shaft CHRYSLER VOYAGER 1996 Service Manual

is mounted to steering column using 2 attaching
screws accessed from top of fixed shroud.(26) Disconnect the steering column shaft coupler,
from the steering gear intermediate steering coupler
(Fig. 20).
(27) Loosen but do not fully remove the 2 nut/
washer assemblies attaching the steering column
lower mounting bracket (Fig. 21). Then remove the 2
nut/washer assemblies attaching the steering column
upper mounting bracket (Fig. 21).
Fig. 17 Gear Selector Cable Mounting Bracket
Fig. 18 Instrument Cluster Trim Bezel
Fig. 19 Steering Column Fixed Shroud
Fig. 20 Steering Column Shaft To Intermediate
Coupler Attachment
Fig. 21 Steering Column Upper And Lower Mounting
Brackets
19 - 42 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

(28) Remove steering column assembly from vehi-
cle. Use care to avoid damage to paint or interior
trim.
INSTALL
(1) Ensure the plastic mounting capsules (Fig. 22)
are installed in the upper mounting bracket of the
steering column. Mounting capsules must be
installed as shown in (Fig. 22) with the thicker edge
of the capsule facing the top of the steering column.
(2) Install steering column assembly into its open-
ing in instrument panel. Install the steering column
lower bracket so the bracket is squarely installed on
its mounting studs (Fig. 21). Then align and install
steering column upper bracket on its mounting studs
(Fig. 21). Tighten the 4 steering column assembly
mounting nut/washer assemblies to a torque of 12
N´m (105 in. lbs.).
(3) Assemble the steering column shaft coupler
(Fig. 20) onto the steering gear intermediate coupler.
Install steering column coupler to intermediate shaft
retaining pinch bolt (Fig. 20). Tighten the pinch bolt
nut to a torque of 28 N´m (250 in. lbs.). Install safety
pin (Fig. 20) in steering column shaft coupler pinch
bolt.
(4) Install the gear slector cable and its mounting
bracket on the upper mounting bracket of the steer-
ing column (Fig. 17). Install and securely tighten the
mounting bracket attaching bolt.
(5) Install the gear selector cable on the pin of the
gear shifter (Fig. 16).
(6) If the vehicle is equipped with a 3 speed non-
electronic transmission, install the PRNDL actuating
cable on the gear shifter pin after the gear selector
cable is installing (Fig. 15).
(7) If the vehicle is equipped with a 3 speed non-
electronic transmission, install the attaching clip
(Fig. 15) for the PRNDL actuating cable on the steer-ing column/shift cable bracket. Cable guide tube will
bow toward passenger side of vehicle. Verify that
actuating cable is operating correctly, then slip the
loop on the end of the cable over end of pin on shift
lever and install in groove (Fig. 15).
(8) Install the steering column fixed shroud on the
steering column assembly (Fig. 19). Shroud is
mounted to steering column using 2 attaching screws
accessed from top of fixed shroud.
(9) Install the instrument cluster trim bezel (Fig.
18) on the instrument panel. The trim bezel is
mounted to the instrument panel using 2 attaching
screws (Fig. 18) and retaining clips.
(10) Install the 3 wiring harness connectors on the
ignition switch (Fig. 14).
(11) Install the vehicle wiring harness connector
into the key cylinder halo light (Fig. 13).
(12) Install the multi-function switch (Fig. 12) on
the tilt head of the steering column assembly. Then
install screw (Fig. 12) attaching multi-function
switch to tilt head of steering column.
(13) Install the vehicle wiring harness connector
on the multi-function switch (Fig. 11). Be sure latch
on connector is fully engaged with tab on switch.
(14) Install the clock spring on the multi-function
switch.
(15) Install the vehicle wiring harness connector
(Fig. 10) on the clock spring assembly.
(16) Install the lower steering column shroud on
the tilt head of the steering column (Fig. 23). Install
and securely tighten the screw attaching the lower
shroud to the tilt head.
(17) Install the upper steering column shroud on
the tilt head of the steering column (Fig. 24). Install
and securely tighten the 2 screws attaching the
upper shroud to the lower shroud.
Fig. 22 Mounting Capsules Correctly Installed On
Steering Column
Fig. 23 Lower Steering Column Shroud Installed
NSSTEERING 19 - 43
REMOVAL AND INSTALLATION (Continued)

CAUTION: Before installing the steering wheel the
clockspring must be centered. If clockspring is not
centered, the wiring in the clockspring may be over-
extended and break when the steering wheel is
rotated. Use the following procedure to center the
clockspring.
CLOCKSPRING CENTERING PROCEDURE
²Depress the 2 plastic locking pins to disengage
the lock mechanism (Fig. 25).
²With the lock mechanism disengaged, rotate the
clockspring rotor clockwise until the rotor stops.Do
not apply excessive force.
²From the end of the clockwise travel, rotate the
rotor three turns counterclockwise. The clockspring
wires should be at the top. Engage clockspring lock-
ing pins.
²From the center locked position, rotate the clock-
spring one-half additional turn counterclockwise. The
clockspring wiring should now be at the bottom. The
clockspring is now correctly positioned for installa-
tion of the steering wheel.
CAUTION: Do not force steering wheel onto steer-
ing column shaft by driving it on. Pull steering
wheel down onto shaft using ONLY the steering
wheel retaining nut.
(18) Align master splines on steering wheel and
steering shaft, and flats on steering wheel with for-
mations on clock spring. Install the steering wheel on
the steering column shaft (Fig. 26). All wiring leads
from the clock springmustbe routed as shown in
(Fig. 26).
NOTE: Before installing the damper on the steering
wheel, inspect the damper to ensure the rubber iso-
lator on the damper is not deteriorated or damaged.If the damper is installed with a damaged isolator a
buzz, squeak or rattle condition may develop.
(19) Install the steering wheel damper on the
steering wheel. When damper is installed, itmustbe
positioned on the steering wheel as shown in (Fig. 7).
(20) Install the steering wheel to steering shaft
retaining nut. Tighten the steering wheel retaining
nut to a torque of 61 N´m (45 ft. lbs.).
(21) Install the wiring leads from the clock spring
on the air bag, horn switch wire, and speed control
switches (Fig. 6). Attach the wire routing clip (Fig. 6)
to the studs on the air bag module.
(22) Install the air bag module in the steering
wheel.
Fig. 24 Upper And Lower Steering Column Shroud
Installed
Fig. 25 Clockspring Assembly
Fig. 26 Steering Wheel And Clock Spring Wire
Routing
19 - 44 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

(4) Raise the front wheels off the ground.
(5) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops at least 20 times.
(6) Check the fluid level add if necessary.
(7) Lower the vehicle, start the engine and turn
the steering wheel slowly from lock to lock.
(8) Stop the engine and check the fluid level and
refill as required.
(9) If the fluid is extremely foamy or milky look-
ing, allow the vehicle to stand a few minutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
REMOVAL AND INSTALLATION
POWER STEERING PUMPÐ2.5L DIESEL
NOTE: The power steering pump is mounted below
the fuel pump on the left side of the engine. The
vehicle should be raised on a hoist to access the
pump from below.
REMOVAL
(1) Remove serpentine drive belt. Refer to Group 7,
Cooling System, for procedure.
(2) Remove power steering pump pulley. Use a hex
wrench to secure the power steering shaft while
removing the pulley bolt with a box wrench. (Fig. 2)
CAUTION: Do not use an impact wrench to remove
the pump pulley ± this can cause rear pump seal
damage. Do not secure power steering shaft with a
wrench on the coupling to the A/C compressor ±
this can cause rear pump seal damage.
(3) Remove coupling bolts (2) from A/C compressor
side of coupling.
(4) Loosen A/C compressor bolts and separate com-
pressor from bracket. Do not disconnect A/C hoses.
(5) Remove bolts (2) securing the power steering
pump to the power steering bracket.
(6) Disconnect power steering pump supply hose at
the pump and drain fluid.
(7) Disconnect power steering pressure hose at the
steering gear assembly.
(8) Remove power steering pump.
INSTALLATION
(1) Install pump on engine.
(2) Tighten pump bracket bolts to 47 N´m (35 ft.
lbs.).(3) Reverse the above procedures in steps 8
through 1 to complete installation.
(4) Add power steering fluid and perform Power
Steering Pump Initial Operation.
Fig. 2 Power Steering Pump Pulley Removal
Fig. 3 Left SIde Motor MountÐVM DIesel
19 - 2 STEERINGNS/GS
SERVICE PROCEDURES (Continued)

TRANSAXLE AND POWER TRANSFER UNIT
CONTENTS
page page
31TH AUTOMATIC TRANSAXLE.............. 1
41TE AUTOMATIC TRANSAXLE............. 71POWER TRANSFER UNIT................. 165
31TH AUTOMATIC TRANSAXLE
INDEX
page page
GENERAL INFORMATION
31TH TRANSAXLE........................ 2
FLUID LEVEL AND CONDITION.............. 2
SELECTION OF LUBRICANT................ 3
SPECIAL ADDITIVES...................... 3
DESCRIPTION AND OPERATION
CLUTCHES, BAND SERVOS, AND
ACCUMULATOR
...................... 3
FLOW CONTROL VALVES.................. 3
GEARSHIFT AND PARKING LOCK CONTROLS . . 4
GOVERNOR............................. 4
HYDRAULIC CONTROL SYSTEM............. 3
PRESSURE REGULATING VALVES........... 3
PRESSURE SUPPLY SYSTEM............... 3
TORQUE CONVERTER CLUTCH SOLENOID
WIRING CONNECTOR................... 4
TORQUE CONVERTER CLUTCH............. 3
DIAGNOSIS AND TESTING
CLUTCH AND SERVO AIR PRESSURE TESTS . 15
FLUID LEAKAGE-TRANSAXLE TORQUE
CONVERTER HOUSING AREA............ 15
HYDRAULIC PRESSURE TESTS............ 13
ROAD TEST............................. 4
THREE SPEED TRANSAXLE DIAGNOSIS AND
TESTS............................... 4
SERVICE PROCEDURES
ALUMINUM THREAD REPAIR.............. 18
FLUID AND FILTER CHANGE............... 16
FLUID DRAIN AND REFILL................. 18
FLUSHING COOLERS AND TUBES.......... 18
OIL PUMP VOLUME CHECK............... 19
REMOVAL AND INSTALLATION
FRONT PUMP OIL SEAL.................. 21
PARK/NEUTRAL STARTING AND BACK-UP
LAMP SWITCH........................ 19
TRANSAXLE AND TORQUE CONVERTER
REMOVAL............................ 20
VEHICLE SPEED SENSOR PINION GEAR..... 19DISASSEMBLY AND ASSEMBLY
ACCUMULATOR-RECONDITION............ 36
DIFFERENTIAL REPAIR................... 46
FRONT CLUTCH-RECONDITION............ 32
FRONT PLANETARY & ANNULUS GEAR-
RECONDITION........................ 35
KICKDOWN SERVO (CONTROLLED LOAD)-
RECONDITION........................ 37
LOW/REVERSE (REAR)
SERVO-RECONDITION.................. 36
OIL PUMP-RECONDITION................. 31
OUTPUT SHAFT REPAIR.................. 43
PARKING PAWL......................... 42
REAR CLUTCH-RECONDITION............. 33
TRANSAXLE........................... 21
TRANSFER SHAFT REPAIR................ 38
VALVE BODY RECONDITION............... 27
CLEANING AND INSPECTION
VALVE BODY........................... 50
ADJUSTMENTS
BAND ADJUSTMENT..................... 51
BEARING ADJUSTMENT PROCEDURES...... 52
DIFFERENTIAL BEARING................. 53
GEARSHIFT CABLE ADJUSTMENT.......... 51
HYDRAULIC CONTROL PRESSURE
ADJUSTMENTS....................... 52
OUTPUT SHAFT BEARING................ 52
THROTTLE PRESSURE LINKAGE
ADJUSTMENT......................... 51
TRANSFER SHAFT BEARING.............. 54
SCHEMATICS AND DIAGRAMS
31TH TRANSAXLE HYDRAULIC SCHEMATIC . . 56
SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE............. 64
31TH TORQUE SPECIFICATIONS........... 65
SPECIAL TOOLS
31TH AUTOMATIC TRANSAXLE............. 66
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 1

GENERAL INFORMATION
31TH TRANSAXLE
NOTE: Safety goggles should be worn at all times
when working on these transaxles.
This transaxle combines torque converter, three
speed transmission, final drive gearing, and differen-
tial into a front wheel drive system. The identifica-
tion markings and usage of the transaxle are charted
in Diagnosis and Tests.
NOTE: Transaxle operation requirements are differ-
ent for each vehicle and engine combination. Some
internal parts will be different to provide for this.
Therefore, when replacing parts, refer to the seven
digit part number stamped on rear of the transaxle
oil pan flange.
Within this transaxle, there are three primary
areas:
(1) Main center line plus valve body.
(2) Transfer shaft center line (includes governor
and parking sprag).
(3) Differential center line.
(4) Center distances between the main rotating
parts in these three areas are held precise to main-
tain a low noise level.
(5) The torque converter, transaxle area, and dif-
ferential are housed in an integral aluminum die
casting.The differential oil sump is common
with the transaxle sump. Separate filling of the
differential is NOT necessary.
(6) The torque converter is attached to the crank-
shaft through a flexible driving plate. Cooling of the
converter is accomplished by circulating the tran-
saxle fluid through a remote cooler. There are two
types of coolers used. An oil-to-water type cooler
located in the radiator side tank and/or an oil-to air
heat exchanger. The torque converter assembly is a
sealed unit that cannot be disassembled.
(7) The transaxle fluid is filtered by an internal fil-
ter attached to the lower side of the valve body
assembly.
(8) Engine torque is transmitted to the torque con-
verter then, through the input shaft to multiple-disc
clutches in the transaxle. The power flow depends on
the application of the clutches and bands. Refer to
Elements in Use Chart in Diagnosis and Tests sec-
tion.
(9) The transaxle consists of:
²Two multiple-disc clutches
²An overrunning clutch
²Two servos
²A hydraulic accumulator
²Two bands²Two planetary gear sets
This provides three forward ratios and a reverse
ratio. The common sun gear of the planetary gear
sets is connected to the front clutch by a driving
shell. The drive shell is splined to the sun gear and
front clutch retainer. The hydraulic system consists
of an oil pump, and a single valve body which con-
tains all of the valves except the governor valves.
The transaxle sump and differential sump are both
vented through the dipstick. Output torque from the
main center line is delivered through helical gears to
the transfer shaft. This gear set is a factor of the
final drive (axle) ratio. The shaft also carries the gov-
ernor and parking sprag. An integral helical gear on
the transfer shaft drives the differential ring gear.
The final drive gearing is completed with one of two
gear ratios of 2.98 or 3.19 depending on model and
application.
FLUID LEVEL AND CONDITION
NOTE: The transmission and differential sump have
a common oil sump with a communicating opening
between the two.
The torque converter fills in both the P Park and N
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate.The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground. This will assure complete oil level sta-
bilization between differential and transmis-
sion.The fluid should be at normal operating
temperature (approximately 82 C. or 180 F.). The
fluid level is correct if it is in the HOT region (cross-
hatched area) on the dipstick.
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, the air bubbles can cause overheat-
ing, fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and servo operation.
Foaming can also result in fluid escaping from the
transaxle dipstick where it may be mistaken for a
leak.
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
21 - 2 TRANSAXLE AND POWER TRANSFER UNITNS

(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)