shaft CHRYSLER CARAVAN 2002 Service Manual

(11) If necessary, remove low/reverse band anchor
pin (Fig. 273).
(12) Remove governor assembly (Fig. 274).(13) Remove transfer shaft bearing retainer snap
ring (Fig. 275).
(14) Set up tools as shown in (Fig. 276).
Fig. 273 Low/Reverse Band Anchor Pin
1 - LOW-REVERSE BAND ANCHOR PIN
2 - OUTPUT SHAFT GEAR
Fig. 274 Governor Assembly
1 - TRANSFER SHAFT
2 - OUTPUT SHAFT GEAR
3 - GOVERNOR ASSEMBLY
Fig. 275 Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS
2 - SNAP RING
3 - OUTPUT SHAFT GEAR
4 - TRANSFER SHAFT
Fig. 276 Remove Transfer Shaft and Bearing
Retainer Assembly
1 - SPECIAL TOOL L-4512
2 - SPECIAL TOOL L-4437
3 - SPECIAL TOOL C-3752
RS31TH AUTOMATIC TRANSAXLE21 - 139
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)
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(15) Remove transfer shaft/bearing retainer assem-
bly (Fig. 277).
(16) Separate bearing retainer from transfer shaft
(Fig. 278).(17) Remove transfer shaft bearing cone from shaft
using Tool C-293-PA and adapters C-293-52 (Fig.
279).
(18) Remove transfer shaft bearing cup from bear-
ing retainer (Fig. 280).
Fig. 277 Remove or Install Transfer Shaft and
Bearing Retainer Assembly
1 - OUTPUT SHAFT GEAR
2 - O-RING
3 - SPECIAL TOOL L-4512
4 - BEARING RETAINER ASSEMBLY
5 - TRANSFER SHAFT
Fig. 278 Transfer Shaft and Bearing Retainer
1 - O-RING
2 - TRANSFER SHAFT
3 - BEARING CONE
4 - TRANSFER SHAFT BEARING RETAINER
Fig. 279 Remove Transfer Shaft Bearing Cone
1 - TOOL C-293-52
2 - TRANSFER SHAFT
3 - TOOL C-293-PA
4 - VISE
Fig. 280 Remove Transfer Shaft Bearing Cup
1 - SPECIAL TOOL L-4518
2 - TRANSFER SHAFT BEARING RETAINER
3-88O'' RING
4 - BEARING CUP
21 - 140 31TH AUTOMATIC TRANSAXLERS
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)
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INSTALLATION
(1) Install transfer shaft bearing cup to bearing
retainer using Tool L-4520 (Fig. 281).
(2) Install transfer shaft bearing cone to transfer
shaft using Tool L-4111 (Fig. 282).(3) Assemble transfer shaft to bearing retainer
(Fig. 283).
(4) Install transfer shaft/bearing retainer assembly
using tool L-4512 (Fig. 284).
Fig. 282 Install Transfer Shaft Bearing Cone
1 - PRESS
2 - SPECIAL TOOL L-4411
3 - BEARING CONE
4 - TRANSFER SHAFT
Fig. 281 Install Transfer Shaft Bearing Cup
1 - PRESS
2 - HANDLE C-4171
3 - SPECIAL TOOL L-4520
4 - TRANSFER SHAFT BEARING RETAINER
5 - ªOº RING
Fig. 283 Transfer Shaft and Bearing Retainer
1 - O-RING
2 - TRANSFER SHAFT
3 - BEARING CONE
4 - TRANSFER SHAFT BEARING RETAINER
Fig. 284 Transfer Shaft and Bearing Retainer
1 - O-RING
2 - TRANSFER SHAFT
3 - BEARING CONE
4 - TRANSFER SHAFT BEARING RETAINER
RS31TH AUTOMATIC TRANSAXLE21 - 141
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)
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(5) Install transfer shaft bearing retainer snap
ring (Fig. 285).
(6) Install governor assembly (Fig. 286).(7) Install low/reverse band anchor pin if previ-
ously removed (Fig. 287).
(8) Install governor support retainer bearing cup
using Tool L-4520 (Fig. 288).
Fig. 285 Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS
2 - SNAP RING
3 - OUTPUT SHAFT GEAR
4 - TRANSFER SHAFT
Fig. 286 Governor Assembly
1 - TRANSFER SHAFT
2 - OUTPUT SHAFT GEAR
3 - GOVERNOR ASSEMBLY
Fig. 287 Low/Reverse Band Anchor Pin
1 - LOW-REVERSE BAND ANCHOR PIN
2 - OUTPUT SHAFT GEAR
Fig. 288 Install Governor Support Retainer Bearing
Cup
1 - PRESS
2 - HANDLE C-4171
3 - SPECIAL TOOL L-4520
4 - GOVERNOR SUPPORT RETAINER
5 - BEARING CUP
21 - 142 31TH AUTOMATIC TRANSAXLERS
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)
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(9) Install governor support retainer (Fig. 289).
(10) Install transfer shaft gear bearing cone using
Tool L-4410 (Fig. 290).
(11) Determine transfer shaft bearing shim thick-
ness. (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 31TH/TRANSFER SYSTEM -
ADJUSTMENTS) Shim thickness need be deter-
mined only if any of the following parts are replaced:
²Transaxle case
²Transfer shaft²Transfer shaft gear
²Transfer shaft bearings
²Governor support retainer
²Transfer shaft bearing retainer
²Retainer snap ring
²Governor support
(12) Install transfer shaft gear and select shim
(Fig. 291).
(13) Install transfer shaft gear nut and washer
(Fig. 292).
Fig. 289 Governor Support Retainer
1 - TRANSFER SHAFT
2 - OUTPUT SHAFT GEAR
3 - BEARING CUP
4 - GOVERNOR SUPPORT RETAINER
Fig. 290 Install Transfer Shaft Gear Bearing Cone
1 - PRESS
2 - HANDLE C-4171
3 - SPECIAL TOOL L-4410
4 - TRANSFER SHAFT GEAR
5 - BEARING CONE
Fig. 291 Transfer Shaft Gear and (Select) Shim
1 - TRANSFER SHAFT GEAR
2 - OUTPUT SHAFT GEAR
3 - SHIM (SELECT)
4 - BEARING CONE
Fig. 292 Transfer Shaft Gear Nut and Washer
1 - OUTPUT SHAFT GEAR
2 - TRANSFER SHAFT GEAR
3 - WASHER
4 - NUT
RS31TH AUTOMATIC TRANSAXLE21 - 143
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)
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(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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(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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valve or plug edges. Squareness of these edges is
vitally important. These edges prevent foreign matter
from lodging between the valves, plugs and bore.
INSPECTION
Inspect the throttle and manual valve levers and
shafts. Do not attempt to straighten a bent shaft or
correct a loose lever. Replace these components if
worn, bent, loose or damaged in any way.
Inspect all of the valve body mating surfaces for
scratches, nicks, burrs, or distortion. Use a straight-
edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light
pressure.
Inspect the valves and plugs for scratches, burrs,
nicks, or scores. Also inspect the coating on the alu-
minum valves and plugs. If the coating is damaged
or worn through, the valve (or valve body) should be
replaced.
Inspect all the valve and plug bores in the valve
body. Use a penlight to view the bore interiors.
Replace the valve body if any bores are distorted or
scored. Inspect all of the valve body springs. The
springs must be free of distortion, warpage or broken
coils.
Trial fit each valve and plug in its bore to check
freedom of operation. When clean and dry, the valves
and plugs should drop freely into the bores. Valve
body bores do not change dimensionally with use. If
the valve body functioned correctly when new, it will
continue to operate properly after cleaning and
inspection. It should not be necessary to replace a
valve body assembly unless it is damaged in han-
dling.
ASSEMBLY
(1) Install shift/shuttle valves and springs as
shown in (Fig. 320).
(2) Install torque converter clutch solenoid, spring,
and plug as shown in (Fig. 319).
(3) Install governor plugs as shown in (Fig. 318).
(4) Install pressure regulator and manual control
springs and valves as shown in (Fig. 317).
(5) Install pressure regulator spring retainer/ad-
justing screw bracket (Fig. 321).
(6) Install manual valve from valve body (Fig.
322).
Fig. 321 Pressure Regulator and Adjusting Screw
Bracket
1 - SCREWDRIVER HANDLE
2 - PRESSURE REGULATOR SPRING RETAINER AND
ADJUSTING SCREW BRACKET
3 - VALVE BODY
4 - SCREWS
Fig. 322 Install Manual Valve
1 - MANUAL VALVE
2 - VALVE BODY
RS31TH AUTOMATIC TRANSAXLE21 - 155
VALVE BODY (Continued)
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