differential CHRYSLER CARAVAN 2002 Owners Manual

1ST GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft first gear is integral to the input shaft,
and is in constant mesh with the intermediate shaft
first speed gear. Because of this constant mesh, the
intermediate shaft first speed gear freewheels until
first gear is selected. As the gearshift lever is moved
to the first gear position, the 1-2 fork moves the 1-2
synchronizer sleeve towards first gear on the inter-
mediate shaft. The synchronizer sleeve engages the
first gear clutch teeth, fixing the gear to the interme-
diate shaft, and allowing power to transmit through
the intermediate shaft to the differential (Fig. 4).
Fig. 4 1st Gear Operation
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3RD GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft third speed gear is in constant mesh with
the intermediate shaft 3-4 cluster gear, which is fixed
to the intermediate shaft. Because of this constant
mesh, the input shaft third speed gear freewheels
until third gear is selected. As the gearshift lever is
moved to the third gear position, the 3-4 fork moves
the 3-4 synchronizer sleeve towards third gear on the
input shaft. The synchronizer sleeve engages the
third gear clutch teeth, fixing the gear to the input
shaft, and allowing power to transmit through the
intermediate shaft to the differential (Fig. 6).
Fig. 6 3rd Gear Operation
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5TH GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft fifth gear is pressed on to the input shaft,
and is in constant mesh with the intermediate shaft
fifth speed gear. Because of this constant mesh, the
intermediate shaft fifth speed gear freewheels until
fifth gear is selected. As the gearshift lever is moved
to the fifth gear position, the 5-R fork moves the 5-R
synchronizer sleeve towards the intermediate shaft
fifth speed gear. The synchronizer sleeve engages the
fifth gear clutch teeth, fixing the gear to the input
shaft, and allowing power to transmit through the
intermediate shaft to the differential (Fig. 8).
Fig. 8 5th Gear Operation
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REVERSE GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft reverse gear is integral to the input
shaft, and is in constant mesh with the reverse idler
gear. The reverse idler gear, which reverses the rota-
tion of the intermediate shaft, is in constant mesh
with the intermediate shaft reverse gear. Because of
this constant mesh, the intermediate shaft reverse
gear freewheels until reverse gear is selected. As the
gearshift lever is moved to the reverse gear position,
the 5-R fork moves the 5-R synchronizer sleeve
towards the intermediate shaft reverse gear. The
synchronizer sleeve engages the reverse gear clutch
teeth, fixing the gear to the intermediate shaft, and
allowing power to transmit through the intermediate
shaft to the differential (in reverse) (Fig. 9).
Fig. 9 Reverse Gear Operation
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(16) Remove reverse idler bolt (Fig. 39). Remove
reverse idler gear, washers, and shaft upon geartrain
removal.
(17) Remove 1-2/5-R shift rail (Fig. 40).(18) Install lifting bar 8489.
(19) Lift geartrain (w/reverse idler gear assy.) out
of transaxle and install on fixture 8487 (Fig. 41).
(20) Remove remaining shift rail and forks from
geartrain (Fig. 41).
(21) Remove lifting bar from geartrain.
NOTE: At this point, differential bearing turning
torque should be measured to ensure proper shim
selection upon reassembly.
(22) Reinstall and torque extension housing and
measure differential turning torque. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/DIFFER-
ENTIAL - ADJUSTMENTS)
(23) Remove differential cover bolts.
(24) Remove differential cover. If necessary, use a
soft tipped hammer to aid in removal.
(25) Remove extension housing.
Fig. 39 Reverse Idler Shaft Bolt
Fig. 40 1/2-5/R Shift Rail Removal/Installation
1 - 1/2-5/R SHIFT RAIL
Fig. 41 Shift Fork/Rail Orientation
1 - 5/R FORK
2 - 3/4 RAIL ASSEMBLY
3 - 3/4 FORK
4 - 1/2 FORK
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(26) Remove differential assembly. Note orienta-
tion of shim, oil slinger, and differential side bearing
races (Fig. 42).
(27) Remove differential chip collector magnet and
clean (Fig. 43).Magnet is adhered with RTV, and
may require force to remove.(28) Remove intermediate shaft bearing race with
puller 8472 (Fig. 44).
(29) Remove shift rail bushing from case with
remover 6786 and slide hammer C-3752 (Fig. 45).
Fig. 42 Differential Shim/Slinger Orientation
1 - SLINGER
2 - BEARING RACE
3 - DIFFERENTIAL ASSEMBLY
4 - SHIM (SELECT)
Fig. 43 Differential Magnet
1 - MAGNET
Fig. 44 Intermediate Shaft Bearing Race Removal
1 - REMOVER 8472
Fig. 45 Shift Rail Bushing Removal
1 - SLIDE HAMMER C-3752
2 - REMOVER 6786
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(30) Remove input shaft bearing using an arbor
press and tool 8474 (Fig. 46).
ASSEMBLY
NOTE: When assembling this transaxle, always use
NEW snap rings.
NOTE: Before assembling transaxle, differential
turning torque must be measured and adjusted.
(Refer to 21 - TRANSMISSION/TRANSAXLE/MANU-
AL/DIFFERENTIAL - ADJUSTMENTS). Differential
turning torque must be measured with geartrain out
of case.
(1) Install input shaft bearing using an arbor press
and remover/installer 8474 (Fig. 47).
(2) Install shift shaft bushing to case using
installer 8475 (Fig. 48).
Fig. 46 Input Shaft Bearing Removal
1 - ARBOR PRESS
2 - DRIVER HANDLE C-4171
3 - REMOVER/INSTALLER 8474
Fig. 47 Input Shaft Bearing Installation
1 - ARBOR PRESS
2 - C-4171 DRIVER HANDLE
3 - REMOVER/INSTALLER 8474
4 - INPUT SHAFT BEARING
Fig. 48 Shift Shaft Bushing Installation
1 - INSTALLER 8475
2 - SHIFT SHAFT BUSHING
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(23) Install back up lamp switch and torque to 23
N´m (17 ft. lbs.) (Fig. 66).
(24) Roll transaxle assembly on side.
(25) Install differential chip collector magnet (Fig.
67). Retain to case with a dab of MopartGear Lube
RTV.
(26) Install differential assembly with bearing
races and select shim (Fig. 68). Shim selection was
determined before transaxle assembly (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/DIFFER-
ENTIAL - ADJUSTMENTS).
(27) Installa1mm(0.04 in.) bead of MopartGas-
ket Maker to differential cover and install to case.
Torque differential cover-to-case bolts to 54 N´m (40
ft. lbs.).
(28) Installa1mm(0.04 in.) bead of MopartGas-
ket Maker to extension housing. Install extensionhousing to differential cover and case and torque
bolts to 28 N´m (250 in. lbs.) (Fig. 69).
Fig. 66 Back-Up Lamp Switch
1 - BACK-UP LAMP SWITCH
Fig. 67 Differential Magnet
1 - MAGNET
Fig. 68 Differential Shim/Slinger Orientation
1 - SLINGER
2 - BEARING RACE
3 - DIFFERENTIAL ASSEMBLY
4 - SHIM (SELECT)
Fig. 69 Extension Housing-to-Case Bolts
1 - EXTENSION HOUSING
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(11) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(12) Lower vehicle.
(13) Install right mount bracket to transaxle (Fig.
80).
(14) Connect gearshift cables to shift levers/cover
assembly (Fig. 81). Install cables into position at
mount bracket and secure with retaining clips.
(15) Connect battery cables.
(16) Check transaxle fluid and engine coolant lev-
els. Adjust if necessary. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/FLUID - STANDARD
PROCEDURE)
Fig. 80 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 81 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
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(7) Install starter motor into position (Fig. 84).
Install and torque bolts to 54 N´m (40 ft. lbs.).
(8) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).
(9) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs (Fig. 85). Whiledepressing inward, rotate slave cylinder clockwise
60É into position until nylon locating tab rests within
transaxle case cutout, and hydraulic tube is vertical.
Connect ªquick-connectº connection until an audible
ªclickº is heard. Verify connection by pulling outward
on connection.
(10) Install underbody splash panel.
(11) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(12) Lower vehicle.
(13) Install right mount bracket to transaxle (Fig.
86).
Fig. 85 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 84 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 86 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
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