shaft CHRYSLER VOYAGER 1996 Service Manual

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
21 - 28 TRANSAXLE AND POWER TRANSFER UNITNS
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
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 31
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
21 - 32 TRANSAXLE AND POWER TRANSFER UNITNS
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
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 33
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
21 - 34 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

TRANSFER SHAFT REPAIR
DISASSEMBLY
NOTE: Remove old sealant before applying new
sealant. Use MoparTRTV sealant or equivalent
when installing cover.
NOTE: Remove or install both governor valves and
governor body.
Fig. 89 Rear Cover Bolts
Fig. 90 Remove or Install Rear Cover
Fig. 91 Remove Transfer Shaft Gear Retaining Nut
Fig. 92 Transfer Shaft Gear Nut and Washer
Fig. 93 Remove Transfer Shaft Gear
21 - 38 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 94 Transfer Shaft Gear and (Select) Shim
Fig. 95 Using Tool L-4406-1 with Adapter L-4406-3,
Remove Transfer Shaft Gear Bearing Cone
Fig. 96 Install Transfer Shaft Gear Bearing Cone
Fig. 97 Governor Support Retainer
Fig. 98 Remove Governor Support Retainer Bearing
Cup
Fig. 99 Install Governor Support Retainer Bearing
Cup
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 39
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 100 Low-Reverse Band Anchor Pin
Fig. 101 Governor Assembly
Fig. 102 Transfer Shaft Bearing Snap Ring
Fig. 103 Remove Transfer Shaft and Bearing
Retainer Assembly
Fig. 104 Remove or Install Transfer Shaft and
Bearing Retainer Assembly Using Tool L-4512
Fig. 105 Transfer Shaft and Bearing Retainer
21 - 40 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 106 Remove Transfer Shaft Bearing Cone
Fig. 107 Install Transfer Shaft Bearing Cone
Fig. 108 Remove Transfer Shaft Bearing Cup
Fig. 109 Install Transfer Shaft Bearing Cup
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 41
DISASSEMBLY AND ASSEMBLY (Continued)

DETERMINING SHIM THICKNESS
Shim thickness need only be determined if any of
the following parts are replaced:
²Transaxle case
²Transfer shaft
²Transfer shaft gear
²Transfer shaft bearings
²Governor support retainer
²Transfer shaft bearing retainer
²Retainer snap ring
²Governor support
Refer to Bearing Adjustment Procedure in rear of
this section to determine proper shim thickness.
ASSEMBLY
To install transfer shaft, reverse the above proce-
dure.
PARKING PAWL
DISASSEMBLY
ASSEMBLY
To install, reverse the above procedure.
Fig. 110 Tighten Transfer Shaft Gear Retaining Nut
to 271 N´m (200 ft. lbs.)
Fig. 111 Checking Transfer Shaft End Play
Fig. 112 Parking Sprag Rod Support
Fig. 113 Support and Bolts
Fig. 114 Parking Pawl, Return Spring, and Pivot
Shaft
21 - 42 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)