torque CHRYSLER VOYAGER 1996 Service Manual

(10) Tighten crossover cable adjuster to 8 N´m (70
in. lbs.) (Fig. 216).CAUTION: Proper torque to the crossover cable
adjusting screw is very important.
(11) Remove lock pin from gearshift housing. Rein-
stall auxiliary vent in gear shift housing (Fig. 217).
Tighten auxiliary vent to 8 N´m (70 in. lbs.).
(12) Check for shift into first and reverse.
(13) Gearshift mechanism and cables are now
functioning properly.
(14) Install gearshift console.
(15) Install gearshift boot.
(16) Install gearshift knob.
(17) Stow gearshift lock pin in glove packet.
Fig. 213 Gearshift Knob
Fig. 214 Gearshift Boot
Fig. 215 Gearshift Console
Fig. 216 Crossover Cable Adjustment
Fig. 217 Auxiliary Vent Installation
21 - 54 A±598 MANUAL TRANSAXLENS/GS
ADJUSTMENTS (Continued)

(10) Tighten crossover cable adjuster to 8 N´m (70
in. lbs.) (Fig. 224).
CAUTION: Proper torque to the crossover cable
adjusting screw is very important.
(11) Remove lock pin from gearshift housing. Rein-
stall auxiliary vent in gear shift housing (Fig. 225).
Tighten auxiliary vent to 8 N´m (70 in. lbs.).
(12) Check for shift into first and reverse.
(13) Gearshift mechanism and cables are now
functioning properly.
(14) Install gearshift console.
(15) Install gearshift boot.
(16) Install gearshift knob.(17) Stow gearshift lock pin in glove packet.
BEARING ADJUSTMENT PROCEDURE
The A-598 (T-750) transaxle has two bearing
adjustment procedures that must be performed if the
transaxle case or related components have been
replaced. If the intermediate shaft, and/or bearing
cups and cones have been replaced, you must per-
form the intermediate shaft preload shim adjust-
ment. If the differential case, cups or cones have
Fig. 220 Lock Pin Installation
Fig. 221 Gearshift Knob
Fig. 222 Gearshift Boot
Fig. 223 Gearshift Console
21 - 56 A±598 MANUAL TRANSAXLENS/GS
ADJUSTMENTS (Continued)

been replaced, you must perform the differential
bearing preload shim adjustment. If the transaxle
case has been replaced, you must perform both pro-
cedures.
GENERAL RULES ON SERVICING BEARINGS
(1) Use extreme care when removing and install-
ing bearing cups and cones. Burrs or nicks on the
bearing seat will give a false end play reading while
gauging for proper shims. Improperly seated bearing
cups and cones are subject to low±mileage failure.
(2) Bearing cups and cones should be replaced if
they show signs of pitting or heat distress. If distress
is seen on either the cup or bearing rollers, both cup
and cone must be replaced.(3) Bearing preload and drag torque specifications
must be maintained to avoid premature bearing fail-
ures. Used (original) bearings may lose up to 50% of
their original drag torque after break in. All bearing
adjustments must be made with no other component
interference or gear intermesh.
(4) Replace bearings as a pair: If one differential
bearing is defective, replace both differential bear-
ings.
(5) Bearing cones must not be reused if removed.
(6) Turning torque readings should be obtained
while smoothly rotating in either direction.
INTERMEDIATE SHAFT BEARING PRELOAD
The intermediate shaft preload must be checked if
the housing, intermediate shaft, bearing plate, bear-
ings, or transaxle case are replaced.
The intermediate shaft bearing preload procedure
must be done with the transaxle out of the vehicle
and on a bench.
(1) Remove end cover (Fig. 226).
(2) Remove 5th shift fork roll pin (Fig. 227).
(3) Use Special Tool 6252 to hold 5th gear. Remove
input shaft 5th gear nut (Fig. 228).
(4) Remove 5th gear synchro snap ring (Fig. 229).
(5) Remove 5th gear synchro, synchro plate, and
fork.
(6) Remove 5th drive gear off of the input shaft
(Fig. 230).
(7) Remove bearing retainer plate (Fig. 231).
(8) Remove bearing preload shim (Fig. 232).
(9) Bolt down the bearing support plate in two
places (verify dowels are in place).
(10) Seat the intermediate bearing cup against the
bearing.
(11) Measure depth of intermediate bearing cup
with dial depth gauge (Fig. 233).
Fig. 224 Crossover Cable Adjustment
Fig. 225 Auxiliary Vent Installation
Fig. 226 End Cover Removed
NS/GSA±598 MANUAL TRANSAXLE 21 - 57
ADJUSTMENTS (Continued)

(14) Apply a bead of MopartGasket Maker or
equivalent onto bearing support plate. Install bearing
support plate.
(15) Install necessary shim calculated from Step
12
(16) Install bearing retainer plate. Tighten bearing
retainer plate to 17 N´m (250 in. lbs.).
(17) Install 5th drive gear onto the input shaft.
(18) Install 5th gear, synchro, fork, and plate.
(19) Install 5th gear synchro snap ring.
(20) Install 5th gear shift fork roll pin.
(21) Use Special Tool 6252 to hold 5th gear and
install new 5th gear nut at input shaft. Tighten the
retaining nut to 176 N´m (130 ft. lbs.).
(22) Use Special Tool 6930 to stake the 5th gear
retaining nut onto the input shaft (Fig. 234).
(23) Apply a bead of MopartGasket Maker or
equivalent onto end cover. Install 5th gear/synchro
end cover. Tighten bolts to 28 N´m (250 in. lbs.).
SPECIFICATIONS
A-598 (T-750) MANUAL TRANSAXLE
DESCRIPTION TORQUE
Back-up Lamp Switch..........27N´m(20ft.lbs.)
Bearing Retainer Plate........28N´m(250 in. lbs.)
Crossover Cable Adj. Screw......8N´m(70in.lbs.)
Drain Plug..................23N´m(17ft.lbs.)
Differential Housing...........54N´m(40ft.lbs.)
Diff. Bearing Retainer.........61N´m(45ft.lbs.)
Diff. Ring Gear Bolts..........94N´m(70ft.lbs.)
End Cover Bolts..............28N´m(21ft.lbs.)
Extension Housing...........28N´m(250 in. lbs.)
Gearshift Housing...........28N´m(250 in. lbs.)
*Input Gear Nut............176 N´m (130 ft. lbs.)
Input Retainer..............28N´m(250 in. lbs.)
Reverse Blocker.............12N´m(105 in. lbs.)
Transaxle Case Bolts..........29N´m(21ft.lbs.)
Vehicle Speed Sensor...........7N´m(60in.lbs.)
Vent........................6N´m(60in.lbs.)
NOTE: *The 5th/input gear is torqued to specifica-
tion and then staked in two places using Special
Tool 6930.
NOTE: Bolts that have thread sealer or torque lock
patches should not be reused. Always install new
bolts in these applications.
A-558 MANUAL TRANSAXLEÐRHD VEHICLES
DESCRIPTION TORQUE
Back-up Lamp Switch..........27N´m(20ft.lbs.)
Bearing Retainer Plate........28N´m(250 in. lbs.)
Crossover Cable Adj. Screw......8N´m(70in.lbs.)
Drain Plug..................23N´m(17ft.lbs.)
Modular Clutch to Drive
Plate Bolts................74N´m(55ft.lbs.)
Transaxle Case Bolts..........29N´m(21ft.lbs.)
Vehicle Speed Sensor...........7N´m(60in.lbs.)
Vent........................6N´m(60in.lbs.)
Fig. 233 Measure Depth Of Cup
Fig. 234 Staking 5th Gear Retaining Nut
NV T750 (A-598) MANUAL TRANSAXLE FLUID
FILL
TRANSAXLEMETRIC MEA-
SUREU.S. MEASURE
NV T750 1.9-2.2 Liters 2.0-2.3 Quarts
NS/GSA±598 MANUAL TRANSAXLE 21 - 59
ADJUSTMENTS (Continued)

SERVICE PROCEDURES
TIRE AND WHEEL ROTATION (NON-DIRECTIONAL
THREAD PATTERN)
Tires on the front and rear axles operate at differ-
ent loads and perform different functions. For these
reasons, they wear at unequal rates, and tend to
develop irregular wear patterns. These effects can be
reduced by timely rotation of tires. The benefits of
rotation are especially worthwhile. Rotation will
increase tread life, help to maintain mud, snow, and
wet traction levels, and contribute to a smooth, quiet
ride.
The suggested rotation method is the forward-cross
tire rotation method (Fig. 6). This method takes
advantage of current tire industry practice which
allows rotation of radial-ply tires. Other rotation
methods may be used, but may not have all the ben-
efits of the recommended method.
NOTE: Only the 4 tire rotation method may be used
if the vehicle is equipped with a low mileage or tem-
porary spare tire.
REPAIRING TIRE LEAKS
For proper repairing, a radial tire must be removed
from the wheel. Before dismounting the tire from the
wheel, a reference mark should be placed on the tire
at the valve stem location. This reference mark will
ensure that the tire is remounted back on the wheel
in its original position. Repairs should only be made
if the defect, or puncture, is in the tread area (Fig.
7). The tire should be replaced if the puncture is
located in the sidewall.Deflate tire completely before dismounting tire
from the wheel. Use lubrication such as a mild soap
solution when dismounting or mounting tire. Use
tools free of burrs or sharp edges which could dam-
age the tire or wheel rim.
Before mounting tire on wheel, make sure all rust
is removed from the rim bead and repaint if neces-
sary.
Install wheel on vehicle, and progressively tighten
all 5 wheel nuts to a torque of 135 N´m (100 ft. lbs.).
TIRE AND WHEEL MATCH MOUNTING
Wheels and tires are match mounted at the factory.
This means that the high spot of the tire is matched
to the low spot on the wheel rim. This technique is
used to reduce run-out in the wheel/tire assembly.
The high spot on the tire is marked with a paint
mark or a bright colored adhesive label on the out-
board sidewall. The low spot on the rim is identified
with a label on the outside of the rim and a dot or
line on the inside of the rim. If the outside label has
been removed the tire will have to be removed to
locate the dot or line on the inside of the rim.
Before dismounting a tire from its wheel, a refer-
ence mark should be placed on the tire at the valve
stem location. This reference will ensure that it is
remounted in the original position on the wheel.
(1) Measure the total indicator runout on the cen-
ter of the tire tread rib. Record the indicator reading.
Mark the tire to indicate the high spot. Place a mark
on the tire at the valve stem location (Fig. 8).
(2) Break down the tire and remount it 180
degrees on the rim (Fig. 9).
(3) Measure the total indicator runout again. Mark
the tire to indicate the high spot.
Fig. 6 Forward-Cross Tire Rotation Method
Fig. 7 Tire Repair Area
22 - 6 TIRES AND WHEELSNS

WARNING: REPLACEMENT WITH USED WHEELS
IS NOT RECOMMENDED. THE SERVICE HISTORY
OF THE RIM MAY HAVE INCLUDED SEVERE TREAT-
MENT OR VERY HIGH MILEAGE. THE RIM COULD
FAIL WITHOUT WARNING.
TIRE AND WHEEL RUNOUT
NOTE: Runout should always be measured off the
vehicle and on a suitable balance machine.
Radial run out is the difference between the high
and low points on the outer edge of the tire or wheel.
Lateral run out is the total side±to±side wobble of
the tire or wheel.
Radial run out of more than 0.762 mm (.030 inch)
measured at the center line of the tread may cause
the vehicle to shake.
Lateral run out of more than 0.762 mm (.030 inch)
measured at the side of the tire as close to the tread
as possible may cause the vehicle to shake.
Sometimes radial run out can be reduced by relo-
cating the wheel and tire on the wheel studs (See
Method 1). If this does not reduce run out to an
acceptable level, the tire can be rotated on the wheel.
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
Check accuracy of the wheel mounting surface;
adjust wheel bearings.
Drive vehicle a short distance to eliminate tire flat
spotting from a parked position.
Verify all wheel nuts are properly torqued (Fig. 2).
Use run out gauge D-128-TR to determine run out
(Fig. 3).
Relocate the wheel on the mounting studs, two
studs over from the original position.
Retighten wheel nuts until all are properly
torqued. This will prevent brake distortion.Check radial run out. If still excessive, mark tire
sidewall, wheel, and stud at point of maximum run
out (Fig. 4) and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
Rotating tire on wheel is particularly effective
when there is run out in both tire and wheel.
Remove tire from wheel and remount wheel on hub
in former position.
Check the radial run out of the wheel (Fig. 5). The
radial run out should be no more than 0.5 mm (0.020
inch) for steel wheels and 0.38 mm (0.015 inch) for
cast aluminum wheels.
Check the lateral run out of the wheel (Fig. 6). The
lateral runout should be no more than 0.8 mm (0.032
inch).
If the point of greatest wheel radial run out is near
the original chalk mark, remount the tire on the rim
180 degrees from its original position. Recheck the
run out. If this does not reduce the run out to an
acceptable level, replace the wheel and/or the tire.
Fig. 2 Tightening Wheel Nuts
Fig. 3 Run Out Gauge
Fig. 4 Chalk Marking On Wheel, Tire And Stud
22 - 10 TIRES AND WHEELSNS
DIAGNOSIS AND TESTING (Continued)

SERVICE PROCEDURES
WHEEL INSTALLATION
To install the wheel, first position it properly on
the mounting surface of the hub using the hub pilot
as a guide. All wheel nuts should be lightly tightened
before progressively tightening them in the proper
sequence (Fig. 7). Then fully tighten the wheel nuts
in the proper sequence (Fig. 7) to a torque of 135
N´m (100 ft. lbs.). Never use oil or grease on studs or
nuts.
TIRE AND WHEEL BALANCE
Balancing need is indicated by vibration of seats,
floor pan, or steering wheel. The vibration will be
noticed mostly when driving over 90 km/h (55 mph)
on a smooth road.
It is recommended that a two plane dynamic bal-
ancer be used when a wheel and tire assembly
require balancing. Static balancing should be used
only when a two plane balancer is not available.
Off-vehicle tire and wheel balancing is recom-
mended to be used on this vehicle.
NOTE: If on vehicle equipment is being used to bal-
ance the tire /wheel assemblies, remove the oppo-
site tire/wheel from the vehicle.
For static balancing, find the location of heavy spot
on tire/wheel causing the imbalance. Counter balance
wheel directly opposite the heavy spot. Determine
weight required to counterbalance the area of imbal-
ance. Place half of this weight on theinnerrim
flange and the other half on theouterrim flange
(Fig. 8).
For dynamic balancing, the balancing equipment is
designed to indicate the location and amount of
weight to be applied to both the inner and outer rim
flanges (Fig. 9).
Fig. 5 Checking Wheel Radial Run Out
Fig. 6 Checking Wheel Lateral Run Out
Fig. 7 Tightening Wheel Nuts
NSTIRES AND WHEELS 22 - 11
DIAGNOSIS AND TESTING (Continued)

SPECIFICATIONS
WHEEL SPECIFICATIONS
Wheel:
Mounting Stud Size..............M12 x 1.5mm
Mounting Stud Lug Nut Hex Size.........19mm
Mounting Lug Nut Tightening
Torque................135 N´m (100 ft. lbs.)
Fig. 8 Static Unbalance & Balance
Fig. 9 Dynamic Unbalance & Balance
22 - 12 TIRES AND WHEELSNS
SERVICE PROCEDURES (Continued)

NOTE: Tighten nuts to 3.4 N´m (30 in. lbs.) torque
in the sequence indicated. Do not over torque, or
glass breakage may result (Fig. 6).
(4) Install interior trim.
REAR WINDOW
Refer to the Safety Precautions in this section for
description of tools and adhesive systems that are
recommended for use in this procedure.
REAR WINDOW REMOVAL ± EXTERIOR
METHOD
(1) Remove rear window wiper arm, if equipped.
(2) Remove screws holding moldings to liftgate at
the sides of the rear window (Fig. 7).
(3) Using pliers, pull outward on molding at the
top and bottom of liftgate.
(4) Using a sharp cold knife, cut urethane adhe-
sive holding the rear window to the liftgate. A power
cutting device can be used if available (Fig. 2).
(5) Remove rear window from vehicle.
REAR WINDOW REMOVAL ± INTERIOR
METHOD
(1) Remove rear window wiper arm, if equipped.
(2) Remove screws holding moldings to liftgate at
the sides of the rear window (Fig. 7).
(3) Remove liftgate inside lamps and trim covers.
(4) Remove center high mounted stop lamp.
(5) Using a reciprocating or oscillating power
knife, cut urethane adhesive holding the rear window
to the liftgate. Refer to instructions provided with
the equipment being used.
(6) Remove rear window from vehicle.
REAR WINDOW INSTALLATION
CAUTION: Open the left front door glass before
installing rear window to avoid pressurizing the
passenger compartment. If a door is slammed
before urethane bonding is cured, water leaks can
result.
Allow the urethane at least 24 hours to cure
before returning the vehicle to use.
To avoid stressing the replacement rear window,
the urethane bonding material on the rear window
fence should be smooth and consistent to the
shape of the replacement glass.
(1) Place replacement glass into rear window open-
ing.
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement rear window. If not, the fence must be
formed to the shape of the new glass.
(3) Using a grease pencil, mark the glass and lift-
gate in several locations to aid installation.
(4) Remove replacement glass from liftgate open-
ing.
(5) Position the rear window inside up on a suit-
able work surface with two padded, wood 10 cm by
10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks,
placed parallel 75 cm (2.5 ft.) apart (Fig. 4).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN REAR WINDOW BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(6) Clean inside of rear window with ammonia
based glass cleaner and lint-free cloth.
(7) Apply molding to top and bottom of rear win-
dow.
(8) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of rear window and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible.
(9) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of rear window. Allow at least three min-
utes drying time.
(10) Apply Pinchweld Primer 15 mm (.75 in.) wide
around the rear window fence. Allow at least three
minutes drying time.
(11) If a low viscosity urethane adhesive is used,
install compression spacers on the fence around the
rear window opening (Fig. 8).
(12) Apply a 10 mm (0.4 in.) bead of urethane
along center line of rear window fence.
Fig. 7 Rear Window Side Moldings
NSBODY 23 - 7
REMOVAL AND INSTALLATION (Continued)

(7) Tighten attaching bolts to 11 to 16 N´m (100 to
140 in. lbs.) torque.
HOOD LATCH STRIKER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts holding striker to inside of hood
(Fig. 44).
(3) Remove hood latch striker from vehicle.
INSTALLATION
(1) Position hood latch striker on vehicle.
(2) Install bolts to hold hood latch striker to hood.
(3) Align hood latch striker to engage smoothly
into hood latch.
(4) Verify hood operation and alignment. Adjust as
necessary.
(5) Tighten attaching bolts to 11 to 16 N´m (100 to
140 in. lbs.) torque.
HOOD RELEASE CABLE
REMOVAL
(1) Remove hood latch.
(2) Disengage cable end from hood latch locking
mechanism.
(3) Slide cable case end sideways in keyhole slot of
hood latch while pinching barb on cable case closed.
(4) Remove cable from latch (Fig. 47).
(5) Remove hood release handle from instrument
panel.
(6) Disengage rubber grommet cable insulator
from hole in dash panel.
(7) Attach a suitable length of mechanic's wire to
latch end of cable to assist cable installation.
(8) Route cable back from latch through engine
compartment toward dash panel near power brake
booster (Fig. 48).
(9) Remove attaching clips from cable case.
(10) From inside vehicle, pull cable through dash
panel until mechanic's wire is exposed.
(11) Disconnect cable from mechanic's wire.(12) Remove hood release cable from vehicle.
INSTALLATION
(1) Place hood release cable in position under
instrument panel.
(2) Attach latch end of hood release cable to
mechanic's wire protruding through dash panel.
(3) Route cable forward through engine compart-
ment toward latch by pulling on mechanic's wire
(Fig. 48).
(4) Disconnect mechanic's wire from cable.
(5) Engage rubber grommet cable insulator into
hole in dash panel.
(6) Install hood release handle into instrument
panel.
(7) Place cable in position on latch.
(8) Slide cable case end sideways into keyhole slot
of hood latch.
(9) Engage cable end into hood latch locking mech-
anism.
(10) Install hood latch.
(11) Install attaching clips to cable case and install
clips into original holes in strut tower, fender, head-
lamp area, and radiator closure panel crossmember.
HOOD RELEASE HANDLE
REMOVAL
(1) Remove lower steering column cover and knee
blocker reinforcement. Refer to Group 8E, Instru-
ment Panel and Systems for proper procedures.
(2) Remove hood latch cable.
(3) Remove screws holding hood latch release han-
dle to instrument panel brace (Fig. 49).
(4) Remove hood latch release handle from vehicle.
INSTALLATION
(1) Position hood latch release handle on vehicle.
(2) Install screws to hold hood latch release handle
to instrument panel brace.
Fig. 47 Hood Release Cable End Attachment
Fig. 48 Hood Release Cable Routing
23 - 42 BODYNS
REMOVAL AND INSTALLATION (Continued)