CHRYSLER VOYAGER 1996 Service Manual

ASSEMBLY
When rebuilding, reverse the above procedure.
VALVE BODY RECONDITION
NOTE: Tighten all valve body screws to 5 N´m (40
in. lbs.).
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.
Fig. 40 Install Overrunning Clutch Rollers and
Springs
Fig. 41 Detent Spring Attaching Screw and Spring
Fig. 42 Using Tool L-4553 on Valve Body Screw
Fig. 43 Remove or Install Valve Body Screws
Fig. 44 Transfer Plate and Separator Plate
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DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 45 Steel Ball Locations
Fig. 46 Remove or Install Throttle Shaft E-Clip
Fig. 47 Throttle Shaft E-Clip, Washer, and Seal
Fig. 48 Manual Valve Lever Assembly
Fig. 49 Throttle Valve Lever Assembly
Fig. 50 Manual Valve
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DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 52 Pressure Regulators and Manual Controls
Fig. 51 Pressure Regulator and Adjusting Screw
Bracket
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DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 53 Governor Plugs
Fig. 54 Pressure Regulator Valve Plugs
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DISASSEMBLY AND ASSEMBLY (Continued)

OIL PUMP-RECONDITION
NOTE: Also, check gear side clearance with a
straight edge and a feeler gauge (See Specifica-
tions).
Fig. 55 Shift Valves and Shuttle Valve
Fig. 56 Reaction Shaft Support Bolts
Fig. 57 Reaction Shaft Support
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DISASSEMBLY AND ASSEMBLY (Continued)

FRONT CLUTCH-RECONDITION
INSPECTION
Inspect plates and discs for flatness. They must not
be warped or cone shaped.
Inspect facing material on all driving discs.
Replace discs that are charred, glazed or heavily pit-
ted. Discs should also be replaced if they show evi-
dence of material flaking off or if facing material can
be scraped off easily. Inspect driving disc splines for
wear or other damage. Inspect steel plate surfaces for
burning, scoring, or damaged driving lugs. Replace if
necessary.
Inspect steel plate lug grooves in clutch retainer
for smooth surfaces, plates must travel freely in
grooves. Inspect band contacting surface on clutchretainer for scores, the contact surface should be
protected from damage during disassembly and han-
dling. Note ball check in clutch retainer, make sure
ball moves freely. Inspect piston seal surfaces in
clutch retainer for nicks or deep scratches, light
scratches will not interfere with sealing of seals.
Inspect clutch retainer inner bore surface for wear
from reaction shaft support seal rings. Inspect
clutch retainer bushing for wear or scores.
Inspect inside bore of piston for score marks, if
light, remove with crocus cloth. Inspect seal grooves
for nicks and burrs. Inspect seals for deterioration,
wear, and hardness. Inspect piston spring, retainer
and snap ring for distortion.
DISASSEMBLY
Fig. 58 Inner and Outer Pump Gears
Fig. 59 Measuring Pump Clearance (Gear to Pocket)
Fig. 60 Front Clutch Waved Snap Ring
Fig. 61 Thick Steel Plate and Waved Snap Ring
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DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
To reassemble, reverse the above procedure.MEASURING PLATE CLEARANCE
REAR CLUTCH-RECONDITION
INSPECTION
Inspect facing material on all driving discs.
Replace discs that are charred, glazed or heavily pit-
ted. Discs should also be replaced if they show evi-
dence of material flaking off or if facing material can
be scraped off easily. Inspect driving disc splines for
wear or other damage. Inspect steel plate and pres-
sure plate surface for burning, scoring or damaged
driving lugs. Re place if necessary. Inspect plates and
discs for flatness, they must not be warped or cone-
shaped.
Inspect steel plate lug grooves in clutch retainer
for smooth surfaces, plates must travel freely in the
grooves. Note ball check in piston; make sure ball
moves freely. Inspect seal rings surfaces in clutch
retainer for nicks or deep scratches; light scratches
will not interfere with sealing of the seals. Inspect
neoprene seal rings for deterioration, wear and hard-
ness. Inspect piston spring and waved snap ring for
distortion or breakage.
Inspect teflon and/or cast iron seal rings on input
shaft for wear. Do not remove rings unless conditions
warrant. Inspect rear clutch to front clutch No. 2
thrust washer for wear. Washer thickness should be
.061 to .063 inch, replace if necessary.
DISASSEMBLY
Press out input shaft, if required.
ASSEMBLY
To reassemble, reverse the above procedure.
Fig. 62 Front Clutch (4-Disc Shown)
Fig. 63 Front Clutch Return Spring Snap Ring
Fig. 64 Front Clutch Return Spring and Piston
Fig. 65 Measuring Front Clutch Plate Clearance
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DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 66 Rear Clutch Outer Snap Ring
Fig. 67 Rear Clutch (4-Disc Shown)
Fig. 68 Piston Spring Waved Snap Ring
Fig. 69 Rear Clutch Piston and Piston Spring
Fig. 70 Remove or Install Input Shaft Snap Ring
Fig. 71 Input Shaft Snap Ring
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DISASSEMBLY AND ASSEMBLY (Continued)

MEASURING PLATE CLEARANCE
FRONT PLANETARY & ANNULUS GEAR-
RECONDITION
Fig. 72 Measuring Rear Clutch Plate Clearance
Fig. 73 Front Planetary Gear Snap Ring and No. 4
Thrust Washer (Always Install a New Snap Ring)
Fig. 74 Front Planetary Gear
Fig. 75 Annulus Gear Support Front Snap Ring
Fig. 76 Front Annulus Gear Support and Snap Ring
Fig. 77 Front Annulus Gear Support Snap Ring
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DISASSEMBLY AND ASSEMBLY (Continued)

LOW/REVERSE (REAR) SERVO-RECONDITION
DISASSEMBLYASSEMBLY
To assemble, reverse the above procedure.
ACCUMULATOR-RECONDITION
DISASSEMBLY
Fig. 78 Low/Reverse Lever
Fig. 79 Low/Reverse Servo Snap Ring
Fig. 80 Remove Retainer, Spring and Servo
Fig. 81 Low/Reverse Servo Assembly
Fig. 82 Accumulator Snap Ring
Fig. 83 Accumulator Plate and Snap Ring
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DISASSEMBLY AND ASSEMBLY (Continued)