engine CHRYSLER VOYAGER 1996 Service Manual

sealers should be avoided, since they may adversely
affect seals.
SPECIAL ADDITIVESÐRHD VEHICLES
The addition of any fluids to the transaxle, other
than the fluid listed above, is not recommended. An
exception to this policy is the use of special dyes to
aid in detecting fluid leaks. The use of transmission
sealers should be avoided, since they may adversely
affect seals.
GEAR RATIOS
Gear ratios for the 2.4L gasoline engine and 2.5L
Turbo Diesel MTX are as follows:
²1stÐ3.36
²2ndÐ1.90
²3rdÐ1.28
²4thÐ0.92
²5thÐ0.71
²ReverseÐ3.17
Final drive ratio of 3.88 was selected for maximum
performance. All forward gears are synchronized.
Gear ratios for the 2.0L GAS MTX are as follows:
²1stÐ3.69
²2ndÐ2.24
²3rdÐ1.45
²4thÐ1.03
²5thÐ0.81
²ReverseÐ3.17
Final drive ratio of 4.08 was selected for maximum
performance. All forward gears are synchronized.
GEAR RATIOSÐRHD VEHICLES
Gear ratios for the 2.0L GAS MTX are as follows:
²1stÐ3.69
²2ndÐ2.24
²3rdÐ1.45
²4thÐ0.1.03
²5thÐ0.81
²ReverseÐ3.17
Final drive ratio of 4.08 was selected for maximum
performance. All forward gears are synchronized.
GEARSHIFT PATTERN
The A-598 transaxle shift pattern is a H±pattern
(Fig. 3). Overdrive fifth and reverse gears are in±line
and to the right of the first through fourth gear posi-
tions.
GEARSHIFT PATTERNÐRHD VEHICLES
The A-558 transaxle shift pattern is a H±pattern
(Fig. 4). Overdrive fifth and reverse gears are in±line
and to the right of the first through fourth gear posi-
tions.
DESCRIPTION AND OPERATION
GEARSHIFT LEVERS
The gear shift levers at the transaxle are service-
able in the vehicle. The shift levers are different from
each other and do not interchange. The select lever is
not interchangeable with model years earlier than 96
(length is different).
AXLE SEALS
The axle shaft seals are identical for both sides of
the differential and will interchange.
DIAGNOSIS AND TESTING
COMMON PROBLEM CAUSES
The majority of transaxle malfunctions are a result
of:
²Insufficient lubrication
²Incorrect lubricant
²Misassembled or damaged internal components
Fig. 3 A-598 Shift Pattern
Fig. 4 A-558 Shift Pattern
NS/GSA±598 MANUAL TRANSAXLE 21 - 3
GENERAL INFORMATION (Continued)

²Improper operation
HARD SHIFTING
Hard shifting may be caused by a misadjusted
crossover cable. If hard shifting is accompanied by
gear clash, synchronizer clutch and stop rings or gear
teeth may be worn or damaged.
Misassembled synchronizer components also cause
shifting problems. Incorrectly installed synchronizer
sleeves, struts, or springs can cause shift problems.
NOISY OPERATION
Transaxle noise is most often a result of worn or
damaged components. Chipped, broken gear or syn-
chronizer teeth, and brinnelled, spalled bearings all
cause noise.
Abnormal wear and damage to the internal compo-
nents is frequently the end result of insufficient
lubricant.
SLIPS OUT OF GEAR
Transaxle disengagement may be caused by mis-
aligned or damaged shift components, or worn teeth
on the drive gears or synchronizer components. Incor-
rect assembly also causes gear disengagement.
LOW LUBRICANT LEVEL
Insufficient transaxle lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method. Leakage is evident by the presence of oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill.
If air±powered lubrication equipment is used to fill
a transaxle, be sure the equipment is properly cali-
brated. Equipment out of calibration can lead to an
underfill condition.
The transaxle fill plug is located on the lower left
side of the transaxle end cover. With the vehicle at a
level position, remove the fill plug and check the
level of the lubricant. The lubricant level should be
within 3.175mm (1/8 inch) from the bottom of the fill
hole. If the lubricant level is low, fill the transaxle to
the bottom of the fill hole with SAE 5W-30 engine oil,
meeting SG and/or SG-CD qualifications, as the fac-
tory fill lubricant. SAE GL5 10W-40 engine oil is a
suitable service fill alternative.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash, and noise.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
SERVICE PROCEDURES
FLUID DRAIN AND FILL
TRANSAXLE FLUID DRAIN
(1) Hoist vehicle.
(2) Install a drain pan underneath the transaxle
drain plug.
(3) Remove the transaxle drain plug. The drain
plug is located on the bottom of the transaxle hous-
ing.
(4) Let fluid drain out till there is just an occa-
sional drip.
(5) Reinstall drain plug. Tighten drain plug to 28
N´m (250 in. lbs.)
TRANSAXLE FLUID FILL
NOTE: All A-598 transaxles are equipped with a fill
plug. The fill plug is located on the end cover side
of the transaxle.
(1) Remove transaxle fill plug
The fluid level should be within 3.175mm (1/8
inch) from the bottom of the transaxle fill hole (vehi-
cle must be level when checking).
(2) Fill transaxle to proper level with SAE 5W-30
engine oil, meeting SG and/or SG-CD qualifications.
G5 SAE 10W-40 engine oil is a suitable service fill
alternative. Dry fill lubricant capacity is approxi-
mately 1.9-2.2 liters (4.0-4.6 pints)..
(3) Wipe the outside of the transaxle if any lubri-
cant spills.
(4) Reinstall transaxle fill plug.
FLUID DRAIN AND FILLÐRHD VEHICLES
TRANSAXLE FLUID DRAIN
(1) Hoist vehicle.
(2) Install a drain pan underneath the transaxle
drain plug.
(3) Remove the transaxle drain plug. The drain
plug is located on the bottom of the transaxle hous-
ing (Fig. 5).
(4) Let fluid drain out till there is just an occa-
sional drip.
(5) Reinstall drain plug. Tighten drain plug to 28
N´m (250 in. lbs.)
TRANSAXLE FLUID FILL
NOTE: All A-558 transaxles are equipped with a fill
plug. The fill plug is located on the end cover side
of the transaxle.
(1) Remove transaxle fill plug
21 - 4 A±598 MANUAL TRANSAXLENS/GS
DIAGNOSIS AND TESTING (Continued)

The fluid level should be within 3.175mm (1/8
inch) from the bottom of the transaxle fill hole (vehi-
cle must be level when checking).
(2) Fill transaxle to proper level with SAE 5W-30
engine oil, meeting SG and/or SG-CD qualifications.
G5 SAE 10W-40 engine oil is a suitable service fill
alternative. Dry fill lubricant capacity is approxi-
mately 1.9-2.2 liters (4.0-4.6 pints).
(3) Wipe the outside of the transaxle if any lubri-
cant spills.
(4) Reinstall transaxle fill plug.
REMOVAL AND INSTALLATION
GEARSHIFT KNOB
REMOVAL
(1) Pull shifter boot down and away from shifter
roll pin.
(2) Pry legs of shift knob away from shift lever roll
pin using a flat blade pry tool (Fig. 6).(3) Remove knob from shifter handle.
INSTALLATION
(1) For installation, reverse removal procedure,
omitting step (2).
GEARSHIFT BOOT
REMOVAL
(1) Remove shifter knob. Refer to gearshift knob
removal.
(2) Pull up on boot until retention clips disengage
from the console and remove (Fig. 7).
INSTALLATION
(1) For installation, reverse removal procedure,
taking care to fully engage the retention clips.
GEARSHIFT BOOT
REMOVAL
(1) Remove shifter knob. Refer to gearshift knob
removal.
(2) Pull up on boot until retention clips disengage
from the console and remove (Fig. 8).
INSTALLATION
(1) For installation, reverse removal procedure,
taking care to fully engage the retention clips.
GEARSHIFT CABLES
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly.
(3) Disconnect gearshift cable ends from transaxle
shift levers (Fig. 9) (Fig. 10).
CAUTION: Pry up with equal force on both sides of
shifter cable isolator bushings to avoid damaging
cable isolator bushings.
Fig. 5 Transaxle Drain Plug
Fig. 6 Shifter Knob
Fig. 7 Shifter Boot
NS/GSA±598 MANUAL TRANSAXLE 21 - 5
SERVICE PROCEDURES (Continued)

(4) Remove cable to bracket retaining clips at tran-
saxle (Fig. 11).CAUTION: It is recommended that new cable retain-
ing clips be used for reinstallation.
(5) Pull cables up out of engine mount bracket.
(6) Remove gearshift knob and boot. Refer to Knob
and Boot Removal in this section.
(7) Remove console screws (Fig. 12).
(8) Remove cable retaining clips at shifter (Fig. 13)
(Fig. 14).
CAUTION: It is recommended that new cable retain-
ing clips be used for reinstallation. Clips must be
installed to span the slotted holes.
(9) Disconnect shift cables from shifter. Pry with
equal force on both sides of shifter cable isolator
bushings to avoid damaging bushings.
(10) Lift vehicle on hoist. Cut gearshift cable tie
strap at floor pan with diagonal cutters.
(11) Remove shift cables from vehicle by grasping
cables and grommets one at a time and tugging down
through floor pan holes (Fig. 15).
Fig. 8 Gearshift Boot
Fig. 9 Crossover Lever Shift Cable
Fig. 10 Selector Lever Shift Cable
Fig. 11 Cable Retaining Clip
Fig. 12 Gearshift Console
21 - 6 A±598 MANUAL TRANSAXLENS/GS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) To install, reverse removal procedure. After
cables have been replaced, cable adjustment should
be checked. Refer to cable adjustment procedure in
this section.
NOTE: High temperature tie straps must be used
when replacing cable(s). Locate the new tie strap at
the white band on the crossover cable and cinch
cables tightly together.
CAUTION: Only the crossover cable is adjustable.
The selector cable does not have any adjustment
capabilities.
GEARSHIFT CABLESÐRHD VEHICLES
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly.(3) Disconnect gearshift cable ends from transaxle
shift levers (Fig. 16) (Fig. 17).
CAUTION: Pry up with equal force on both sides of
shifter cable isolator bushings to avoid damaging
cable isolator bushings.
(4) Remove cable to bracket retaining clips at tran-
saxle (Fig. 18).
CAUTION: It is recommended that new cable retain-
ing clips be used for reinstallation.
(5) Pull cables up out of engine mount bracket.
(6) Remove gearshift knob and boot. Refer to Knob
and Boot Removal in this section.
(7) Remove console screws (Fig. 19).
(8) Remove cable retaining clips at shifter (Fig. 20)
(Fig. 21).
CAUTION: It is recommended that new cable retain-
ing clips be used for reinstallation. Clips must be
installed to span the slotted holes.
(9) Disconnect shift cables from shifter. Pry with
equal force on both sides of shifter cable isolator
bushings to avoid damaging bushings.
(10) Lift vehicle on hoist. Cut gearshift cable tie
strap at floor pan with diagonal cutters.
(11) Remove shift cables from vehicle by grasping
cables and grommets one at a time and tugging down
through floor pan holes (Fig. 22).
INSTALLATION
(1) To install, reverse removal procedure. After
cables have been replaced, cable adjustment should
be checked. Refer to cable adjustment procedure in
this section.
NOTE: High temperature tie straps must be used
when replacing cable(s). Locate the new tie strap at
the white band on the crossover cable and cinch
cables tightly together.
CAUTION: Only the crossover cable is adjustable.
The selector cable does not have any adjustment
capabilities.
GEARSHIFT MECHANISM REPLACEMENT
REMOVAL
(1) Remove shifter knob and boot. refer to Shifter
Knob And Boot Removal procedure in this section.
(2) Remove console assembly. Refer to Console
Removal procedure in this section.
Fig. 13 Selector Cable Clip
Fig. 14 Crossover Cable Clip
NS/GSA±598 MANUAL TRANSAXLE 21 - 7
REMOVAL AND INSTALLATION (Continued)

DIFFERENTIAL BEARING RETAINER AXLE
SEAL
REMOVAL
(1) Remove axle shaft. Refer to Group 2, Suspen-
sion and Driveshafts for service procedures.
(2) Insert a flat±blade pry tool into the axle seal
bore.
(3) Using the pry tool, carefully pop out the seal
taking care not to nick the seal bore.
INSTALLATION
(1) Clean axle shaft seal bore of any excess seal-
ant.
(2) Align axle shaft seal with axle shaft seal bore.
(3) Position axle seal at extension housing.
(4) Using Tool L-4520 and Tool C-4171, tap seal
into position.
SHIFT SHAFT SEALS
It isnotnecessary to remove the shift shaft cover
from the transaxle to service the shift shaft seals.
REMOVAL
(1) Remove the shift lever from the seal that is to
be serviced. Refer to shift lever removal for service
procedure.
(2) Using a pick tool, pry up on the shift shaft seal
and remove seal from bore.
INSTALLATION
(1) Position new shift shaft seal in bore.
(2) Install shift shaft seal into bore using an
appropriate size deep±well socket.
TRANSAXLE
The following items can be serviced without remov-
ing the transaxle from the vehicle:
²Gearshift housing
²5th speed synchronizer
²5th speed gear
²Roller detents and springs
²Speedometer pinion
²Vehicle speed sensor
²Bearing retainer plate.
²All external covers
²Shift shaft seals
²Axle shaft seals
To service any other component of the A-598 tran-
saxle you must remove it from the vehicle.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove air intake hose. Disconnect air mass
meter connector.
(3) Remove intercooler hose.(4) Remove connectors for back-up lamp (Fig. 28)
and crank position sensor (Fig. 29).
(5) Remove crank position sensor (2.5L VM Diesel
only).
(6) Remove wiring harness bracket at transaxle
(Fig. 30).
(7) Remove crossover and shift selector cables (Fig.
31).
(8) Remove the two top bolts at the rear engine
mount bracket.
(9) Remove bolts securing the coolant reservoir to
the top of the engine. Move the coolant reservoir out
of the way.
(10) Install an engine support chain to the cylinder
head assembly (Fig. 32).
Fig. 28 Back-up Lamp Connector
Fig. 29 Crankshaft Position Sensor
21 - 12 A±598 MANUAL TRANSAXLENS/GS
REMOVAL AND INSTALLATION (Continued)

(11) Remove three upper bellhousing bolts (Fig.
33).
(12) Install engine bridge fixture to chain and sup-
port engine (Fig. 34).(13) Hoist the vehicle.
(14) Remove front wheels.
(15) Remove axle shaft hub nuts.
(16) Remove steering knuckle steering stop studs.
(17) Remove lower control arm pinch bolts (Fig.
35).
(18) Using a pry bar, unseat lower control arm
from steering knuckle (Fig. 36).
(19) Remove drain plug and drain transaxle fluid
(Fig. 37).
(20) Remove right and left axle shaft assemblies
(21) Remove vehicle speed sensor wiring connector
(Fig. 38).
(22) Remove clutch cable retaining clip (Fig. 39).
Remove clutch cable from transaxle housing.
(23) Remove adapter plate and front engine mount
bolts (Fig. 40) (Fig. 41).
(24) Remove two remaining rear engine mount
bolts.
CAUTION: Always use a safety chain when remov-
ing or installing transaxle assembly.
Fig. 30 Wiring Harness Bracket
Fig. 31 Shift Cables
Fig. 32 Engine Support Chain
Fig. 33 Upper Bellhousing Bolts
Fig. 34 Engine Bridge Fixture
NS/GSA±598 MANUAL TRANSAXLE 21 - 13
REMOVAL AND INSTALLATION (Continued)

(4) Check the transaxle for leaks and recheck the
level of the transaxle lubricant.
INPUT SHAFT FRONT BEARING RETAINER
REMOVAL
(1) Remove the transaxle assembly from the vehi-
cle. For removal procedure, refer to Transaxle,
Removal and Installation.
(2) From inside the bellhousing, remove the E-clip
retaining the clutch release lever shaft (Fig. 43).
(3) Pull release lever shaft out of the clutch bell-
housing (Fig. 44).
(4) Remove the clutch release bearing from the
input bearing retainer sleeve (Fig. 45).
(5) Remove the three bolts retaining the input
shaft bearing retainer sleeve (Fig. 46).
(6) Remove the input bearing retainer sleeve from
the front of the bellhousing.
INSTALLATION
(1) For installation, reverse removal procedure.
Use MopartGasket Maker to seal input bearing
retainer sleeve to bellhousing.
Fig. 40 Front Engine Mount (Left Side)
Fig. 41 Front Engine Mount (Right Side)
Fig. 42 Left Mount Bolts
Fig. 43 E-clip at Clutch Release Lever Shaft
Fig. 44 Clutch Release Shaft
NS/GSA±598 MANUAL TRANSAXLE 21 - 15
REMOVAL AND INSTALLATION (Continued)

(2) Tighten the input bearing retainer sleeve bolts
to 28 N´m (250 in. lbs.).
INPUT SHAFT SEAL
REMOVAL
(1) Remove input shaft front bearing retainer from
transaxle case. Refer to Input Bearing Retainer
Removal in this group.
(2) Place the retainer in a soft-jawed vise.
(3) Using a flat-blade pry tool, remove the input
shaft seal from the retainer.
INSTALLATION
(1) Position the new input shaft seal in the
retainer.
(2) Place the retainer on a flat surface (seal side
down).
(3) Push down on bearing retainer to install seal
(Fig. 47).
(4) Install input bearing retainer. Refer to Input
Bearing Retainer Installation in this group.
A-558 TRANSAXLE ASSEMBLYÐRHD VEHICLES
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove air intake hose.
(3) Remove connector for back-up lamp (Fig. 48).
(4) Remove wiring harness bracket at transaxle
(Fig. 49).
(5) Unbolt slave cylinder and actuator rod at the
transaxle (Fig. 50).
(6) Install engine support fixture and chain onto
engine (Fig. 51) and (Fig. 52).
(7) Remove cover from accelerator cables at throt-
tle body (Fig. 53).
(8) Remove throttle body to transaxle bracket (Fig.
54).
(9) Remove two (2) upper transaxle nuts/studs
(Fig. 54).
(10) Remove crossover and shift selector cables
(Fig. 55).
(11) Lift the vehicle on hoist.
Fig. 45 Clutch Release Fork
Fig. 46 Input Bearing Retainer
Fig. 47 Install Seal
Fig. 48 Back-up Lamp Connector
21 - 16 A±598 MANUAL TRANSAXLENS/GS
REMOVAL AND INSTALLATION (Continued)

Fig. 49 Wiring Harness Bracket
Fig. 50 Hydraulic Clutch Linkage
Fig. 51 Engine Bridge Fixture
NS/GSA±598 MANUAL TRANSAXLE 21 - 17
REMOVAL AND INSTALLATION (Continued)