CHRYSLER VOYAGER 1996 Service Manual

CAUTION: Always use new retaining bolt, old
retaining bolt may not be reused.
(9) Install the new retaining bolt and washer (Fig.
226). Tighten to 271 N´m (200 ft. lbs.) (Fig. 227).
(10) Using an inch-pound torque wrench, check the
turning torque (Fig. 228).The torque should be
between 3 and 8 inch-pounds.
If the turning torque is too high, install a .04 mm
(.0016 inch) thicker shim. If the turning torque is too
low, install a .04 mm (.0016 inch) thinner shim.
Repeat until the proper turning torque is 3 to 8 inch
pounds.
NOTE: Install 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.
Fig. 226 Install Output Gear Bolt and Washer
Fig. 227 Tighten Output Gear to 271 N´m
(200 ft. lbs.)
Fig. 228 Check Output Gear Bearings Turning
Torque
Fig. 229 Output Gear Retaining Bolt Stirrup
(Serration Side Out)
Fig. 230 Stirrup Strap (Align Strap Holes With
Tapped Gear Holes)
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DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 231 Install Strap Bolts
Fig. 232 Turn Stirrup Clockwise Against Flats Of
Output Gear Retaining Bolt
Fig. 233 Tighten Stirrup Strap Bolts To 23 N´m
(200 in. lbs.)
Fig. 234 Bend Tabs On Strap Up Against Flats Of
Bolts
Fig. 235 Install Transfer Shaft Bearing Cone
Fig. 236 Install Bearing Cup To Shaft
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DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Screw Tool 5049-A onto transfer shaft.
Install transfer shaft.
TRANSFER SHAFT BEARING
(1) Install a 4.66 mm (.184 inch) gauging shim on
the transfer shaft.
(2) Install transfer shaft gear and bearing assem-
bly and torque the nut to 271 N´m (200 ft. lbs.).
To measure bearing end play:
²Attach Tool L-4432 to the transfer gear.
²Mount a steel ball with grease into the end of
the transfer shaft.
²Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
²Using a dial indicator, measure transfer shaft
end play.
(3) Refer to the Transfer Bearing Shim Chart for
the required shim combination to obtain the proper
bearing setting.
(4) Use Tool 6259 to remove the retaining nut and
washer. Remove the transfer shaft gear using Tool
L-4407.
Fig. 237 Install Transfer Shaft
Fig. 238 Install Transfer Shaft Bearing Snap Ring
Fig. 239 Install Transfer Shaft Bearing Cup Into
Retainer
Fig. 240 Install Bearing Cup Retainer
Fig. 241 Install Transfer Gear Bearing Cone
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DISASSEMBLY AND ASSEMBLY (Continued)

TRANSFER SHAFT BEARING SHIM CHART
End Play Shim Needed Part Number End Play Shim Needed Part Number
.05mm .002 in. 4.66mm .183 in. 4505588 .76mm .030 in. 3.94mm .155 in. 4412818
.08mm .003 in. 4.62mm .182 in. 4412835 .79mm .031 in. 3.90mm .154 in. 4412817
.10mm .004 in. 4.58mm .180 in. 4412834 .81mm .032 in. 3.90mm .154 in. 4412817
.13mm .005 in. 4.58mm .180 in. 4412834 .84mm .033 in. 3.86mm .152 in. 4412816
.15mm .006 in. 4.54mm .178 in. 4412833 .86mm .034 in. 3.82mm .150 in. 4412815
.18mm .007 in. 4.50mm .177 in. 4412832 .89mm .035 in. 3.82mm .150 in. 4412815
.20mm .008 in. 4.50mm .177 in. 4412832 .91mm .036 in. 3.78mm .149 in. 4412814
.23mm .009 in. 4.46mm .175 in. 4412831 .94mm .037 in. 3.74mm .147 in. 4412813
.25mm .010 in. 4.46mm .175 in. 4412831 .97mm .038 in. 3.74mm .147 in. 4412813
.28mm .011 in. 4.42mm .174 in. 4412830 .99mm .039 in. 3.70mm .146 in. 4412812
.30mm .012 in. 4.38mm .172 in. 4412829 1.02mm .040 in. 3.66mm .144 in. 4412811
.33mm .013 in. 4.38mm .172 in. 4412829 1.04mm .041 in. 3.66mm .144 in. 4412811
.36mm .014 in. 4.34mm .171 in. 4412828 1.07mm .042 in. 3.62mm .143 in. 4412810
.38mm .015 in. 4.30mm .169 in. 4412827 1.08mm .043 in. 3.62mm .143 in. 4412810
.41mm .016 in. 4.30mm .169 in. 4412827 1.12mm .044 in. 3.58mm .141 in. 4412809
.43mm .017 in. 4.26mm .168 in. 4412826 1.14mm .045 in. 3.54mm .139 in. 4412808
.46mm .018 in. 4.22mm .166 in. 4412825 1.17mm .046 in. 3.54mm .139 in. 4412808
.48mm .019 in. 4.22mm .166 in. 4412825 1.19mm .047 in. 3.50mm .138 in. 4412807
.50mm .020 in. 4.18mm .165 in. 4412824 1.22mm .048 in. 3.46mm .136 in. 4412806
.53mm .021 in. 4.18mm .165 in. 4412824 1.24mm .049 in. 3.46mm .136 in. 4412806
.56mm .022 in. 4.14mm .163 in. 4412823 1.27mm .050 in. 3.42mm .135 in. 4412805
.58mm .023 in. 4.10mm .161 in. 4412822 1.30mm .051 in. 3.38mm .133 in. 4412804
.61mm .024 in. 4.10mm .161 in. 4412822 1.32mm .052 in. 3.38mm .133 in. 4412804
.64mm .025 in. 4.06mm .160 in. 4412821 1.35mm .053 in. 3.34mm .132 in. 4412803
.66mm .026 in. 4.02mm .158 in. 4412820 1.37mm .054 in. 3.34mm .132 in. 4412803
.69mm .027 in. 4.02mm .158 in. 4412820 1.40mm .055 in. 3.30mm .130 in. 4412802
.71mm .028 in. 3.98mm .157 in. 4412819 1.45mm .057 in 3.26mm .128 in. 4412801
.74mm .029 in. 3.94mm .155 in. 4412818 1.47mm .058 in. 2.22mm .127 in. 4505570
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DISASSEMBLY AND ASSEMBLY (Continued)

(5) Remove the gauging shim and install the cor-
rect shim (Fig. 242). Install the transfer gear and
bearing assembly (Fig. 243).
CAUTION: Original retaining nut may not be
reused. Always use a new retaining nut when reas-
sembling.
(6) Install the new retaining nut and washer and
torque to 271 N´m (200 ft. lbs.) (Fig. 244).Measure
transfer shaft end play, end play should be .05
to .10 mm (.002 to .004 inch).
(7) Measure bearing end play as outlined in . End
play should be between .05 mm and .10 mm (.002 to
.004 inch).
NOTE: If end play is too high, install a .04 mm
(.0016 inch) thinner shim. If end play is too low,
install a .04 mm (.0016 inch) thicker shim combina-
tion. Repeat until .05 to .10 mm (.002 to .004 inch)
end play is obtained.NOTE: Install the low/reverse reaction plate
stepped side up.
Fig. 242 Transfer Shaft Gear and (Select) Shim
Fig. 243 Install Transfer Shaft Gear
Fig. 244 Tighten Nut to 271 N´m (200 ft. lbs.)
Fig. 245 Install Rear Cover
Fig. 246 Install Rear Cover Bolts
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DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 247 Install Low/Reverse Clutch Pack
Fig. 248 Install Low/Reverse Reaction Plate Snap
Ring
Fig. 249 Install One Disc
Fig. 250 Tapered Snap Ring Instructions
Fig. 251 Snap Ring Installed
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DISASSEMBLY AND ASSEMBLY (Continued)

Press down clutch pack with finger and zero dial
indicator.Low/Reverse clutch pack clearance is
0.89 to 1.04 (.035 to .042 inch).
Select the proper low/reverse reaction plate to
achieve specifications:
NOTE: When installing the 2-4 clutch plates and
discs, the orientation should be alternated so thepilot pads of adjacent plates do not align, refer to
(Fig. 254).
Fig. 252 Check Low/Reverse Clutch Clearance
LOW/REVERSE REACTION PLATE CHART
PART NUMBER THICKNESS
4567893 6.92mm (.273 in.)
4567899 6.66mm (.262 in.)
4567898 6.40mm (.252 in.)
4567897 6.14mm (.242 in.)
4567896 5.88mm (.232 in.)
4567895 5.62mm (.221 in.)
4567894 5.36mm (.211 in.)
Fig. 253 Install 2/4 Clutch Pack
Fig. 254 Stagger 2/4 Clutch Plate Pads
Fig. 255 Install 2/4 Clutch Return Spring
Fig. 256 Proper Orientation of 2/4 Clutch Retainer
and Spring
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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.Press down clutch pack with finger and zero dial
indicator.The 2/4 clutch pack clearance is 0.76 to
2.64mm (.030 to .104 inch).If not within specifica-
tions, the clutch is not assembled properly.There is
no adjustment for the 2/4 clutch clearance.
DETERMINING No. 4 THRUST PLATE
THICKNESSÐINPUT SHAFT END PLAY
To determine the proper thickness of the No. 4
thrust plate, select the thinnest No. 4 thrust plate.
Using petrolatum (Fig. 263) to hold thrust plate in
position, install input clutch assembly. Be sure the
input clutch assembly is completely seated (Fig. 264).
CAUTION: If view through input speed sensor hole
is not as shown above, the input clutches assembly
is not seated properly.
Remove the oil pump O-ring (Fig. 265). You will be
able to install and remove the oil pump and gasket
very easily to select the proper No. 4 thrust plate.
Fig. 257 Install 2/4 Clutch Retainer
Fig. 258 Install 2/4 Clutch Retainer Snap Ring
Fig. 259 Check 2/4 Clutch Clearance
Fig. 260 Install Rear Sun Gear
Fig. 261 Install Front Carrier and Rear Annulus
Assembly
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DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Use screw-in dowels or phillips-head screw-
drivers to align pump to case.CAUTION: Be sure to reinstall O-ring on oil pump
after selecting the proper No. 4 thrust plate.
Measure the input shaft end play with the tran-
saxle in the vertical position. This will ensure that
the measurement will be accurate.
NOTE: Input shaft end play must be .005 to .025
inch.
For example, if end play reading is .055 inch, select
No. 4 Thrust Plate which is .071 to .074 thick. This
should provide an input shaft end play reading of
.020 inch which is within specifications.
Fig. 262 Install Front Sun Gear Assembly
Fig. 263 Select Thinnest No. 4 Thrust Plate
Fig. 264 View Through Input Speed Sensor Hole
Fig. 265 Remove Oil Pump O-Ring
Fig. 266 Measure Input Shaft End Play
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DISASSEMBLY AND ASSEMBLY (Continued)

See chart to select the proper No. 4 thrust plate.
Reinstall the input clutches assembly with the
selected thrust plate .
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.
NO. 4 THRUST PLATE CHART
PART NUMBER THICKNESS
4431662 .91mm (.036 in.)
4431663 1.14mm (.045 in.)
4431664 1.37mm (.054 in.)
4431665 1.60mm (.063 in.)
3836237 1.73mm (.068 in.)
4431666 1.80mm (.071 in.)
3836238 1.96mm (.077 in.)
4431667 2.03mm (.080 in.)
3836239 2.16mm (.085 in.)
4431668 2.24mm (.088 in.)
3836240 2.39mm (.094 in.)
4431669 2.46mm (.097 in.)
3836241 2.62mm (.103 in.)
4446670 2.67mm (.105 in.)
4446671 2.90mm (.114 in.)
4446672 3.15mm (.124 in.)
4446601 3.38mm (.133 in.)
Fig. 267 Install Input Clutches Assembly
Fig. 268 Install Caged Needle Bearing
Fig. 269 Install Bypass Valve
Fig. 270 Install Oil Pump Gasket
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DISASSEMBLY AND ASSEMBLY (Continued)