Trans Solenoid / Pressure Switch Assembly Leaking?

Here’s the replacement procedure for 41TE Automatic Transaxles.

Words and Photos: Mark Yanochko

In the previous issue of Mopar Magazine, the Diagnostics article covered transmission problems. One problem discussed was fluid leaks from the solenoid/pressure switch assembly gaskets. Fixing this leak problem was discussed, but without illustrations or photographs. Let’s look at the step-by-step procedure, with photographs.

The solenoid/pressure switch assembly, A, is mounted on the front side of the transaxle cover with three mounting bolts (Figure 1). An assembly gasket, B (Figure 1), and mounting gasket, C (Figure 2), have been known to leak. Note: It is impractical to disassemble the unit and replace the assembly gasket; rather, a new solenoid/pressure switch assembly is installed.

Be sure this solenoid/pressure switch assembly is leaking. When the vehicle is on a lift, the fluid can travel to the bottom side of the housing. It might appear that the pan is leaking; verify the location of the leak along the bottom edge of the transaxle housing, D, as shown in Figure 2.

The assembly is replaced in the following manner:
1. On vehicles, such as the PT Cruiser, the air cleaner assembly, E, and the battery, F, must be removed to gain access to the assembly (Figure 3).
2. Disconnect the input speed sensor, G, and the solenoid/pressure switch assembly connector, H (Figure 4).
3. Disconnect the transaxle oil cooler lines, J (Figure 5).
4. Remove the three bolts holding the solenoid/pressure switch assembly to the transaxle case (two of the three bolts, K, are shown in Figure 6).
5. Remove the solenoid/pressure switch assembly and mounting gasket.
6. Clean the gasket mounting surface, L, shown in Figure 7. Caution: Be sure to keep foreign material from entering the ports in the transaxle case; erratic transaxle operation and/or failure can occur.
7. Place the new mounting gasket, M, on the solenoid/pressure switch assembly, fitting the gasket over the three (3) ports, N, on the assembly, P (Figure 8); no gasket sealer or adhesive is required with the new gasket.
8. Install the solenoid/pressure switch assembly with the new mounting gasket on the transaxle case.
9. Install the three (3) solenoid/pressure switch assembly-to-transaxle case bolts; torque to 110 in.-lbs.
10. Install the assembly connector; torque the screw to 35 in.-lbs.
11. Install the transmission cooler lines.
12. Install the input speed sensor; torque to 20 ft.-lbs.
13. Install the battery.
14. Install the air cleaner assembly.

Mark Yanochko is a 32-year veteran of the automotive technical, service and 
repair industry.