  
  49. Connect the oil cooler lines to the transaxle.
  50.  
  51. Install the fluid level indicator/tube assembly.
  52.  
  53. Install the bolt at the fluid level indicator/tube assembly and tighten to 44 inch lbs. (5 Nm).
  54.  
  55. Install the battery tray.
  56.  
  57. Install the tie straps holding the harness and ground cable to the battery tray.
  58.  
  59. Install the battery and battery hold down bolt.
  60.  
  61. Connect the battery cables.
  62.  
  63. Fill the transaxle with the proper type and amount of fluid.
  64.  
  65. If the transaxle assembly has been replaced or overhauled (clutch and/or seal replacement), it is necessary to perform the Quick-Learn Procedure. Refer to Automatic Transaxle, Quick-Learn Procedure.
  66.  

6-Speed Transaxle (62TE)-3.8L & 4.0L Engines



Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the battery cables.
  4.  
  5. Disconnect the battery cables.
  6.  
  7. Remove the battery hold down bolt and remove the battery.
  8.  
  9. Remove the clips holding the harness and ground cable to the battery tray.
  10.  
  11. Remove the battery tray.
  12.  
  13. Remove the radiator overflow bottle.
  14.  
  15. Disconnect the oil cooler lines from the transaxle using Disconnect Tool 8875A.
  16.  
  17. Remove the bolts holding the heater lines.
  18.  
  19. Unplug the input speed sensor.
  20.  
  21. Disconnect the gearshift cable from the transaxle manual valve lever.
  22.  
  23. Disconnect the gearshift cable from the bracket.
  24.  
  25. Disconnect the electrical connector at the Crankshaft Position (CKP) sensor.
  26.  
  27. Remove the hold down bolt at the CKP sensor.
  28.  
  29. Remove the CKP sensor.
  30.  
  31. Disconnect the solenoid pack connector at the transaxle.
  32.  
  33. Support the transaxle with a floor jack.
  34.  
  35. Remove the bolts (1) at the left transaxle mount (2).

    Click image to see an enlarged view

    Fig. Remove the bolts (1) at the left transaxle mount (2)-3.8L and 4.0L engines

  36.  
  37. Remove the transaxle upper bellhousing-to-block bolts (3).

    Click image to see an enlarged view

    Fig. Remove the transaxle upper bellhousing-to-block bolts-3.8L and 4.0L engines

  38.  
  39. Raise and safely support the vehicle.
  40.  
  41. Remove the bolt holding the ground cable to the transaxle.
  42.  
  43. Remove the tie strap to transaxle valve body pan.
  44.  
  45. Remove both halfshafts. Refer to Front Drive Axle, Halfshafts, removal & installation.
  46.  
  47. Remove the front and both side splash shields.
  48.  
  49. Remove the rear transaxle mount bracket bolt.
  50.  
  51. Remove the remaining rear transaxle mount bracket bolts.
  52.  
  53. Support the engine and transaxle with jacks.
  54.  
  55. Remove the crossmember through bolt.
  56.  
  57. Remove the transaxle crossmember bolts (1).
  58.  
  59. Remove the transaxle crossmember (3).

    Click image to see an enlarged view

    Fig. Remove the transaxle crossmember-3.8L and 4.0L engines

  60.  
  61. Lower the engine and transaxle to gain access to the left transaxle mount bracket bolts.
  62.  
  63. Remove the bolts holding the left transaxle mount to the transaxle.
  64.  
  65. Remove the left transaxle mount.
    NOTE
    The 3 bolts on the left side of the front bracket hold the starter in place, ensure the starter is supported.

  66.  
  67. Remove the front mount bracket bolts.
  68.  
  69. Remove the heater line bracket bolt.
  70.  
  71. Remove the bolt at the transaxle front mount bracket to engine.
  72.  
  73. Remove the front mount bracket.
  74.  
  75. On 4.0L engines:
    1. Remove the bolts to the exhaust bracket.
    2.  
    3. Remove the exhaust cross under pipe, if equipped.
    4.  
    5. Remove the bolts to the standoff bracket.
    6.  
    7. Remove the bracket.
    8.  
    9. Remove the torque converter dust shield bolt.
    10.  
    11. Remove the torque converter dust shield.
    12.  
    13. Remove the torque converter-to-flexplate bolts (1). Upon removing bolts, a tight-tolerance (slotted) bolt will be encountered. Mark this location (flexplate and converter) with paint for assembly reference.
      NOTE
      The bolts on each side of the inspection opening were removed with the exhaust bracket.



      Click image to see an enlarged view

      Fig. Remove the torque converter-to-flexplate bolts (1)-4.0L engine

    14.  
    15. Remove the 6 transaxle-to-engine lower bolts.
    16.  
    17. Lower the transaxle from the engine compartment.
    18.  

  76.  
  77. On 3.8L engines:
    1. Remove the bolts holding the structural collar to the oil pan (1) and the transaxle (2).

      Click image to see an enlarged view

      Fig. Remove the bolts holding the structural collar to the oil pan (1) and the transaxle (2)-3.8L engine

    2.  
    3. Remove the torque converter-to-flexplate bolts (1). Upon removing the bolts, a tight-tolerance (slotted) bolt will be encountered. Mark this location (flexplate and converter) with paint for assembly reference.
    4.  
    5. Remove the 2 remaining lower bellhousing bolts.
    6.  
    7. Lower the transaxle from the engine compartment.

      Click image to see an enlarged view

      Fig. Remove the torque converter-to-flexplate bolts (1)-3.8L engine

    8.  

  78.  

To install:

  1. Install the transaxle into position.
    NOTE
    The 2 transaxle-to-engine bolts next to the inspection cover will have an exhaust bracket under them.

  2.  
  3. On 4.0L engines:
    1. Install the transaxle-to-engine 2 outer lower bolts and torque to 44 ft. lbs. (60 Nm).
    2.  
    3. Install the torque converter-to-flexplate bolts and tighten to 65 ft. lbs. (88 Nm).
    4.  
    5. Install the torque converter dust shield and bolt. Tighten the bolt to 88 inch lbs. (10 Nm).
    6.  
    7. Install the bolts to the standoff bracket and tighten to 70 ft. lbs. (95 Nm).
    8.  
    9. Install the remaining transaxle-to-engine lower bolts and torque to 44 ft. lbs. (60 Nm).
    10.  
    11. Install the cross under exhaust pipe, if equipped.
    12.  
    13. Install the bolts to the exhaust bracket.
    14.  

  4.  
  5. On 3.8L engines:
    1. Install the transaxle into position.
    2.  
    3. Install the 2 lower transaxle-to-engine bolts and torque to 44 ft. lbs. (60 Nm).
    4.  
    5. Install the torque converter-to-flexplate bolts (1) and tighten to 65 ft. lbs. (88 Nm).
    6.  
    7. Install the bolts holding the structural collar to the oil pan (1) and the transaxle (2). Tighten the bolts to 55 ft. lbs. (75 Nm).
    8.  

  6.  
  7. Install the left side transaxle mount bracket and bolts. Tighten the bolts to 55 ft. lbs. (75 Nm).
  8.  
  9. Lift the transaxle into place.
  10.  
  11. Install the left motor mount bolts and tighten to 74 ft. lbs. (100 Nm).
  12.  
  13. Install the rear mount and bolts and tighten to 74 ft. lbs. (100 Nm).
  14.  
  15. Install the starter motor along with the front mount bracket.
  16.  
  17. Install the front mount bracket bolts and tighten to 74 ft. lbs. (100 Nm).
  18.  
  19. Install the transaxle crossmember and tighten to 37 ft. lbs. (50 Nm).
  20.  
  21. Install the front mount through bolt and tighten to 37 ft. lbs. (50 Nm).
  22.  
  23. Install the front and both side splash shields, if equipped.
  24.  
  25. Install the ground cable bolt and tighten to 40 ft. lbs. (54 Nm).
  26.  
  27. Install the halfshaft assemblies. Refer to Front Drive Axle, Halfshafts, removal & installation.
  28.  
  29. Lower the vehicle.
  30.  
  31. Install the left side mount bolts along with the heater tube bracket and tighten to 74 ft. lbs. (100 Nm).
  32.  
  33. Connect the input speed sensor connector.
  34.  
  35. Connect both output speed sensor connectors.
  36.  
  37. Connect the solenoid/pressure switch assembly connector.
  38.  
  39. Install the transaxle-to-engine upper bolts and tighten to 70 ft. lbs. (95 Nm).
  40.  
  41. Install and connect the CKP sensor and tighten to 105 inch lbs. (12 Nm).
  42.  
  43. Connect the oil cooler lines to the transaxle. An audible click should be heard. Verify the connection by pulling outward.
  44.  
  45. Connect the gearshift cable to the bracket.
  46.  
  47. Connect the gearshift cable to the transaxle manual valve lever. Verify the adjustment.
  48.  
  49. Install the battery tray.
  50.  
  51. Install the tie straps holding the harness and ground cable to the battery tray.
  52.  
  53. Install the battery and battery hold down bolt.
  54.  
  55. Connect the battery cables.
  56.  
  57. Fill the transaxle with the proper type and amount of fluid.
  58.  
  59. If the transaxle assembly has been replaced or overhauled (clutch and/or seal replacement), it is necessary to perform the Quick-Learn Procedure. Refer to Automatic Transaxle, Quick-Learn Procedure.
  60.  

 
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