CHRYSLER VOYAGER 1996 Service Manual

(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (Vaculay
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Add 4 Quarts of Mopar ATF Plus 3 Type 7176
transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be in
the HOT range.
TRANSAXLE OIL PAN DROP METHOD
This procedure involves removing the transaxle oil
pan to drain the transaxle fluid.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N²m (165 in. lbs.).
(6) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be inthe HOT range. Drive the vehicle a minimum of 10
miles.
(10) Raise the vehicle on the hoist.
(11) Check for leaks around the transaxle oil pan
sealing surfaces.
(12) Recheck the fluid level. The level should be in
the HOT range.
SEVERE USAGE SERVICE
If the vehicle exhibits any of the following symp-
toms, it is recommended that the transaxle oil and
filter be replaced.
²Transaxle oil discolored
²Transaxle oil has high mileage
²Oil feels grimy when rubbed between fingertips
²Poor shift quality
²Delayed gear engagement
²Vehicle shudder between shifts
TRANSAXLE OIL AND FILTER REPLACEMENT
This procedure involves changing the transaxle
fluid and filter, driving the vehicle for 10 miles and
changing the transaxle fluid a second time.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Separate the filter and O-ring from the valve
body. Inspect the O-ring for cuts or improper instal-
lation. This could lead to delayed garage shifts.
(6) Install a new filter. Replace the O-ring as nec-
essary.
(7) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N²m (165 in. lbs.).
(8) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(9) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(10) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(11) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range. Drive the vehicle a minimum of
10 miles.
(12) Raise the vehicle on the hoist.
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 17
SERVICE PROCEDURES (Continued)

(13) Remove the pan and clean all sealant from
the pan and transaxle mating surfaces. Clean the
magnet and the inside of the pan.
(14) Separate the filter from the valve body to
allow additional fluid to drain from the transaxle.
Inspect the filter O-ring for any damage and replace
as necessary.
(15) After the transaxle has stopped draining,
reinstall the filter and O-ring.
(16) Apply a 1/8 inch bead of Mopar RTV Sealant
to the mounting flange of the transaxle oil pan.
Apply RTV Sealant to the underside of the attaching
bolts. Attach the oil pan to the transaxle. Tighten the
bolts to 19 N²m (165 in. lbs.).
(17) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(18) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(19) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(20) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range.
FLUID DRAIN AND REFILL
(1) Raise vehicle on a hoist (See Group 0, Lubrica-
tion). Place a drain container with a large opening,
under transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and gasket on bottom of the
valve body and tighten retaining screws to 5 N´m (40
inch-pounds).
(4) Clean the oil pan and magnet. Reinstall pan
using new sealant. Tighten oil pan bolts to 19 N´m
(165 in. lbs.).
(5) Pour four quarts of Mopar ATF PLUS 3 (Auto-
matic Transmission Fluid) Type 7176 through the
dipstick opening.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Add sufficient fluid to bring level to 1/8 inch
below the ADD mark.
(8) Recheck fluid level after transaxle is at normal
operating temperature. The level should be in the
HOT region.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum transaxle
case and valve body can be repaired by the use of Heli-
Coils, or equivalent. This repair consists of drilling out
the worn-out damaged threads. Then tapping the hole
with a Heli-Coil tap, or equivalent, and installing a
Heli-Coil insert, or equivalent, into the hole. This
brings the hole back to its original thread size.
Heli-Coil, or equivalent, tools and inserts are readily
available from most automotive parts suppliers.
FLUSHING COOLERS AND TUBES
When a transaxle failure has contaminated the
fluid, the oil cooler(s) must be flushed. The cooler
bypass valve in the transaxle must be replaced also.
The torque converter must also be replaced with an
exchange unit. This will ensure that metal particles
or sludged oil are not later transferred back into the
reconditioned (or replaced) transaxle.
The recommended procedure for flushing the cool-
ers and tubes is to use Tool 6906A Cooler Flusher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover plate filler plug on Tool 6906A.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906A.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
21 - 18 TRANSAXLE AND POWER TRANSFER UNITNS
SERVICE PROCEDURES (Continued)

(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines. Monitor pressure readings
and clear return lines. Pressure readings should sta-
bilize below 20 psi. for vehicles equipped with a sin-
gle cooler and 30 psi. for vehicles equipped with dual
coolers. If flow is intermittent or exceeds these pres-
sures, replace cooler.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(11) Place CLEAR suction line into a one quart
container of Mopar ATF Plus 3ttype 7176 automatic
transmission fluid.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
OIL PUMP VOLUME CHECK
After the new or repaired transmission has been
installed, fill to the proper level with MopartAT F
PLUS 3 (Type 7176) automatic transmission fluid.
The volume should be checked using the following
procedure:
(1) Disconnect theFrom coolerline at the trans-
mission and place a collecting container under the
disconnected line.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engineat curb idle speed, with the
shift selector in neutral.
(3) If fluid flow is intermittent or it takes more
than 20 seconds to collect one quart of ATF PLUS 3,
disconnect theTo Coolerline at the transaxle.
(4) Refill the transaxle to proper level and recheck
pump volume.
(5) If flow is found to be within acceptable limits,
replace the cooler. Then fill transmission to the
proper level, using MopartATF PLUS 3 (Type 7176)
automatic transmission fluid.
(6) If fluid flow is still found to be inadequate,
check the line pressure using the Transaxle Hydrau-
lic Pressure Test procedure.
REMOVAL AND INSTALLATION
VEHICLE SPEED SENSOR PINION GEAR
When the sensor is removed for any reason, a
NEW O-ring must be installed on its outside diame-
ter.
REMOVAL
(1) Remove harness connector from sensor. Make
sure weatherseal stays on harness connector.
(2) Remove bolt securing the sensor in the exten-
sion housing.
(3) Carefully pull sensor and pinion gear assembly
out of extension housing.
(4) Remove pinion gear from sensor.
INSTALLATION
(1) To install, reverse the above procedure. Make
sure extension housing and sensor flange are clean
prior to installation. Always use a NEW sensor
O-ring.
(2) Tighten bolt to 7 N´m (60 in. lbs.). Tighten
speedometer cable to 4 N´m (35 in. lbs.).
PARK/NEUTRAL STARTING AND BACK-UP LAMP
SWITCH
TEST
The park/neutral starting switch is the center ter-
minal of the 3 terminal switch. It provides ground for
the starter solenoid circuit through the selector lever
in only Park and Neutral positions.
(1) To test switch, remove wiring connector from
switch and test for continuity between center pin of
switch and transaxle case. Continuity should exist
only when transaxle is in Park or Neutral.
(2) Check gearshift cable adjustment before replac-
ing a switch which tests bad.
REMOVAL
(1) Unscrew switch from transaxle case allowing
fluid to drain into a container. Move selector lever to
Park, then to Neutral position, and inspect to see the
switch operating lever fingers are centered in switch
opening.
INSTALLATION
(1) Screw the switch with a new seal into tran-
saxle case and tighten to 33 N´m (24 ft. lbs.). Retest
switch with the test lamp.
(2) Add fluid to transaxle to bring up to proper
level.
(3) The back-up lamp switch circuit is through the
two outside terminals of the 3 terminal switch.
(4) To test switch, remove wiring connector from
switch and test for continuity between the two out-
side pins.
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 19
SERVICE PROCEDURES (Continued)

(5) Continuity should exist only with transaxle in
Reverse position.
(6) No continuity should exist from either pin to
the case.
TRANSAXLE AND TORQUE CONVERTER REMOVAL
NOTE: Transaxle removal does NOT require engine
removal.
The transaxle and torque converter must be
removed as an assembly; otherwise, the torque con-
verter drive plate, pump bushing, or oil seal may be
damaged. The drive plate will not support a load;
therefore, none of the weight of the transaxle should
be allowed to rest on the plate during removal.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner and hoses.
(3) Disconnect throttle linkage and shift linkage
from transaxle.
(4) Unplug torque converter clutch connector,
located near the dipstick. Unplug the gear position
switch.
(5) Remove transaxle dipstick tube.
(6) Remove the transaxle cooler lines and plug.
(7) Install engine support fixture (Fig. 5) .
(8) Remove bell housing upper bolts.
(9) Raise vehicle. Remove front wheels. Refer to
Group 2, Suspension to remove or install wheel hub
nut and both drive shafts.
CAUTION: The exhaust flex joint must be discon-
nected from the exhaust manifold anytime the
engine is lowered. If the engine is lowered while the
flex pipe is attached, damage will occur.(10) Remove bolts securing exhaust flex joint to
exhaust manifold. Disconnect exhaust pipe from
manifold.
(11) Remove torque converter dust cover. Mark
torque converter and drive plate with chalk, for reas-
sembly. Rotate engine clockwise and remove torque
converter mounting bolts.
(12) Remove engine mount bracket from front
crossmember.
(13) Remove front mount insulator through-bolt
and bellhousing bolts.
(14) Position transaxle jack (Fig. 6) .
(15) Remove rear engine mount shield.
(16) Remove rear engine mount bracket bolts and
bracket.
(17) Remove left engine mount thru-bolt.
(18) Remove left engine mount from transaxle.
(19) Remove starter. Remove lower bell housing
bolts.
(20) Carefully work transaxle and torque converter
assembly rearward off engine block dowels and dis-
engage converter hub from end of crankshaft.Attach
a small C clamp to edge of bell housing. This
will hold torque converter in place during tran-
saxle removal.Lower transaxle and remove assem-
bly from under the vehicle.
(21) To remove torque converter assembly, remove
C±clamp from edge of bellhousing and slide converter
out of transaxle.
INSTALLATION
(1) When installing transaxle, reverse the above
procedure.
(2) If torque converter was removed from transaxle
be sure to align pump inner gear pilot flats with
torque converter impeller hub flats.
(3) Adjust gearshift and throttle cables.
(4) Refill transaxle with Mopar ATF PLUS 3
(Automatic Transmission Fluid) Type 7176.
Fig. 5 Engine Support Fixture
Fig. 6 Transaxle Jack
21 - 20 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)

FRONT PUMP OIL SEAL
The pump oil seal can be replaced without remov-
ing the pump and reaction shaft support assembly
from the transaxle case.
REMOVAL
(1) Screw seal remover Tool C-3981-B into seal
(Fig. 7), then tighten screw portion of tool to with-
draw the seal.
INSTALLATION
(1) To install a new seal, place seal in opening of
the pump housing (lip side facing inward). Using Tool
C-4193 and Handle Tool C-4171, drive new seal into
housing until tool bottoms (Fig. 8).
DISASSEMBLY AND ASSEMBLY
TRANSAXLE
Prior to removing any transaxle parts, plug all
openings and clean the unit, preferably with steam.
When disassembling, each part should be washed in
a suitable solvent, then dried with compressed air.
Do not wipe parts with shop towels. All mating sur-
faces in the transaxles are accurately machined;
therefore, careful handling of all parts must be exer-
cised to avoid nicks or burrs.
DISASSEMBLY
Remove all old sealant before applying new seal-
ant.
Use only MopartSilicone Rubber Sealant or equiv-
alent when installing oil pan.
Put sealant on the oil pan flange (Fig. 10) and on
all oil pan bolts (underside of bolt head).
Fig. 7 Remove Pump Oil Seal
Fig. 8 Install Pump Oil Seal
Fig. 9 Transaxle Oil Pan Bolts
Fig. 10 Transaxle Oil Pan
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 21
REMOVAL AND INSTALLATION (Continued)

Remove neutral starting and back-up lamp switch.
Measuring input shaft end play before disassembly
will usually indicate if a thrust washer change isrequired. The thrust washer is located between input
and output shafts.
Fig. 11 Oil Filter Screws
Fig. 12 Oil Filter
Fig. 13 Remove Parking Rod E-Clip
Fig. 14 Parking Rod
Fig. 15 Valve Body Attaching Bolts
Fig. 16 Valve Body and Governor Tubes
21 - 22 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

Attach a dial indicator to transaxle bell housing
with its plunger seated against end of input shaft
(Fig. 17).
Move input shaft in and out to obtain end play
reading. End play specifications are 0.19 to 1.50 mm
(0.008 to 0.060 inch).
Record indicator reading for reference when reas-
sembling the transaxle.
Remove Number 6 thrust washer from sun
gear driving shell.
Fig. 17 Measure Input Shaft End Play
Fig. 18 Loosen Lock Nut and Tighten Kickdown
Band Adjusting Screw
Fig. 19 Pump Attaching Bolts
Fig. 20 Install Tool C-3752 with Adapters L-4437
Fig. 21 Oil Pump with No. 1 Thrust Washer
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 23
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 22 Oil Pump Gasket
Fig. 23 Loosen Kickdown Band Adjusting Screw
Fig. 24 Kickdown Band and Strut
Fig. 25 Front Clutch Assembly
Fig. 26 No. 2 Thrust Washer and Rear Clutch
Fig. 27 No. 3 Thrust Washer
21 - 24 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 28 Front Planetary Gear Snap Ring
Fig. 29 Front Planetary Gear Assembly
Fig. 30 Sun Gear Driving Shell
Fig. 31 Sun Gear Driving Shell Components
Fig. 32 No. 9 Thrust Washer
Fig. 33 Rear Planetary Gear Assembly
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 25
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 34 No. 10 Thrust Washer
Fig. 35 Overrunning Clutch Cam Assembly
Fig. 36 Overrunning Clutch Rollers and Spring
Fig. 37 Loosen or Adjust Low/Reverse Band
Fig. 38 Low/Reverse Band and Strut
Fig. 39 No. 11 Thrust Washer
21 - 26 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)