lock CHRYSLER VOYAGER 1996 Service Manual

INSTALLATION
(1) Assemble the differential side gears, pinion
gears and pinion gears with the pinion gear washers.
(2) Install pinion shaft retaining pin (Fig. 172).
(3) Stake pinion shaft retaining pin with a suitable
chisel (Fig. 173).
(4) Rotate the assembly two full revolutions both
clockwise and counterclockwise. Set up dial indicator
as shown and record end play (Fig. 174) (Fig. 175).
Rotate side gear 90 degrees and record another end
play. Again, rotate side gear 90 degrees and record a
final end play.(5) Using the smallest end play recorded, shim
that side gear to within .02540 mm to .3302 mm
(0.001 to 0.013 inch). The other side gear should be
checked using the same procedure.
CAUTION: Side gear end play must be within 02540
mm to .3302 mm (0.001 to 0.013 inch). Five select
thrust washers are available: 0.027, 0.032, 0.037,
0.042, and 0.047 inch.
SYNCHRONIZER
The 1±2 synchronizer is a dual-cone synchronizer
(Fig. 176). The disassembly and assembly procedures
are the same as the 3±4 synchronizer (Fig. 177)
Fig. 171 Differential Gears
Fig. 170 Remove Pinion Gears, Side Gears, and
Thrust Washers by Rotating Side Gears to Opening
in CaseFig. 172 Install Retaining Pin
NS/GSA±598 MANUAL TRANSAXLE 21 - 43
DISASSEMBLY AND ASSEMBLY (Continued)

(3) Install the synchro springs into the synchro
struts.
(4) Line up stop ring tang over the struts in the
hub. Install stop rings. Center the struts by pushing
on both stop rings.
(5) Install the outer cones (dual-cone synchronizer)
into the synchronizer stop rings.
(6) Install the inner cones (dual-cone synchronizer)
into the outer cones.
SHIFT COVER
The gearshift cover can be disassembled and worn
parts can be replaced individually (Fig. 178).
DISASSEMBLY
(1) Remove gearshift housing roll pin at shift lever
(Fig. 179).
(2) Remove shift selector shaft dust boot (Fig. 180).
(3) Remove selector shaft oil seal (Fig. 181).
(4) Remove shifter housing vent cap at crossover
lever (Fig. 182).(5) Remove roll pin and crossover lever at cross-
over shaft (Fig. 183).
(6) Remove the 5th/reverse gear blocker (Fig. 184).
(7) Remove the crossover shaft (Fig. 185).
Fig. 178 Gearshift Housing-Exploded View
Fig. 179 Shift Lever Roll Pin
NS/GSA±598 MANUAL TRANSAXLE 21 - 45
DISASSEMBLY AND ASSEMBLY (Continued)

(8) Remove selector shaft inner C-clip (Fig. 186).
(9) Remove selector shaft outer C-clip (Fig. 187).
Fig. 180 Dust Boot
Fig. 181 Oil Seal
Fig. 182 Vent Cap
Fig. 183 Crossover Lever and Roll Pin
Fig. 184 5th/Reverse Blocker
Fig. 185 Crossover Shaft
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DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Drive roll pin out far enough to clear the
selector shaft, but not through. The pin must
remain in the selector so not to break the housing.
(10) Remove selector shaft center roll pin (Fig.
188).
(11) Remove selector shaft from the shift housing
(Fig. 189) (Fig. 190).
ASSEMBLY
(1) Install selector shaft components and selector
shaft into shift housing.
(2) Install selector shaft roll pin flush with selec-
tor.
(3) Install outer selector shaft C-clip.
(4) Install inner selector shaft C-clip.
(5) Install crossover shaft.
NOTE: Proper torque of the 5-R blocker bolts is
very important.
(6) Install the 5th/reverse gear blocker bolts (Fig.
191).(7) Install roll pin and crossover lever at crossover
shaft
(8) Install vent cap.
Fig. 186 Inner C-clip
Fig. 187 Outer C-clip
Fig. 188 Center Roll Pin
Fig. 189 Selector Shaft Removal
Fig. 190 Selector Shaft Components
NS/GSA±598 MANUAL TRANSAXLE 21 - 47
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: The C-Clip grooves in the selector shaft will
damage the oil seal. Install oil seal after selector
shaft is installed. Always use a new oil seal when
selector shaft is removed.
(9) Install selector shaft oil seal (Fig. 192).
(10) Install selector shaft dust boot.
(11) Install selector shaft selector lever.
NOTE: Roll pin must be flush with top of lever.
TRANSAXLE CASE
INTERMEDIATE SHAFT FRONT BEARING CUP
REMOVAL
(1) Insert Special Tool 6787 into the intermediate
shaft front bearing cup (Fig. 193).
(2) Tighten the special tool so that the tool fingers
spread out and seat underneath the bearing cup.(3) Install Special Tool 3752 (Slide Hammer) onto
the Special Tool 6787.
(4) Remove the intermediate shaft front bearing
cup (Fig. 194).
(5) Remove the bearing oil feeder (if necessary).
INSTALLATION
(1) Insert the bearing oil feeder (if necessary) into
the transaxle case (Fig. 195).
Fig. 191 5±R Blocker Bolts
Fig. 192 Selector Shaft Oil Seal
Fig. 193 Special Tool 6787 Installed in Bearing Cup
Fig. 194 Remove Intermediate Shaft Front Bearing
Cup
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DISASSEMBLY AND ASSEMBLY (Continued)

REVERSE SHIFT LEVER
REMOVAL
(1) Remove reverse shift lever E-clip.
(2) Remove the flat and wave washers.
(3) Remove the reverse shift lever from the mount-
ing stud.
INSTALLATION
(1) Position the reverse shift lever onto the mount-
ing stud.
(2) Install the washers onto the mounting stud.
(3) Install the E-clip.
CLEANING AND INSPECTION
TRANSAXLE
Clean the gears, bearings, shafts, synchronizers,
thrust washers, oil feeder, shift mechanism, gear
case, and bellhousing with solvent. Dry all parts
except the bearings with compressed air. Allow thebearings to either air dry or wipe them dry with
clean shop towels.
Inspect the gears, bearings, shafts and thrust
washers. Replace the bearings and cups if the rollers
are worn, chipped, cracked, flat spotted, or brin-
nelled, or if the bearing cage is damaged or distorted.
Replace the thrust washers if cracked, chipped, or
worn. Replace the gears if the teeth are chipped,
cracked, or worn thin. Inspect the synchronizers.
Replace the sleeve if worn or damaged in any way.
Replace the stop rings if the friction material is
burned, flaking off, or worn. Check the condition of
the synchro struts and springs. Replace these parts if
worn, cracked, or distorted.
SYNCHRONIZER
CLEAN
Do not attempt to clean the blocking rings in sol-
vent. The friction material will become contaminated.
Place synchronizer components in a suitable holder
and clean with solvent. Air dry.
INSPECT
Proper inspection of components involve:
²Teeth, for wear, scuffed, nicked, burred, or bro-
ken teeth
²Struts, for wear or distortion
²Springs, for distortion, cracks, or wear
If any of these conditions exist in these compo-
nents, replace as necessary.
ADJUSTMENTS
GEARSHIFT CROSSOVER CABLE
Before replacing the gearshift cables for a hard-
shifting complaint, disconnect both cables at the
transaxle. Then, from the driver's seat, manually
operate the gearshift lever through all gear ranges. If
the gearshift lever moves smoothly, the cable(s)
should NOT be replaced. If the gear lever binds
replace the cable that is causing the binding condi-
tion. If the problem still exists, check the crossover
cable adjustment (Fig. 210).
(1) Working over the left front fender, remove the
auxiliary vent from the selector shaft housing (Fig.
211).
(2) Locate the gearshift lock pin that has been
included in the new vehicle packet located in the
glove box.
(3) Place transaxle gearshift in the neutral posi-
tion.
(4) Insert lock pin (so long end is down) into same
threaded hole (Fig. 212). A hole in the selector shaft
will align with the lock pin, allowing the lock pin to
Fig. 208 Slide Hammer 3752
Fig. 209 Shift Rail Bushing Removal
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DISASSEMBLY AND ASSEMBLY (Continued)

be screwed into the housing. This operation locks the
selector shaft in the 3-4 neutral position.
(5) Remove gearshift knob (Fig. 213).
(6) Remove gearshift boot (Fig. 214).
(7) Remove gearshift console screws and remove
the console (Fig. 215).
(8) Loosen crossover cable adjustment screw.
(9) Verify gearshift mechanism is in the neutral
position.CAUTION: Be sure crossover bellcrank does NOT
move when tightening adjusting screw.
Fig. 210 Gearshift Mechanism
Fig. 211 Auxiliary Vent Removal
Fig. 212 Lock Pin Installation
NS/GSA±598 MANUAL TRANSAXLE 21 - 53
ADJUSTMENTS (Continued)

(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
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ADJUSTMENTS (Continued)

GEARSHIFT CROSSOVER CABLE
Before replacing the gearshift cables for a hard-
shifting complaint, disconnect both cables at the
transaxle. Then, from the driver's seat, manually
operate the gearshift lever through all gear ranges. If
the gearshift lever moves smoothly, the cable(s)
should NOT be replaced. If the gear lever binds
replace the cable that is causing the binding condi-
tion. If the problem still exists, check the crossover
cable adjustment (Fig. 218).
(1) Working over the left front fender, remove the
auxiliary vent from the selector shaft housing (Fig.
219).
(2) Locate the gearshift lock pin that has been
included in the new vehicle packet located in the
glove box.
(3) Place transaxle gearshift in the neutral posi-
tion.
(4) Insert lock pin (so long end is down) into same
threaded hole (Fig. 220). A hole in the selector shaft
will align with the lock pin, allowing the lock pin to
be screwed into the housing. This operation locks the
selector shaft in the 3-4 neutral position.
(5) Remove gearshift knob (Fig. 221).
(6) Remove gearshift boot (Fig. 222).
(7) Remove gearshift console screws and remove
the console (Fig. 223).(8) Loosen crossover cable adjustment screw.
(9) Verify gearshift mechanism is in the neutral
position.
CAUTION: Be sure crossover bellcrank does NOT
move when tightening adjusting screw.
Fig. 218 Gearshift Mechanism
Fig. 219 Auxiliary Vent Removal
NS/GSA±598 MANUAL TRANSAXLE 21 - 55
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
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ADJUSTMENTS (Continued)