CHRYSLER VOYAGER 1996 Service Manual

NOTE: Dependent on engine application, some accu-
mulators will have two springs and others will have
one spring. The springs are color coded according to
application and year. When disassembling, mark accu-
mulator spring location to ease assembly.
Fig. 68 Accumulator (Underdrive)
Fig. 69 Accumulator (Overdrive)
Fig. 70 Remove Low/Reverse Accumulator Snap Ring
Fig. 71 Remove Low/Reverse Accumulator Plug
(Cover)
Fig. 72 Remove Low/Reverse Accumulator Piston
Fig. 73 Remove Low/Reverse Accumulator
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DISASSEMBLY AND ASSEMBLY (Continued)

Measure the input shaft end play with the tran-
saxle in the vertical position. This will ensure that
the measurement will be accurate.
Measuring input shaft end play before disassembly
will usually indicate when a #4 thrust plate change
is required. The #4 thrust plate is located behind the
overdrive clutch hub.
Attach a dial indicator to transaxle bell housing
with its plunger seated against end of input shaft
(Fig. 74).
Move input shaft in and out to obtain end play
reading. End play specifications are .13 to .64 mm
(.005 to .025 inch).
Record indicator reading for reference when reas-
sembling the transaxle.
CAUTION: Be sure input speed sensor is removed
before removing oil pump.
OIL PUMP INSPECTION
When disassembling the transaxle it is necessary
to inspect the oil pump for wear and damage.
(1) Remove the reaction shaft support bolts.
Fig. 74 Measure Input Shaft End Play
Fig. 75 Remove Pump Attaching Bolts
Fig. 76 Install Tool C-3752
Fig. 77 Remove Oil Pump
Fig. 78 Oil Pump Removed
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DISASSEMBLY AND ASSEMBLY (Continued)

(2) Remove reaction shaft support from pump
housing (Fig. 80).
(3) Remove the pump gears and check for wear
and damage.
(4) Install the gears and check clearances.
(5) Measure the clearance between the outer gear
and the pump pocket (Fig. 81). Clearance should be
0.045-0.141mm (0.0018-0.0056 in.).
(6) Measure the clearance between the outer gear
and the pump crescent. Clearance should be 0.020-
0.046mm (0.0008-0.0018 in.) (Fig. 82).
(7) Measure the clearance between the inner gear
and the pump crescent. Clearance should be 0.020-
0.046mm (0.0008-0.0018 in.) (Fig. 83).
Fig. 79 Remove Oil Pump Gasket
Fig. 80 Reaction Shaft Support
Fig. 81 Measure Outer Gear to Pocket
Fig. 82 Measure Outer Gear To Crescent
Fig. 83 Measure Inner Gear To Crescent
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 99
DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: The cooler bypass valve must be
replaced if a transaxle failure has occurred. Do not
reuse old valve or attempt to clean old valve. When
installing bypass valve, insert with O-ring end
towards rear of case.
Fig. 84 Remove Bypass Valve
Fig. 85 Remove Caged Needle Bearing
Fig. 86 Remove Input Clutches Assembly
Fig. 87 No. 4 Thrust Plate
Fig. 88 Remove Front Sun Gear Assembly
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DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Verify that Miller Tool 5058 is centered prop-
erly to the 2/4 clutch retainer before depressing the
tool.
Fig. 89 Remove Front Carrier and Rear Annulus
Assembly
Fig. 90 Remove Rear Sun Gear
Fig. 91 Remove 2/4 Clutch Retainer Snap Ring
Fig. 92 Remove 2/4 Clutch Retainer
Fig. 93 2/4 Clutch Retainer
Fig. 94 Remove 2/4 Clutch Return Spring
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 101
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Tag 2/4 clutch pack for reassembly identifi-
cation.
Fig. 95 Remove 2/4 Clutch Pack
Fig. 96 Remove Tapered Snap Ring
Fig. 97 Remove Low/Reverse Reaction Plate
Fig. 98 Remove One Disc
Fig. 99 Remove Low/Reverse Reaction Plate Snap
Ring
Fig. 100 Remove Low/Reverse Clutch Pack
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DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Tag low/reverse clutch pack for reassembly
identification.
Fig. 101 Remove Rear Cover Bolts
Fig. 102 Remove Rear Cover
Fig. 103 Remove Transfer Shaft Gear Nut
Fig. 104 Transfer Shaft Gear Nut and Coned Washer
Fig. 105 Remove Transfer Shaft Gear
Fig. 106 Remove Transfer Shaft Gear and (Select)
Shim
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DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Screw Tool 5049-A onto transfer shaft.
Remove transfer shaft.
Fig. 107 Remove Bearing Cup Retainer
Fig. 108 Remove Transfer Gear Bearing Cone
Fig. 109 Remove Transfer Shaft Bearing Cup
Fig. 110 Remove Transfer Shaft Bearing Snap Ring
Fig. 111 Remove Transfer Shaft
Fig. 112 Bearing Cup Removed
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DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Remove output gear stirrup and strap bolts.
All transaxles utilize a stirrup and retaining strap
that is attached to the output gear. The stirrup pre-
vents the output gear retaining bolt from turning
and backing out of the rear carrier. The strap is used
to hold the stirrup to the output gear and prevent
the stirrup retaining bolts from backing out.
CAUTION: When installing, be sure guide bracket
and split sleeve touch the rear of the transaxle
case.
Fig. 113 Remove Transfer Shaft Bearing Cone
Fig. 114 Loosen Stirrup Strap Bolts
Fig. 115 Remove Strap Bolts
Fig. 116 Remove Stirrup Strap
Fig. 117 Remove Stirrup
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DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 118 Remove Output Gear Bolt
Fig. 119 Output Gear Bolt and Washer
Fig. 120 Remove Output Gear
Fig. 121 Output Gear and (Select) Shim
Fig. 122 Remove Bearing Cone
Fig. 123 Remove Rear Carrier Assembly
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DISASSEMBLY AND ASSEMBLY (Continued)