shaft CHRYSLER CARAVAN 2002 Service Manual

(39) Remove rear planetary gear assembly (Fig.
53).
(40) Remove #10 thrust washer (Fig. 54).(41) Remove overrunning clutch cam assembly
(Fig. 55). Collect eight rollers and eight springs from
rear of case (Fig. 56).
Fig. 53 Rear Planetary Gear Assembly
1 - REAR PLANETARY GEAR ASSEMBLY
Fig. 54 No. 10 Thrust Washer
1 - OVERRUNNING CLUTCH CAM ASSEMBLY
2 - #10 THRUST WASHER
Fig. 55 Overrunning Clutch Cam Assembly
1 - OUTPUT SHAFT
2 - OVERRUNNING CLUTCH CAM ASSEMBLY
Fig. 56 Overrunning Clutch Rollers and Spring
1 - LOW-REVERSE BAND
2 - OVERRUNNING CLUTCH ROLLERS (8)
3 - OVERRUNNING CLUTCH SPRINGS (8)
21 - 50 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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(42) Remove low/reverse band (Fig. 57).
(43)
Remove and inspect #11 thrust washer (Fig. 58).
ASSEMBLY
CAUTION: If transaxle failure has occurred, it is nec-
essary to flush the transaxle oil cooler and lines to
remove debris and particles that could contaminate
and/or fail a new or rebuilt unit. (Refer to 7 - COOLING/
TRANSMISSION - STANDARD PROCEDURE)
NOTE: This procedure does not include assembly
of final drive (differential) components. (Refer to 21- TRANSMISSION/TRANSAXLE/AUTOMATIC - 31TH/
FINAL DRIVE - ASSEMBLY)
NOTE: This procedure does not include assembly
of transfer system (transfer shaft and output shaft)
components. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 31TH/TRANSFER SYSTEM -
INSTALLATION)
(1) Install #11 thrust washer (Fig. 59).
(2) Install low/reverse band (Fig. 60). Do not
install strut or adjust at this time.
Fig. 57 Low/Reverse Band and Strut
1 - #11 THRUST WASHER
2 - LOW-REVERSE BAND
3 - STRUT
Fig. 58 No. 11 Thrust Washer
1 - #11 THRUST WASHER
2 - OUTPUT SHAFT
Fig. 59 No. 11 Thrust Washer
1 - #11 THRUST WASHER
2 - OUTPUT SHAFT
Fig. 60 Low/Reverse Band and Strut
1 - #11 THRUST WASHER
2 - LOW-REVERSE BAND
3 - STRUT
RS31TH AUTOMATIC TRANSAXLE21-51
31TH AUTOMATIC TRANSAXLE (Continued)
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(3) Assemble Tool L-4440 to overrunning clutch as
shown in (Fig. 61).
(4) Orient springs as shown on left side of (Fig.
62).
(5) Install overrunning clutch/tool assembly to
transaxle and remove Tool L-4440.(6) Install #10 thrust washer to rear of rear plan-
etary gear assembly. Use petrolatum to retain and
secure during installation.
(7) Install rear planetary gear assembly (Fig. 63).
(8) Install #9 thrust washer (Fig. 64). Use petrola-
tum to secure.
Fig. 61 Install Overrunning Clutch Rollers and
Springs
1 - TOOL L-4440
2 - ROLLER (8)
3 - OVERRUNNING CLUTCH CAM ASSEMBLY
4 - SPRING (8)
Fig. 62 Proper Spring/Roller Orientation
1 - TOOL L-4440
2 - SPRING
3 - ROLLER
4 - CONTACT AREA
Fig. 63 Rear Planetary Gear Assembly
1 - REAR PLANETARY GEAR ASSEMBLY
Fig. 64 No. 9 Thrust Washer
1 - #9 THRUST WASHER
2 - OUTPUT SHAFT
3 - REAR PLANETARY GEAR ASSEMBLY
21 - 52 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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(9) Install sun gear driving shell (Fig. 65).
(10) Install front planetary gear assembly (Fig.
66).(11) Install front planetary gear snap ring (Fig.
67).
(12) Install #3 thrust washer (Fig. 68). Refer to
end play specification recorded during transaxle dis-
assembly to determine whether or not replacement is
necessary.
Fig. 65 Sun Gear Driving Shell
1 - SUN GEAR DRIVING SHELL
2 - REAR PLANETARY GEAR
Fig. 66 Front Planetary Gear Assembly
1 - SUN GEAR
2 - FRONT PLANETARY GEAR ASSEMBLY
3 - #6 THRUST WASHER
Fig. 67 Front Planetary Gear Snap Ring
1 - FRONT PLANETARY GEAR SNAP RING
2 - SNAP RING PLIERS
3 - FRONT PLANETARY GEAR ASSEMBLY
Fig. 68 No. 3 Thrust Washer
1 - OUTPUT SHAFT
2 - SUN GEAR DRIVING SHELL
3 - #3 THRUST WASHER (SELECT FIT)
RS31TH AUTOMATIC TRANSAXLE21-53
31TH AUTOMATIC TRANSAXLE (Continued)
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(18) Inspect #1 thrust washer (on reaction support)
and replace as necessary.
(19) Install oil pump to transaxle (Fig. 73). Torque
bolts to 31 N´m (275 in. lbs.).
(20) Set up tools as shown in (Fig. 74) to measure
input shaft end play.Input shaft end play should
be within 0.19-1.50mm (0.008-0.060 in.).(21) Install park pawl, spring, and pivot shaft (Fig.
75)
(22) Install rod support and bolts (Fig. 76). Torque
bolts to 28 N´m (250 in. lbs.). (Fig. 77).
Fig. 73 Oil Pump Attaching Bolts
1 - SEAL
2 - PUMP ATTACHING BOLTS (7)
3 - PUMP HOUSING
Fig. 74 Measure Input Shaft End Play using End
Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
Fig. 75 Parking Pawl, Return Spring, and Pivot Shaft
1 - PARK PAWL
2 - RETURN SPRING
3 - NOTE: SMALL DIAMETER TO REAR
4 - PIVOT SHAFT
Fig. 76 Support and Bolts
1 - BOLT (2)
2 - PARKING SPRAG ROD SUPPORT
RS31TH AUTOMATIC TRANSAXLE21-55
31TH AUTOMATIC TRANSAXLE (Continued)
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(23) Assemble kickdown servo as shown in (Fig.
78).(24) Install kickdown servo piston assembly and
return spring (Fig. 79).
(25) Install kickdown servo rod guide (Fig. 80).
Place snap ring into position for installation.
Fig. 77 Parking Sprag Rod Support
1 - PARKING SPRAG ROD SUPPORT
2 - BOLT (2)
3 - OUTPUT SHAFT GEAR
Fig. 78 Controlled Load Kickdown Servo
1 - KICKDOWN PISTON
2 - O-RING
3 - SNAP RING
4 - PISTON ROD GUIDE
5 - SNAP RING
6 - O-RING
7 - PISTON RETURN SPRING
8 - PISTON ROD
9 - SEAL RINGS
Fig. 79 Kickdown Piston Return Spring and Piston
1 - RETURN SPRING
2 - KICKDOWN LEVER
3 - PISTON ROD
4 - KICKDOWN SERVO PISTON
Fig. 80 Kickdown Servo Rod Guide and Snap Ring
1 - SNAP RING
2 - ACCUMULATOR PLATE
3 - RETURN SPRING
4 - O-RING
5 - PISTON ROD GUIDE
21 - 56 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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(13) Install halfshafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(14) Lower vehicle.
(15) Torque rear mount bracket-to-transaxle verti-
cal bolts (Fig. 98) to 102 N´m (75 ft. lbs.).
(16) Connect back up lamp switch connector.
(17) Connect gearshift cable to manual valve and
left upper mount bracket (Fig. 102).
(18) Connect throttle valve cable to lever and
bracket (Fig. 103).
(19) Connect torque converter clutch connector.
(20) Install fluid level indicator/tube assembly
(Fig. 104).
(21) Raise vehicle on hoist.
(22) Torque rear mount bracket-to-transaxle case
horizontal bolt (Fig. 98) to 102 N´m (75 ft. lbs.).
(23) Torque rear mount thru-bolt to 54 N´m (40 ft.
lbs.).
(24) Lower vehicle.
(25) Connect battery negative cable.
(26) Fill transaxle with ATF+4 transmission fluid.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/FLUID - STANDARD PROCEDURE)
Fig. 102 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 103 Kickdown Cable at TransaxleÐTypical
1 - LEVER
2 - BRACKET
3 - THROTTLE VALVE CABLE
Fig. 104 Fluid Level Indicator Assembly
1 - INDICATOR ASSEMBLY
2 - BOLT
3 - KICKDOWN CABLE BRACKET
4 - SEAL
RS31TH AUTOMATIC TRANSAXLE21-63
31TH AUTOMATIC TRANSAXLE (Continued)
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SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE
GENERAL SPECIFICATIONS
Transaxle TypeThree speed automatic with torque converter and
integral differential
Cooling Method Air to oil heat exchanger
Lubrication Method Pump (internal-external gear-type)
GEAR RATIOS
1st Gear 2.69
2nd Gear 1.55
3rd Gear 1.00
Reverse Gear 2.10
BAND ADJUSTMENT
Kickdown (Front)ÐBacked Off From 8 N²m (72 in. lbs.) 21¤4turns
Low-Reverse (Rear)ÐBacked Off From 5 N²m (41 in.
lbs.)3
1¤2Turns
BEARING SETTINGS (END PLAY & TURNING TORQUE)
Description Metric Standard
Differential Assembly 0.7-1.4 N´m 6-12 in. lbs.
Output Shaft 0-0.3 N´m 0-3 in. lbs.
Transfer Shaft 0.051-0.254 mm 0.002-0.010 in. (end play)
Overall Drag At Output Hub 0.03-1.8 N´m 3-16 in. lbs.
CLUTCH CLEARANCES
Description Metric Standard
Front Clutch (Not Adjustable) 1.27-2.79 mm 0.050-0.110 in.
Rear Clutch 0.71-1.10 mm 0.028-0.043 in.
END PLAY
Description Metric Standard
Input Shaft 0.19-1.50 mm 0.008-0.060 in.
Front Clutch Retainer 0.76-2.69 mm 0.030-0.106 in.
Front Carrier 0.18-1.45 mm 0.007-0.057 in.
Front Annulus Gear 0.09-0.50 mm 0.0035-0.020 in.
Planet Pinion 0.15-0.59 mm 0.006-0.023 in.
Reverse Drum 0.76-3.36 mm 0.030-0.132 in.
21 - 72 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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OIL PUMP CLEARANCE
Description Metric Standard
Outer Gear-to-Pocket 0.045-0.141mm 0.0018-0.0056 in.
Outer Gear Side Clearance 0.020-0.046mm 0.0008-0.0018 in.
Inner Gear Side Clearance 0.020-0.046mm 0.0008-0.0018 in.
THRUST WASHERS
Description Metric Standard
Reaction Shaft Support (No. 1) 1.34-1.62 mm 0.053-0.064 in.
Rear Clutch Retainer (No. 2) 1.53-1.62 mm 0.060-0.064 in.
Output Shaft (No. 3) (Select) 1.96-2.03 mm 0.077-0.080 in
Output Shaft (No. 3) (Select) 2.15-2.22 mm 0.085-0.087 in.
Output Shaft (No. 3) (Select) 2.34-2.41 mm 0.092-0.095 in.
Front Annulus (No. 4) 2.95-3.05 mm 0.116-0.120 in.
Front Carrier (Nos. 5&6) 1.21-1.28 mm 0.048-0.050 in.
Sun Gear-Front (No. 7) 0.85-0.91 mm 0.033-0.036 in
Sun Gear-Rear (No. 8) 0.85-0.91 mm 0.033-0.036 in.
Rear Carrier (Nos. 9&10) 1.21-1.28 mm 0.048-0.050 in.
Rev. Drum (No. 11) 1.53-1.62 mm 0.060-0.064 in.
RS31TH AUTOMATIC TRANSAXLE21-73
31TH AUTOMATIC TRANSAXLE (Continued)
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TORQUE SPECIFICATIONS
Description N´m Ft. Lbs. In. Lbs.
Bolt, Differential Bearing Retainer-to-Case 34 Ð 300
Bolt, Differential Cover-to-Case 19 Ð 165
Bolt, Differential Ring Gear-to-Case 95 70 Ð
Bolt, Extension Housing-to-Case 28 Ð 250
Bolt, Drive Plate-to-Crankshaft 95 70 Ð
Bolt, Drive Plate-to-Torque Converter 68 50 Ð
Bolt, Governor-to-Support 7 Ð 60
Bolt, Output Gear Strap 23 17 Ð
Bolt, Oil Pan-to-Case 19 Ð 165
Bolt, Oil Pump-to-Case 31 Ð 275
Bolt, Park Rod Support-to-Case 28 Ð 250
Bolt, Reaction Support-to-Pump Body 28 Ð 250
Bolt, Sprag Retainer-to-Case 28 Ð 250
Bolt, Starter Motor-to-Transaxle 54 40 Ð
Bolt, Transaxle Case-to-Engine Block 95 70 Ð
Bolt, Transfer Gear Cover-to-Case 19 Ð 165
Bolt, Transfer Gear Strap 23 17 Ð
Bolt, Valve Body-to-Case 12 Ð 105
Fitting, Transaxle Oil Cooler-to-Case 7 Ð 60
Screw, Fluid Filter 5 Ð 45
Screw, Cooler Bypass Valve-to-Transfer Plate 5 Ð 40
Screw, Governor Counterweight 28 Ð 250
Screw, Manual Valve Lever-to-Shaft 12 Ð 105
Screw, Speedo Adapter-to-Extension Housing 7 Ð 60
Screw, Valve Body-to-Transfer Plate 5 Ð 45
Nut, Kickdown Band Adjuster Lock 47 35 Ð
Nut, Output Gear-to-Shaft 271 200 Ð
Nut, Reverse Band Adjuster Lock 14 Ð 125
Nut, Transfer Gear-to-Shaft 271 200 Ð
Plug, Pressure Tap 5 Ð 45
Plug, Rear Band Lever Pivot Shaft 7 Ð 60
Switch, Park/Neutral 34 25 Ð
21 - 74 31TH AUTOMATIC TRANSAXLERS
31TH AUTOMATIC TRANSAXLE (Continued)
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