transfer shaft CHRYSLER CARAVAN 2002 Repair Manual

(14) Torque stirrup and strap bolts to 23 N´m (200
in. lbs..) (Fig. 264).
(15) Bend tabs of strap up against ªflatsºof retain-
ing bolts to prevent bolts from backing out of gear in
the event they come loose.
(16) Install transfer shaft and gear. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/TRANSFER SYSTEM - INSTALLATION)
(17) Assemble transaxle geartrain. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC - 31TH
- ASSEMBLY)
ADJUSTMENTS
ADJUSTMENT - OUTPUT SHAFT BEARING
(1) With output shaft gear removed, install a 13.65
mm (0.537 inch) and a 1.34 mm (0.053 inch) gauging
shims on the planetary rear annulus gear hub usinggrease to hold the shims in place. The 13.65 mm
shim has a larger inside diameter and must be
installed over the output shaft first. The 1.34 mm
shim pilots on the output shaft.
(2) Install output shaft gear and bearing assembly,
torque to 271 N´m (200 ft. lbs.).
(3) To measure bearing end play:
(4) Attach Tool L-4432 to the output shaft gear.
(5) Mount a steel ball with grease into the end of
the output shaft.
(6) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
(7) Using a dial indicator, mounted to the trans-
axle case, measure output shaft end play.
(8) Once bearing end play has been determined,
refer to the output shaft bearing shim chart.
(9) The 12.65 mm (0.498 inch), 13.15 mm (0.518
inch) or 13.65 mm (0.537 inch) shims are always
installed first.These shims have lubrication slots
which are necessary for proper bearing lubrica-
tion.
(10) Shims thinner than 12.65 mm listed in the
chart are common to both the transfer shaft and out-
put shaft bearings.
(11) Use Tool L-4434 to remove the retaining nut
and washer. To remove the output shaft gear use Tool
L-4407.
(12) Remove the two gauging shims and install the
proper shim combination, making sure to install the
12.65, 13.15, or 13.65 mm shim first. Use grease to
hold the shims in place. Install the output shaft gear
and bearing assembly.
(13) Install the retaining nut and washer and
torque to 271 N´m (200 ft. lbs.).
(14) Using an inch-pound torque wrench, check the
turning torque.The torque should be between 3
and 8 inch-pounds.
(15) If the turning torque is too high, install a
0.05mm (0.002 inch) thicker shim. If the turning
torque is too low, install a 0.05 mm (0.002 inch) thin-
ner shim. Repeat until the proper turning torque is 3
to 8 inch pounds.
Fig. 264 Tighten Strap Retaining Nuts
1 - STRAP
2 - OUTPUT GEAR
3 - STIRRUP
RS31TH AUTOMATIC TRANSAXLE21 - 135
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)
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OUTPUT SHAFT BEARING SHIM CHART
End Play (with 13.65 mm and
1.34 mm gauging shims
installed)Required Shim Combination Total Thickness
mm inch mm mm inch
.0 .0 13.65 + 1.34 14.99 .590
.05 .002 13.65 + 1.24 14.89 .586
.10 .004 13.65 + 1.19 14.84 .584
.15 .006 13.65 + 1.14 14.79 .582
.20 .008 13.65 + 1.09 14.74 .580
.25 .010 13.65 + 1.04 14.69 .578
.30 .012 13.65 + .99 14.64 .576
.35 .014 13.65 + .94 14.59 .574
.40 .016 13.15 + 1.39 14.54 .572
.45 .018 13.15 + 1.34 14.49 .570
.50 .020 13.15 + 1.29 14.44 .568
.55 .022 13.15 + 1.24 14.39 .566
.60 .024 13.15 + 1.19 14.34 .564
.65 .026 13.15 + 1.14 14.29 .562
.70 .028 13.15 + 1.09 14.24 .560
.75 .030 13.15 + 1.04 14.19 .558
.80 .032 13.15 + .99 14.14 .556
.85 .034 13.15 + .94 14.09 .554
.90 .036 12.65 + 1.39 14.04 .552
.95 .038 12.65 + 1.34 13.99 .550
1.00 .040 12.65 + 1.29 13.94 .548
1.05 .042 12.65 + 1.24 13.89 .547
1.10 .044 12.65 + 1.19 13.84 .545
1.15 .046 12.65 + 1.14 13.79 .543
1.20 .048 12.65 + 1.09 13.74 .541
1.25 .049 12.65 + 1.04 13.69 .539
1.30 .051 12.65 + .99 13.64 .537
1.35 .053 12.65 + .94 13.59 .535
21 - 136 31TH AUTOMATIC TRANSAXLERS
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)
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TRANSFER SYSTEM -
TRANSFER SHAFT/GEAR/
BEARING
REMOVAL
(1) Remove transfer gear cover bolts (Fig. 265).
(2) Separate transfer gear cover from transaxle
(Fig. 266). Repair any cover imperfections. Clean
cover and case of old adhesive sealant.
(3) Using a suitable punch, bend retaining strap
tabs to facilitate bolt removal.(4) Remove stirrup and retaining strap-to-transfer
gear bolts.
(5) Remove stirrup and retaining strap.
(6) Using Tool L-4434 (Fig. 267), remove transfer
shaft gear retaining nut and washer (Fig. 268).
Fig. 265 Rear Cover Bolts
1 - REAR COVER
2 - REAR COVER BOLTS (10)
Fig. 266 Remove Rear Cover
1 - OUTPUT SHAFT GEAR
2 - USE MOPAR SILICONE RUBBER ADHESIVE SEALER
3 - REAR COVER
4 - TRANSFER SHAFT GEAR
Fig. 267 Remove Transfer Shaft Gear Retaining Nut
1 - TRANSFER SHAFT GEAR
2 - SCREW (2)
3 - OUTPUT SHAFT GEAR
4 - SPECIAL TOOL L-4434
Fig. 268 Transfer Shaft Gear Nut and Washer
1 - OUTPUT SHAFT GEAR
2 - TRANSFER SHAFT GEAR
3 - WASHER
4 - NUT
RS31TH AUTOMATIC TRANSAXLE21 - 137
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(7) Using Tool L-4407A, remove transfer shaft gear
and select shim (Fig. 269).
(8) Using Tool L-4406-1 and adapter L-4406-3,
remove transfer shaft gear bearing cone (Fig. 270).(9) Remove governor support retainer (Fig. 271).
(10) Remove governor support retainer bearing cup
(Fig. 272).
Fig. 269 Remove Transfer Shaft Gear using L-4407A
1 - TRANSFER GEAR
2 - TOOL L-4407A
Fig. 270 Remove Transfer Shaft Gear Bearing Cone
1 - SPECIAL TOOL L-4406-1
2 - TRANSFER SHAFT GEAR
Fig. 271 Governor Support Retainer
1 - TRANSFER SHAFT
2 - OUTPUT SHAFT GEAR
3 - BEARING CUP
4 - GOVERNOR SUPPORT RETAINER
Fig. 272 Remove Governor Support Retainer
Bearing Cup
1 - PRESS
2 - HANDLE C-4171 (WITH SPECIAL TOOL L-4517)
3 - GOVERNOR SUPPORT RETAINER
21 - 138 31TH AUTOMATIC TRANSAXLERS
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)
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(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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