CHRYSLER VOYAGER 2002 Service Manual

(14) Using Tool L-4434 and adapter C-4658 (Fig.
293), torque transfer shaft gear retaining nut to 271
N´m (200 ft. lbs.).
(15) Measure transfer shaft end play. Set up Tool
L-4432 and C-4658 as shown in (Fig. 294). Measure
end play with dial indicator.
(16) Position stirrup and strap on transfer gear.
(17) Install bolts but do not tighten.
(18) Rotate stirrup clockwise until it contacts
transfer gear retaining nut flat.(19) Torque stirrup and strap-to-transfer gear bolts
to 23 N´m (200 in. lbs.).
(20) Bend tabs of strap up against ªflatsº of retain-
ing bolts.
(21) Install a bead of MopartSilicone Rubber
Adhesive Sealant to transfer gear cover (Fig. 295).
Immediately install to transaxle case.
(22) Install and torque transfer gear cover-to-case
bolts (Fig. 296) to 19 N´m (165 in. lbs.).
Fig. 293 Tighten Transfer Shaft Gear Retaining Nut
to 271 N´m (200
1 - TRANSFER SHAFT GEAR
2 - TORQUE WRENCH
3 - SPECIAL TOOL L-4434 AND ADAPTER C-4658
Fig. 294 Measuring Transfer Shaft End-Play
1 - SPECIAL TOOL L-4432 AND C-4658
2 - TRANSFER SHAFT GEAR
3 - STEEL BALL (USE GREASE TO HOLD IN PLACE)
4 - DIAL INDICATOR
5 - SCREW (2)
Fig. 295 Install Rear Cover
1 - OUTPUT SHAFT GEAR
2 - USE MOPAR SILICONE RUBBER ADHESIVE SEALER
3 - REAR COVER
4 - TRANSFER SHAFT GEAR
Fig. 296 Rear Cover Bolts
1 - REAR COVER
2 - REAR COVER BOLTS (10)
21 - 144 31TH AUTOMATIC TRANSAXLERS
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)
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ADJUSTMENTS
ADJUSTMENT - TRANSFER SHAFT BEARING
(1) Use Tool L-4434 to remove the retaining nut
and washer. Remove the transfer shaft gear using
Tool L-4407.
(2) Install a 2.29 mm (0.090 inch) and a 1.39 mm
(0.055 inch) gauging shims on the transfer shaft
behind the governor support.
(3) Install transfer shaft gear and bearing assem-
bly and torque the nut to 271 N´m (200 ft. lbs.).
(4) To measure bearing end play:Attach Tool
L-4432 to the transfer gear.
(5) Mount a steel ball with grease into the end of
the transfer shaft.
(6) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
(7) Using a dial indicator, measure transfer shaft
end play.
(8) Refer to the Transfer Bearing Shim Chart for
the required shim combination to obtain the proper
bearing setting.
(9) Use Tool L-4434 to remove the retaining nut
and washer. Remove the transfer shaft gear using
Tool L-4407.
(10) Remove the two gauging shims and install the
correct shim combination. Install the transfer gear
and bearing assembly.
(11) Install the retaining nut and washer and
torque to 271 N´m (200 ft. lbs.). Measure transfer
shaft end play, end play should be 0.05 to 0.25 mm
(0.002 to 0.010 inch).
(12) Measure bearing end play as outlined in Step
(4). End play should be between 0.05 mm and 0.25
mm (0.002 to 0.010 inch).
NOTE: If end play is too high, install a 0.05 mm
(0.002 inch) thinner shim combination. If end play is
too low, install a 0.05 mm (0.002 inch) thicker shim
combination. Repeat until 0.05 to 0.25 mm (0.002 to
0.010 inch) end play is obtained.
End Play
(with 2.29
mm and 1.39
mm gauging
shims
installed)Required Shim
CombinationTotal
Thickness
mm inch mm mm inch
.0 .0 2.29 + 1.39 3.68 .145
.05 .002 2.29 + 1.39 3.68 .145
.10 .004 2.29 + 1.39 3.68 .145
.15 .006 2.29 + 1.39 3.68 .145
.20 .008 2.29 + 1.34 3.63 .143
.25 .010 2.29 + 1.29 3.58 .141
.30 .012 2.29 + 1.24 3.53 .139
.35 .014 2.29 + 1.19 3.48 .137
.40 .016 2.29 + 1.14 3.43 .135
.45 .018 2.29 + 1.09 3.38 .133
.50 .020 2.29 + 1.04 3.33 .131
.55 .022 2.29 + .99 3.28 .129
.60 .024 1.84 + 1.39 3.23 .127
.65 .026 1.84 + 1.34 3.18 .125
.70 .028 1.84 + 1.29 3.13 .123
.75 .030 1.84 + 1.24 3.08 .121
.80 .032 1.84 + 1.19 3.03 .119
.85 .034 1.84 + 1.14 2.98 .117
.90 .036 1.84 + 1.09 2.93 .115
.95 .038 1.84 + 1.04 2.88 .113
1.00 .040 1.84 + .99 2.83 .111
1.05 .042 1.39 + 1.39 2.78 .109
1.10 .044 1.39 + 1.34 2.73 .107
1.15 .046 1.39 + 1.29 2.68 .105
1.20 .048 1.39 + 1.24 2.63 .103
1.25 .049 1.39 + 1.19 2.58 .101
1.30 .050 1.39 + 1.14 2.53 .099
1.35 .052 1.39 + 1.09 2.48 .097
1.40 .055 1.39 + 1.04 2.43 .095
1.45 .057 1.39 + .99 2.38 .093
1.50 .059 .94 + 1.39 2.33 .091
1.55 .061 .94 + 1.34 2.28 .089
1.60 .063 .94 + 1.29 2.23 .087
RS31TH AUTOMATIC TRANSAXLE21 - 145
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)
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VALVE BODY
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect throttle valve cable from throttle
valve lever at transaxle.
(3) Disconnect gearshift cable from gearshift lever
at transaxle.
(4) Disconnect torque converter clutch solenoid
connector.
(5) Raise vehicle on hoist.
(6) Remove transaxle oil pan bolts (Fig. 297).
(7) Separate oil pan from case and drain fluid into
suitable container (Fig. 298).(8) Remove oil filter-to-valve body screws (Fig.
299).
(9) Remove oil filter and gasket (Fig. 300).
Fig. 297 Transaxle Oil Pan Bolts
1 - TRANSAXLE OIL PAN
2 - OIL PAN BOLTS
Fig. 298 Transaxle Oil Pan
1 - TRANSAXLE OIL PAN
2 - OIL FILTER
Fig. 299 Oil Filter Screws
1 - SCREWDRIVER HANDLE
2 - SPECIAL TOOL L-4553
3 - OIL FILTER SCREWS (2)
4 - OIL FILTER
Fig. 300 Oil Filter and Gasket
1 - OIL FILTER
2 - GASKET
3 - VALVE BODY
21 - 146 31TH AUTOMATIC TRANSAXLERS
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(10) Remove cooler bypass valve from valve body
(Fig. 301).
(11) Remove park rod e-clip (Fig. 302).(12) Remove park rod from valve body (Fig. 303).
(13) Remove valve body-to-transaxle case bolts
(Fig. 304).
Fig. 301 Cooler Bypass Valve and Seal
1 - TRANSFER PLATE
2 - BYPASS VALVE
3 - SEAL
Fig. 302 Parking Rod E-Clip
1 - VALVE BODY
2 - SCREWDRIVER
3 - ªEº CLIP
4 - PARKING ROD
Fig. 303 Parking Rod
1 - VALVE BODY
2 - PARKING ROD
Fig. 304 Valve Body Attaching Bolts
1 - VALVE BODY
2 - VALVE BODY ATTACHING BOLTS (7)
3 - GOVERNOR TUBES
RS31TH AUTOMATIC TRANSAXLE21 - 147
VALVE BODY (Continued)
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(14) Remove valve body from transaxle. Note ori-
entation of governor tubes (Fig. 305).
DISASSEMBLY
CAUTION: Do not clamp any portion of valve body
or transfer plate in a vise. Any slight distortion of
the aluminum body or transfer plate will result in
sticking valves, excessive leakage, or both. When
removing or installing valves or plugs, slide them in
or out carefully. Do not use force.
NOTE: TAG ALL SPRINGS AS THEY ARE REMOVED
FOR REASSEMBLY IDENTIFICATION.
(1) Remove detent spring-to-valve body screws and
remove spring (Fig. 306).(2) Remove valve body-to-separator plate screws
(Fig. 307) (Fig. 308).
Fig. 305 Valve Body and Governor Tubes
1 - VALVE BODY ASSEMBLY
2 - GOVERNOR TUBES
Fig. 306 Detent Spring Attaching Screw and Spring
1 - SPECIAL TOOL L-4553
2 - DETENT SPRING SCREW
3 - SCREWDRIVER HANDLE
Fig. 307 Using Tool L-4553 on Valve Body Screw
1 - SCREWDRIVER HANDLE
2 - VALVE BODY ASSEMBLY
3 - SPECIAL TOOL L-4553
Fig. 308 Remove Valve Body-to-Transfer Plate
Screws
1 - SCREWDRIVER HANDLE
2 - VALVE BODY SCREWS (16)
3 - VALVE BODY
4 - SPECIAL TOOL L-4553
21 - 148 31TH AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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(3) Separate transfer and separator plate from
valve body assembly (Fig. 309). Note check ball loca-
tions (Fig. 310) for proper reassembly.(4) Remove throttle valve shaft-to-manual valve
shaft e-clip (Fig. 311). Note orientation of washer and
seal (Fig. 312).
Fig. 309 Separate Transfer Plate and Separator
Plate from Valve Body
1 - SEPARATOR PLATE
2 - TRANSFER PLATE
3 - OIL SCREEN
4 - VALVE BODY
Fig. 310 Steel Ball Locations
1 - MANUAL VALVE
2 - STEEL BALLS (8)
3 - STEEL BALLS
Fig. 311 Remove Throttle Shaft E-Clip
1 - MANUAL VALVE LEVER ASSEMBLY
2 - THROTTLE VALVE LEVER ASSEMBLY
3 - SCREWDRIVER
4 - ªEº CLIP
Fig. 312 Throttle Shaft E-Clip, Washer, and Seal
1 - MANUAL VALVE LEVER ASSEMBLY
2 - OIL SEAL
3 - ªEº CLIP
4 - THROTTLE VALVE LEVER ASSEMBLY
5 - WASHER
RS31TH AUTOMATIC TRANSAXLE21 - 149
VALVE BODY (Continued)
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(5) Remove manual valve shaft/lever from throttle
valve shaft (Fig. 313).
(6) Remove throttle valve lever/shaft (Fig. 314).(7) Remove manual valve from valve body (Fig.
315).
(8) Remove pressure regulator spring retainer/ad-
justing screw bracket (Fig. 316).
Fig. 313 Manual Valve Lever
1 - THROTTLE VALVE LEVER ASSEMBLY
2 - MANUAL VALVE LEVER ASSEMBLY
3 - VALVE BODY
Fig. 314 Throttle Valve Lever Assembly
1 - THROTTLE VALVE LEVER ASSEMBLY
2 - MANUAL VALVE
3 - VALVE BODY
Fig. 315 Manual Valve
1 - MANUAL VALVE
2 - VALVE BODY
Fig. 316 Pressure Regulator and Adjusting Screw
Bracket
1 - SCREWDRIVER HANDLE
2 - PRESSURE REGULATOR SPRING RETAINER AND
ADJUSTING SCREW BRACKET
3 - VALVE BODY
4 - SCREWS
21 - 150 31TH AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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(9) Remove springs and valves as shown in (Fig.
317).
Fig. 317 Pressure Regulators and Manual Controls
1 - VALVE BODY 7 - SPRING
2 - LINE PRESSURE VALVE 8 - KICKDOWN VALVE
3 - SPRING 9 - SPRING
4 - ADJUSTING SCREW 10 - MANUAL VALVE
5 - SCREW 11 - THROTTLE VALVE
6 - GUIDE
RS31TH AUTOMATIC TRANSAXLE21 - 151
VALVE BODY (Continued)
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(10) Remove governor plugs as shown in (Fig. 318).
Fig. 318 Governor Plugs
1 - SHUTTLE VALVE SECONDARY SPRING 5 - SCREW (4)
2 - SHUTTLE VALVE 6 - END COVER
3 - 1-2 SHIFT VALVE GOVERNOR PLUG 7 - 2-3 SHIFT VALVE GOVERNOR PLUG
4 - END COVER 8 - E-CLIP
21 - 152 31TH AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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(11) Remove torque converter clutch solenoid,
spring, and plug as shown in (Fig. 319).
Fig. 319 Torque Converter Clutch Solenoid and Regulator/Control Valves
1 - CONVERTER PRESSURE CONTROL
VA LV E3 - SCREW (3) 5 - REGULATOR VALVE THROTTLE
PRESSURE PLUG
2 - END COVER4 - REGULATOR VALVE THROTTLE
PRESSURE PLUG SPRING 6 - SWITCH VALVE
RS31TH AUTOMATIC TRANSAXLE21 - 153
VALVE BODY (Continued)
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