differential CHRYSLER VOYAGER 1996 Owner's Manual

WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
(4) Use Miller Special Tool 5048, 5048-3 Collets,
and L-4539-2 Button to remove the differential bear-
ing cone on the extension housing side.
(5) Use Miller Special Tool 5048, 5048-4 Collets,
and L-4539-2 Button to remove the differential bear-
ing cone on the bearing retainer side (Fig. 289) (Fig.
290) (Fig. 291).
(6) Using Miller Special Tool L-4518, remove the
differential bearing race from the extension housing.
(7) Using Miller Special Tool 6062A, remove the
differential bearing race from the bearing retainer
(Fig. 292) (Fig. 293).
Fig. 288 Remove Bearing Retainer
Fig. 289 Position Button and Collets Onto
Differential and Bearing (Ring Gear Side)
Fig. 290 Position Tool 5048 Over Button and Collets
at Differential Bearing (Ring Gear Side)
Fig. 291 Remove Differential Bearing Cone (Ring
Gear Side)
Fig. 292 Position Bearing Cup Remover Tool in
Retainer
21 - 140 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

CHECKING SIDE GEAR END PLAY
Check side gear end play whenever the differential
is removed for service.
NOTE: Side gear end play must be BETWEEN 0.001
to 0.013 inch.
ASSEMBLE
NOTE: Use MoparTSilicone Rubber Adhesive Seal-
ant, or equivalent, on retainer and extension hous-
ing/adapter plate to seal to case.
(1) Using Miller Special Tool L-4410, and C-4171,
install differential bearing to differential (extension
housing side) (Fig. 296).
Fig. 293 Remove Bearing Cup
DIFFERENTIAL SERVICE TOOLS
COMPONENT REMOVER INSTALLER
Diff. Bear. On
Retainer Side5048, 5048-4
Collets,
L-4539-2
Button5052, C-4171
Diff. Bear. On
Ext. Hous. Side5048, 5048-3
Collets,
L-4539-2
ButtonL-4410, C-4171
Diff. Race. On
Retainer Side6062-A 6061, C-4171
Diff. Race. On
Ext. Hous. SideL-4518 L-4520, C-4171
Extension
Housing Seal7794-A, C-637
Slide HammerL-4520, C-4171
Bearing
Retainer Seal794-A, C-637
Slide HammerL-4520, C-4171
Fig. 294 Checking Side Gear End Play (Extension
Housing Side)
Fig. 295 Checking Side Gear End Play (Bearing
Retainer Side)
Fig. 296 Position Bearing Cone Onto Differential
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 141
DISASSEMBLY AND ASSEMBLY (Continued)

(2) Using Miller Special Tool 5052 and C-4171,
install differential bearing to differential (bearing
retainer side).
(3) Using Miller Special Tool 6061 and C-4171,
install differential bearing race to bearing retainer
(Fig. 297).
(4) Using Miller Special Tool L±4520 and C-4171,
install differential bearing to extension housing.
DIFFERENTIAL BEARING PRELOAD
ADJUSTMENT
NOTE: Perform all differential bearing preload mea-
surements with the transfer shaft and gear
removed.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING
EXISTING SHIM
(1) Position the transaxle assembly vertically on
the support stand, differential bearing retainer side
up.
(2) Install Tool L-4436A into the differential and
onto the pinion mate shaft (Fig. 298).
(3) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.
(4) Using Tool L-4436A and an inch-pound torque
wrench, check the turning torque of the differential
(Fig. 299).The turning torque should be
between 5 and 18 inch-pounds.
(5) If the turning torque is within specifications,
remove tools. Setup is complete.
(6) If turning torque is not within specifications
proceed with the following steps.
(a) Remove differential bearing retainer from
the transaxle case.
(b) Remove the bearing cup from the differential
bearing retainer using Tool 6062A.(c) Remove the existing shim from under the
cup.
(d) Measure the existing shim.
NOTE: If the turning torque was too high when
measured, install a .05 mm (.002 inch) thinner shim.
If the turning torque is was too low, install a .05 mm
(.002 inch) thicker shim. Repeat until 5 to 18 inch-
pounds turning torque is obtained.
Oil Baffle is not required to be installed when
making shim selection.
(e) Install the proper shim under the bearing
cup. Make sure the oil baffle is installed properly
in the bearing retainer, below the bearing shim
and cup.
(f) Install the differential bearing retainer using
Tool 5052 and C-4171. Seal the retainer to the
housing with MOPARtAdhesive Sealant and
torque bolts to 28 N´m (250 in. lbs.).
Fig. 297 Differential Bearing Retainer
Fig. 298 Tool L-4436 and Torque Wrench
Fig. 299 Checking Differential Bearings Turning
Torque
21 - 142 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

(7) Using Tool L-4436A and an inch-pound torque
wrench, recheck the turning torque of the differential
(Fig. 299).The turning torque should be
between 5 and 18 inch-pounds.
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Differential carrier
²Differential bearing retainer
²Extension housing
²Differential bearing cups and cones
PRELOAD ADJUSTMENT W/O SHIM
(1) Remove the bearing cup from the differential
bearing retainer using Miller special Tool 6062A.
(2) Remove existing shim from under bearing cup.
(3) Reinstall the bearing cup into the retainer
using Miller Special Tool 6061, and C-4171.
NOTE: Oil baffle is not required when making the
shim calculation.
(4) Install the bearing retainer into the case.
Torque bolts to 28 N´m (250 in. lbs.).(5) Position the transaxle assembly vertically on
the support stand and install Miller Special Tool
L-4436-A into the bearing retainer.
(6) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.
(7) Attach a dial indicator to the case and zero the
dial. Place the tip on the end of Special Tool
L-4436-A.
(8) Place a large screwdriver to each side of the
ring gear and lift. Check the dial indicator for the
amount of end play.
CAUTION: Do not damage the transaxle case
and/or differential retainer sealing surface.
(9) Using the end play measurement that was
determined, add .18mm (.007 inch). This should give
you between 5 and 18 inch pounds of bearing pre-
load. Refer to the Differential Bearing Shim Chart to
determine which shim to use.
(10) Remove the differential bearing retainer.
Remove the bearing cup.
DIFFERENTIAL BEARING SHIM CHART
PART NUMBER SHIM THICKNESS
MM INCH
4659257 .980 0.0386
4659258 1.02 0.0402
4659259 1.06 0.0418
4659260 1.10 0.0434
4659261 1.14 0.0449
4659262 1.18 0.0465
4659263 1.22 0.0481
4659264 1.26 0.0497
4659265 1.30 0.0512
4659266 1.34 0.0528
4659267 1.38 0.0544
4659268 1.42 0.0560
4659269 1.46 0.0575
4659270 1.50 0.0591
4659271 1.54 0.0607
4659272 1.58 0.0623
4659273 1.62 0.0638
4659274 1.66 0.0654
4659275 1.70 0.0670
4659283 2.02 0.0796
4659284 2.06 0.0812
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 143
DISASSEMBLY AND ASSEMBLY (Continued)

(11) Install the oil baffle. Install the proper shim
combination under the bearing cup.
(12) Install the differential bearing retainer. Seal
the retainer to the housing with MopartSilicone
Rubber Adhesive Sealant. Torque bolts to 28 N´m
(250 in. lbs.).
(13) Using Miller Special Tool L-4436-A and an
inch-pound torque wrench, check the turning torque
of the differential (Fig. 299). The turning torque
should be between 5-18 inch-pounds.
NOTE: If turning torque is too high install a .05mm
(.002 inch) thicker shim. If the turning torque is too
low, install a .05mm (.002 inch) thinner shim. Repeat
until 5-18 inch-pounds of turning torque is
obtained.
CLEANING AND INSPECTION
CLEANING VALVE BODY
Prior to removing any transaxle parts, plug all
openings and clean unit, preferably by steam. Clean-
liness through entire disassembly and assembly can-
not be overemphasized. When disassembling, each
part should be washed in a suitable solvent, then
dried by compressed air.Do not wipe parts with
shop towels.All mating surfaces in the transaxles
are accurately machined; therefore, careful handling
of all parts must be exercised to avoid nicks or burrs.
NOTE: Tag all springs, as they are removed, for
reassembly identification.
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT
Lift and rotate the gearshift hand lever into the
park (P) gate position and remove the ignition key.This confirms the shift lever is in the gated park (P)
position.
After confirming the park gate position, turn the
ignition switch. If the starter will operate, the park
gate position is correct. Move the shift lever into the
neutral (N) position. If the starter will operate in this
position, the linkage is properly adjusted. If the
starter fails to operate in either position, linkage
adjustment is required.
(1) Park the vehicle on level ground and set the
parking brake.
(2) Place the gearshift lever in park (P) gate posi-
tion and remove key.
(3) Loosen the cable adjustment screw at the tran-
saxle operating lever (Fig. 300).
(4) Pull the transaxle operating lever fully forward
to the park detent position.
(5) Release the park brake, then rock the vehicle
to assure it is in park lock. Reset the park brake.
(6) Tighten the cable adjustment screw to 8 N´m
(70 in. lbs.). Gearshift cable should now be properly
adjusted.
(7) Check adjustment by using the preceding pro-
cedure.
Fig. 300 Gearshift Cable Adjustment
21 - 144 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

SPECIFICATIONS
41TE AUTOMATIC TRANSAXLE
Type..........................Fully adaptive,
electronically controlled,
four speed automatic with
torque converter
and integral differential
Torque Converter Diameter........241 millimeters
(9.48 in.)
Oil Capacity........................8.6 Liters
(18.25 pints)
OilType...........MopartATF PLUS 3Type 7176
Cooling Method...........Water Heat Exchanger
and/or air to oil
heat exchanger
Lubrication......Pump (internal-external gear-type
Gear Ratios
Transmission Portion
First Gear..............................2.84
Second Gear.............................1.57
Direct Gear.............................1.00
Overdrive Gear..........................0.69
Reverse Gear............................2.21
Overall Top Gear Ratio
3.8 Liter................................2.38
3.3 Liter................................2.49
2.4 Liter................................2.69
Pump Clearances
Outer Gear To Pocket.............0.045-0.141mm
(0.0018-0.0056 in.)
Outer Gear Side Clearance.........0.020-0.046mm
(0.0008-0.0018 in.)
Inner Gear Side Clearance.........0.020-0.046mm
(0.0008-0.0018 in.)
Tapered Roller Bearing Settings
Differential Assembly . . .5 to 18 in. lbs. Drag Torque
Output Hub............3to8in.lbs. Drag Torque
Transfer Shaft.........0.002 to 0.004 in. End Play
Overall Drag At Output Hub........3to16in.lbs.
Drag Torque
Clutch Pack Clearances
Low/Rev Clutch
(Select Reaction Plate)............0.89-1.04mm
(0.035-0.042 in.)
Two/Four Clutch
(No Selection)...................0.76-2.64mm
(0.030-0.104 in.)Reverse Clutch (Select Snap Ring).....0.76-1.24mm
(0.030-0.049 in.)
Overdrive Clutch
(No Selection)...................0.96-2.26mm
(0.038-0.089 in.)
Underdrive Clutch
Select Pressure Plate)............0.91-1.47mm
(0.036-0.058 in.)
Transmission End Play.............0.12-0.63mm
(0.005-0.025 in.)
41TE TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Cooler Line Fittings..........12N´m(105 in. lbs.)
Differential Cover............19N´m(165 in. lbs.)
Differential Ring Gear.........95N´m(70ft.lbs.)
Differential Bearing Ret........28N´m(21ft.lbs.)
Driveplate To Crank. Bolts......95N´m(70ft.lbs.)
Driveplate To Torque Conv.......75N´m(55ft.lbs.)
Eight Way Solenoid Conn........4N´m(35in.lbs.)
Extension Housing............28N´m(21ft.lbs.)
Input Speed Sensor............27N´m(20ft.lbs.)
L/R Clutch Retainer............5N´m(45in.lbs.)
Oil Pan To Trans. Case........19N´m(165 in. lbs.)
Output Gear Bolt...........271 N´m (200 ft. lbs.)
Output Gear Stirrup Ret........23N´m(17ft.lbs.)
Output Speed Sensor..........27N´m(20ft.lbs.)
Pressure Taps................5N´m(45in.lbs.)
Pump To Case Bolts...........27N´m(20ft.lbs.)
Reaction Shaft Bolts...........27N´m(20ft.lbs.)
Rear End Cover..............19N´m(14ft.lbs.)
Sixty-Way Connector...........4N´m(35in.lbs.)
Solenoid Assembly To Case.....12N´m(105 in. lbs.)
Transmission Range Sensor......5N´m(45in.lbs.)
Transfer Gear Nut..........271 N´m (200 ft. lbs.)
Transfer Plate To Case........12N´m(105 in. lbs.)
Valve Body To Case Bolts......12N´m(105 in. lbs.)
Valve Body Bolts..............5N´m(45in.lbs.)
Vent Assembly..............12N´m(105 in. lbs.)
21 - 158 TRANSAXLE AND POWER TRANSFER UNITNS

Adapter C-4996
Remover Kit L-4406
Gear Puller L-4407A
Bearing Installer L-4410
Gear Checking Plate L-4432
Bearing Puller L-4435
Differential Tool L-4436A
Special Jaw Set L-4518
21 - 160 TRANSAXLE AND POWER TRANSFER UNITNS
SPECIAL TOOLS (Continued)

POWER TRANSFER UNIT
INDEX
page page
GENERAL INFORMATION
POWER TRANSFER UNIT................ 165
DIAGNOSIS AND TESTING
FLUID LEAK DIAGNOSIS................. 167
SEAL IDENTIFICATION................... 165
REMOVAL AND INSTALLATION
DIFFERENTIAL CARRIER SEAL............ 170
END COVER BALL BEARING.............. 178
END COVER SEAL...................... 169
HALF SHAFT INNER SEAL................ 175
INPUT SHAFT COVER SEAL.............. 174
INPUT SHAFT END SEAL................. 177INPUT SHAFT SEAL..................... 169
OUTER HALF SHAFT SEAL............... 177
POWER TRANSFER UNIT (P.T.U.).......... 167
POWER TRANSFER UNIT OUTPUT SEAL.... 171
REAR COVER O-RING................... 171
ADJUSTMENTS
OUTPUT FLANGE SHIM SELECTION........ 180
SPECIFICATIONS
TORQUE............................. 180
SPECIAL TOOLS
SDP POWER TRANSFER UNIT............ 181
GENERAL INFORMATION
POWER TRANSFER UNIT
The Power Transfer Unit (P.T.U.) is attached to a
modified automatic transaxle case where the right
half shaft extension housing would normally be
located. The Transfer Unit provides the power to the
rear wheels through a hypoid ring gear and pinion
set.
The Power Transfer Unit is sealed from the tran-
saxle and has its own oil sump. The Unit uses SAE
85W-90 gear lubricant and holds 1.15 liters (1.22
quarts).
The Power Transfer Unit fill plug is located on the
end cover (Fig. 1).Do not mistake the black plas-
tic inspection plug located on the P.T.U. case
for the fill plug.Service of the Power Transfer Unit is limited to:
²Seals
²Gaskets
²One ball bearing
²Output flange
If the ring gear and pinion, any tapered roller
bearings, case, covers, or pinion carrier fail the entire
unit must be replaced.
DIAGNOSIS AND TESTING
SEAL IDENTIFICATION
For accurate seal diagnosis, repair seal name and
location is critical. Refer to (Fig. 2), (Fig. 3), (Fig. 4)
and (Fig. 5) for correct seal name and location.
Fig. 1 Fill Plug LocationFig. 2 Seal Location
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 165

FLUID LEAK DIAGNOSIS
When diagnosing fluid leaks on the Power Transfer
Unit two weep holes are provided to diagnose certainseal leaks. These holes are located on the bottom side
of the assembly (Fig. 6).
If fluid leak is detected from either weep hole, seal
replacement is necessary.Do not attempt to repair
the leak by sealing weep holes,they must be kept
clear of sealants for proper seal operation.
If fluid is leaking from weep hole A (Fig. 6) the
type of fluid leaking will determine which seal needs
to be replaced. If the fluid leaking is red in color
(transmission fluid) this indicates that the Transmis-
sion differential carrier seal should be replaced. If
the fluid leaking is light brown (gear lube) this indi-
cates that the Power Transfer Unit input seal should
be replaced. For replacement of these seals refer to
Power Transfer Unit Service Procedures.
If fluid is leaking from weep hole B (Fig. 6) the
type of fluid leaking will determine which seal is
leaking. If the fluid leaking is red in color (transmis-
sion fluid) this indicates that the input shaft end seal
should be replaced. If the fluid leaking is light brown
(gear lube) this indicates that the half shaft inner
seal and P.T.U. input shaft cover seal should be
replaced. For replacement of these seals refer to
Power Transfer Unit Service Procedures.
Before condemning any seal or gasket be sure that
the rear rocker arm cover on the engine is not the
cause of the oil leak. Oil leaking from the rocker arm
cover is easily mistaken for a leaking Power Transfer
Unit.
REMOVAL AND INSTALLATION
POWER TRANSFER UNIT (P.T.U.)
REMOVAL
(1) Raise vehicle and remove front wheels.
Fig. 3 Seal Location
Fig. 4 Seal Location
Fig. 5 Seal Location
Fig. 6 Weep Hole Locations
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 167
DIAGNOSIS AND TESTING (Continued)

INSTALLATION
(1) Clean and inspect seal area.
(2) Lay housing on bench and install new seal with
seal driver C-4657 and handle C-4171 (Fig. 20). The
seal must be installed with the spring side facing
towards the ring gear. Drive the seal in until it bot-
toms against the case shoulder.
(3) Install input shaft.
(4) Install oil trough.(5) Apply MopartGasket Maker or equivalent to
sealing surfaces of end cover and reinstall. Tighten
bolts to 28 N´m (250 in. lbs.).
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly into vehicle.
(7) Check and fill fluids as required.
DIFFERENTIAL CARRIER SEAL
The Power Transfer Unit must be removed from
the vehicle to replace this seal.
REMOVAL
(1) Remove P.T.U. from vehicle.
Fig. 15 P.T.U. End Cover Bolts
Fig. 16 End Cover Removal
Fig. 17 Oil Trough
Fig. 18 Input Shaft and Ring Gear Removal
21 - 170 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)