A T T E N T I O N

YOUR WARRANTY DEPENDS ON YOUR ADHERENCE TO THESE GUIDELINES

A604/40TES/41TE/41TES/41AE/42TE INSTALLATION
FAMILIES GUIDE
PURPOSE: This document supplies a general overview of installing an A604, 40TES, 41TE, 41TES, 41AE, or
42TE transmission, hereafter referred to as A604. It is not intended to be a step by step
manual. Consult the service manual for complete information and safety precautions.

VEHICLE PREP:
• Scan original vehicle computer, record any codes for later review and resolve all codes.
• Inspect flex plate carefully and entirely for cracks or any damage.
• Inspect all engine and transmission mounts for wear and damage.
• Inspect axle shafts and CV-joints for wear, binding, and damage. Repair or replace as needed.

PRE-INSTALLATION CHECKLIST:
• Compare the replacement transmission and torque converter to the original before installation.
• Transmission cooler and lines must be hot flushed or replaced.
• Ensure all dowel pins are clean, installed properly, and are in good condition.
• Seat the torque converter completely in the transmission before installation in the vehicle.
• Verify that the engine block and bell housing surfaces are clean and free of paint, grease,
oil, and corrosion.
• Check the torque converter bolts to make sure they have not stretched. Replace the bolts if they have
stretched. If your transmission came with new torque converter bolts, use them.
• Test all sensors and switches that have been transferred from the original transmission for
correct operation.
• Clean the axle shaft before installation to prevent transmission output seal damage.
• Do NOT allow the weight of the vehicle on the front wheels with the axle stub shaft not in place and
properly tightened. Front wheel bearing inner race separation may occur. This will cause a grinding/
growling noise that was not there before transaxle replacement.

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INSTALLATION STEPS:
• Do NOT use air tools to force the transmission against the engine block; this may damage or break
the transmission case.
• Tighten all bell housing bolts evenly in a criss-cross pattern.
• Confirm that the transmission has a good ground connection; reattach all ground straps to the correct
location free of paint, grease, oil, and corrosion.
• Adjust gearshift linkage after installation.
• Check the torque converter bolts for stretch. Do not reuse stretched bolt. If your transmission came with
new torque converter bolts, use them.
FLUID FILL PROCEDURE:
Fill the transmission with purchased MOPAR® ATF+4 or 100% compatible synthetic transmission fluid.
The average dry fill capacity of an A604 is 9.0 quarts. The actual amount of fluid needed may vary
depending on the size of the internal cooler, length, and diameter of cooler lines, presence of an auxiliary
cooler, and residual fluid from the dyno testing process.

• Put the vehicle on a lift, and with the wheels off the ground, remove the dipstick and insert
a clean funnel in the transmission fill tube.
• Pour in 4 quarts of fluid and start the engine.
• Verify the fluid level is at LEAST up to the full cold mark on the dipstick. Add fluid if needed.
• Move selector lever into each gear range pausing for 5 seconds in each shift lever position.
• Return the selector lever to Park.
• Attach a scan tool to the vehicle. Run the engine while monitoring the transmission temperature.
• Run the vehicle until the transmission temperature is between 165°F and 190°F.
• Place the transmission into the drive range
and release the brake. Allow for a light
throttle upshift to the highest gear.
• Use the brakes to stop the wheels.
• Return the selector lever to Park.
• Lower the vehicle to the ground making
sure it is sitting level.
• Recheck the fluid level.
Continue adding fluid in small amounts
and rechecking the level until the level
is at the full HOT mark on the dipstick.
• Check to make sure there are no leaks.
• Perform the Quick Learn Procedure.
• Road test the vehicle and recheck the fluid level.
• Make any final fluid level adjustments.

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PROGRAMMING/QUICK LEARN:
This transmission will not function correctly in vehicles that have been tuned with aftermarket programming.
Harsh shifting, rough lock up apply, or lock-up timing issues, along with shuttle shifting and unexpected
downshifts, will occur.
Any external aftermarket electronic performance-enhancing devices must be removed.

QUICK LEARN PROCEDURE:

A professional scanner is required to perform this procedure.
The installation of the transmission must be complete with fluid at the proper level.
Transmission temperature must be at least 60 degrees F.
If any codes are stored in the computer, record them for future reference and clear all codes.
Locate the Clutch Volume Index (CVI) values in the transmission menu. Typical CVI values are as folows:

The installing facility should verify they have the proper tools and that the scan tool they have is capable of
performing the necessary procedures. As an option, the vehicle may be towed to a dealership to perform
these functions at the installation facility’s expense.

Operating the vehicle in any manner without performing the procedures described below can cause
immediate damage to the transmission.

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QUICK LEARN PROCEDURE (cont.):
To perform the Quick Learn Procedure, the following conditions must be met:
• The brakes must be applied.
• The engine speed must be above 500 rpm.
• The throttle angle (TPS) must be less than 3 degrees.
• The shift lever position must stay in Park until prompted to shift to overdrive.
• The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool
indicates the procedure is complete.
• The calculated oil temperature must be above 60°F and below 200°F.

1. Plug the scan tool into the diagnostic connector. The connector is located under the instrument panel.
2. Go to the Transmission > Miscellaneous > Quick Learn Procedure screen. (Typically).
3. Follow the instructions of the scan tool to perform the Quick Learn Procedure.

Quick Learn Detail:

Using a capable scan tool, check the temperature of the fluid. The calculated oil temperature must be above
60°F, and below 200°F before “quick learn” can be initiated.
No DTC’s should be present in the entire system.

1. Select Quick Learn from the Miscellaneous or Special Function Menu of the scan tool.
2. Follow the prompts given by the scan tool.
3. Start with the vehicle in Park.
4. The engine must be running, the brake pedal depressed and the emergency brake on during the
entire procedure.
5. Move the shift lever to OD when prompted.
6. Move the shift lever to Neutral when prompted.
7. Move the shift lever back to OD when prompted.
8. Notice Quick Learn will begin to apply various clutch assemblies.
9. Move the shift lever to Park position when the scan tool prompts and indicates Quick Learn is complete.

NOTE: The owner cannot pull any loads for the next 300 miles to allow for a complete adaptation of the shifts.
It is recommended that this 300 miles be done throughout several days. There are both warm and cold shifts
that need to adapt. The miles should be done during city driving. Shifts do not adapt cruising at highway
speeds.

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