CHRYSLER VOYAGER 2001 Service Manual

Remove input shaft-to-clutch retainer snap ring
(Fig. 130) (Fig. 131). Press input shaft out of retainer
if necessary.
Fig. 130 Input Shaft Snap Ring
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - SNAP RING PLIERS
4 - SNAP RING
Fig. 131 Input Shaft Snap
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - SNAP RING
RSAUTOMATIC - 31TH21-87
CLUTCH - REAR (Continued)

Fig. 132 Rear Clutch Assembly
1 - SNAP RING (SELECT)
2 - REACTION PLATE
3 - CLUTCH DISC
4 - CLUTCH PLATE
5 - REACTION PLATE
6 - CLUTCH RETAINER
7 - INPUT SHAFT8 - SNAP RING
9 - PISTON
10 - SPRING
11 - SNAP RING (WAVE)
12 - SEAL
13 - SEAL
21 - 88 AUTOMATIC - 31THRS
CLUTCH - REAR (Continued)

ASSEMBLY
(1) Install input shaft-to-clutch retainer snap ring
(Fig. 133) (Fig. 134) (Fig. 132).(2) Install rear clutch piston, belleville spring and
waved snap ring (Fig. 135). Install snap ring using a
suitable screwdriver (Fig. 136).
Fig. 133 Install Input Shaft Snap Ring
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - SNAP RING PLIERS
4 - SNAP RING
Fig. 134 Input Shaft Snap Ring
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - SNAP RING
Fig. 135 Rear Clutch Piston and Piston Spring
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - PISTON SPRING
4 - WAVED SNAP RING
5 - PISTON
6 - PISTON SEALS
Fig. 136 Piston Spring Waved Snap Ring
1 - REAR CLUTCH RETAINER
2 - PISTON SPRING
3 - SCREWDRIVER
4 - WAVED SNAP RING
RSAUTOMATIC - 31TH21-89
CLUTCH - REAR (Continued)

(3) Install rear clutch pack (Fig. 137).
(4) Install snap ring using a suitable screwdriver
(Fig. 138).(5) Using feeler gauges, measure rear clutch clear-
ance (Fig. 139).Rear clutch clearance should be
within 0.71-1.10 mm (0.028-0.043 in.).
FINAL DRIVE
DISASSEMBLY
NOTE: The differential is serviced as an assembly.
Service is limited to bearing cups and cones. Any
other failure must be repaired by differential assem-
bly and transfer shaft replacement.
(1) Remove transfer shaft.
(2) Measure differential bearing turning torque.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/BEARINGS - ADJUSTMENTS)
(3) Remove adapter plate seal.
(4) Remove differential cover-to-transaxle case
bolts (Fig. 140).
(5) Remove differential cover (Fig. 141). Clean sur-
faces of old adhesive prior to reassembly.
(6) Remove bearing retainer axle seal using slide
hammer C-637 and Tool 7794A, or Tool L-4518.
(7) Remove differential bearing retainer-to-trans-
axle case bolts (Fig. 142).
Fig. 137 Rear Clutch (4-Disc Shown)
1 - REAR CLUTCH RETAINER
2 - CLUTCH PLATES
3 - THICK STEEL PLATE
4 - SNAP RING (SELECTIVE)
5 - DRIVING DISCS
6 - PRESSURE PLATE
Fig. 138 Rear Clutch Outer Snap Ring
1 - SCREWDRIVER
2 - SNAP RING
3 - REAR CLUTCH ASSEMBLY
Fig. 139 Measuring Rear Clutch Plate Clearance
1 - REAR CLUTCH ASSEMBLY
2 - FEELER GAUGE
3 - SELECTIVE SNAP RING
21 - 90 AUTOMATIC - 31THRS
CLUTCH - REAR (Continued)

(8) Remove bearing retainer from transaxle. Use to
L-4435 to aid in removal by rotating retainer out of
assembly (Fig. 143). Clean surfaces of old adhesive
prior to reassembly.
(9) Remove adapter plate-to-transaxle case bolts.WARNING: HOLD ON TO DIFFERENTIAL WHILE
REMOVING EXTENSION HOUSING TO PREVENT IT
FROM ROLLING OUT OF TRANSAXLE.
Fig. 140 Differential Cover Bolts
1 - DIFFERENTIAL COVER
2 - DIFFERENTIAL COVER BOLT
Fig. 141 Remove Differential Cover
1 - GOVERNOR PRESSURE PLUG
2 - DIFFERENTIAL COVER
3 - 1/8 INCH BEAD OF R T V SEALANT
4 - DIFFERENTIAL ASSEMBLY
Fig. 142 Differential Bearing Retainer Bolts
1 - DIFFERENTIAL BEARING RETAINER
2 - DIFFERENTIAL BEARING RETAINER BOLTS (6)
Fig. 143 Remove Bearing Retainer Using Tool
L-4435
1 - GOVERNOR PRESSURE PLUG
2 - DIFFERENTIAL BEARING RETAINER
3 - SPECIAL TOOL L-4435
RSAUTOMATIC - 31TH21-91
FINAL DRIVE (Continued)

(10) Remove extension housing from transaxle
case. Use Tool L-4435 to aid in removal by rotating
plate out of assembly. Clean surfaces of old adhesive
prior to reassembly.
(11) Measure and record differential side gear end
play using dial indicator C-3339 and Tool C-4995 as
shown in (Fig. 144) and (Fig. 145).Side gear end
play must be within 0.001-0.013 in. Replace dif-
ferential assembly if outside this range.(12) Remove differential bearing cone (from exten-
sion housing side) using Tool C-293, and adapters
C-293-3, and C-293-36 (Fig. 146).
(13) Set up tools as shown in (Fig. 147) and (Fig.
148) to facilitate differential bearing removal from
ring gear side.
Fig. 144 Checking Side Gear End Play
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
4 - SIDE GEAR
Fig. 145 Checking Side Gear End Play (Typical)
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
Fig. 146 Remove Differential Bearing Cone
(Extension Housing Side)
1 - SPECIAL TOOL C-293
2 - SPECIAL TOOL C-293-36
3 - SPECIAL TOOL C-293-3
Fig. 147 Differential Bearing Removal Set-Up (Ring
Gear Side)
1 - SPECIAL TOOL L-4539-2
2 - SPECIAL TOOL 5048
3 - SPECIAL TOOL 5048-4
21 - 92 AUTOMATIC - 31THRS
FINAL DRIVE (Continued)

(14) Remove differential bearing cone (Fig. 149).(15) Remove bearing retainer bearing cup using
Tool 6062A (Fig. 150) (Fig. 151). Remove shim and oil
baffle.
Fig. 148 Position Tool 5048 Over Button and Collets
at Differential Bearing
1 - SPECIAL TO0L 5048
2 - DIFFERENTIAL
3 - SPECIAL TOOL 5048-4
Fig. 149 Remove Differential Bearing Cone
1 - SPECIAL TOOL 5048
2 - RING GEAR
Fig. 150 Position Bearing Cup Remover Tool in
Retainer
1 - SPECIAL TOOL 6062A
2 - DIFFERENTIAL BEARING RETAINER
Fig. 151 Remove Bearing Cup using 6062A
1 - SPECIAL TOOL 6062A
2 - DIFFERENTIAL BEARING RETAINER
RSAUTOMATIC - 31TH21-93
FINAL DRIVE (Continued)

ASSEMBLY
NOTE: The differential is serviced as an assembly.
Service is limited to bearing cups and cones. Any
other failure must be repaired by differential assem-
bly and transfer shaft replacement.
(1) Install shim and bearing cup using Tool 5052
and driver handle C-4171 (Fig. 152). Install bearing
cup into extension housing using Tool 6536 and
driver handle C-4171.
(2) Position bearing cone onto differential (Fig.
153), and install bearing cone using Tool 6536 and
driver handle C-4171 (Fig. 154).(3) Measure side gear end play using dial indicator
C-3339 and Tool C-4996 (Fig. 155) (Fig. 156).Side
gear end play must be between 0.001 and 0.013
in.
(4) Apply a bead of Moparž Silicone Rubber Adhe-
sive Sealant to the adapter plate. Load differential
assembly into position and install adapter plate .
(5) Using Tool L-4435, index adapter plate until
bolt holes align.
(6) Install adapter plate-to-transaxle case bolts
and torque to 28 N´m (250 in. lbs.) torque.
Fig. 152 Bearing Retainer Bearing Cup Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5052
3 - DIFFERENTIAL BEARING RETAINER
Fig. 153 Position Bearing Cone Onto Differential
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL BEARING
Fig. 154 Install Differential Bearing Cone
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 6536
3 - DIFFERENTIAL ASSEMBLY
Fig. 155 Checking Side Gear End Play
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
4 - SIDE GEAR
21 - 94 AUTOMATIC - 31THRS
FINAL DRIVE (Continued)

(7) Apply a bead of Moparž Silicone Rubber Adhe-
sive Sealant to the differential bearing retainer (Fig.
157).(8) Install bearing retainer and index using Tool
L-4435 until bolt holes align (Fig. 158).
(9) Install and torque bearing retainer bolts to 34
N´m (25 ft. lbs.) torque (Fig. 159).
Fig. 156 Checking Side Gear End Play (Typical)
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
Fig. 157 Differential Bearing Retainer (Typical)
1 - DIFFERENTIAL BEARING CUP
2 - DIFFERENTIAL
3 - DIFFERENTIAL BEARING RETAINER
Fig. 158 Index Bearing Retainer using Tool L-4435
1 - GOVERNOR PRESSURE PLUG
2 - DIFFERENTIAL BEARING RETAINER
3 - SPECIAL TOOL L-4435
Fig. 159 Differential Bearing Retainer Bolts
1 - DIFFERENTIAL BEARING RETAINER
2 - DIFFERENTIAL BEARING RETAINER BOLTS (6)
RSAUTOMATIC - 31TH21-95
FINAL DRIVE (Continued)

(10) Install bearing retainer axle seal using Tool
L-4520 (inverted), and driver handle C-4171 (Fig.
160).
(11) Install adapter plate axle seal using Tool
L-4520 (inverted), and driver handle C-4171.
(12) Check differential turning torque. (Refer to 21
- TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/BEARINGS - ADJUSTMENTS)
(13) Apply an 1/8º bead of Moparž Silicone Rubber
Adhesive Sealant to the differential cover (Fig. 161).(14) Install differential cover-to-transaxle case
bolts and torque to 19 N´m (165 in. lbs.) torque (Fig.
162).
(15) Install transfer shaft and related components.
ADJUSTMENT - DIFFERENTIAL BEARING
NOTE: Transfer shaft MUST be removed from trans-
axle to obtain an accurate differential turning torque
measurement.
Differential turning torque should be measured
and adjusted during any transaxle or differential
teardown/assembly, or if any of the following parts
are replaced:
²Transaxle case
²Differential carrier
²Differential bearing retainer
²Extension housing
²Differential bearing cups and cones
(1) Position the transaxle assembly vertically on
the support stand, differential bearing retainer side
up.
(2) Install Tool L-4436A into the differential and
onto the pinion mate shaft (Fig. 163).
(3) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.
(4) Using Tool L-4436A and an inch-pound torque
wrench, check the turning torque of the differential
(Fig. 164).Turning torque should be within 5±18
in. lbs.
Fig. 160 Install Bearing Retainer Axle Seal
1 - SPECIAL TOOL L-4520
2 - SPECIAL TOOL C-4171
Fig. 161 Install Differential Cover
1 - GOVERNOR PRESSURE PLUG
2 - DIFFERENTIAL COVER
3 - 1/8 INCH BEAD OF R T V SEALANT
4 - DIFFERENTIAL ASSEMBLY
Fig. 162 Differential Cover Bolts
1 - DIFFERENTIAL COVER
2 - DIFFERENTIAL COVER BOLT
21 - 96 AUTOMATIC - 31THRS
FINAL DRIVE (Continued)