shaft CHRYSLER VOYAGER 1996 Service Manual

OUTPUT SHAFT REPAIR
NOTE: Transfer shaft should be removed for repair
of output shaft. Planetary gear sets must be
removed to accurately check output shaft bearing
turning torque.
Fig. 115 Remove Output Shaft Retaining Nut and
Washer
Fig. 116 Remove Output Shaft Gear
Fig. 117 Output Shaft Gear and (Select) Shim
Fig. 118 Remove Output Shaft Gear Bearing Cone
Fig. 119 Install Output Shaft Gear Bearing Cone
Fig. 120 Remove Output Shaft and Rear Annulus
Gear Assembly
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 43
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 121 Remove Output Shaft
Fig. 122 Remove Rear Planetary Annulus Gear
Bearing Cone
Fig. 123 Install Rear Planetary Annulus Gear
Bearing Cone
Fig. 124 Install Output Shaft into Rear Planetary
Annulus Gear
Fig. 125 Remove Output Shaft Gear Bearing Cup
Fig. 126 Remove Rear Planetary Annulus Gear
Bearing Cup
21 - 44 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

DETERMINING SHIM THICKNESS
Shim thickness need only be determined if any of
the following parts are replaced:
²Transaxle case
²Output shaft
²Rear planetary annulus gear
²Output shaft gear
²Rear annulus and output shaft gear bearing
cones
²Overrunning clutch race cups
Refer to Bearing Adjustment Procedure at the rear
of this section, to determine proper shim thickness.
Check output shaft bearings turning torque,
using an inch-pound torque wrench. If turning
torque is 3 to 8 inch-pounds, the proper shim
has been installed.
Fig. 127 Install Output Shaft Gear Bearing Cup
Fig. 128 Install Rear Planetary Annulus Gear
Bearing Cup
Fig. 129 Install Output Shaft Assembly
Fig. 130 Output Shaft and (Select) Shims in Position
Fig. 131 Start Output Shaft Gear onto Output Shaft
Fig. 132 Holding Output Shaft Gear
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 45
DISASSEMBLY AND ASSEMBLY (Continued)

DIFFERENTIAL REPAIR
NOTE: The transfer shaft should be removed for
differential repair and bearing turning torque check-
ing.
Fig. 133 Tighten Output Shaft Retaining Nut to 271
N´m (200 ft. lbs.)
Fig. 134 Checking Output Shaft End Play
Fig. 135 Checking Bearings Turning Torque
Fig. 136 Remove Extension Seal
Fig. 137 Install New Seal into Extension
Fig. 138 Differential Cover Bolts
21 - 46 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

To install the differential bearing cup and cone on
the ring gear side, use Special Tool 5052, and Special
Tool C-4171.
NOTE: The differential is serviced as an assembly.
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
any other part fails within the differential, you must
replace the differential assembly along with the
transfer shaft.
CAUTION: Side gear end play must be BETWEEN
0.001 to 0.013 inch.
Fig. 151 Position Button and Collets Onto
Differential and Bearing (Ring Gear Side)
Fig. 152 Position Tool 5048 Over Button and Collets
at Differential Bearing
Fig. 153 Remove Differential Bearing Cone
Fig. 154 Checking Side Gear End Play
Fig. 155 Checking Side Gear End Play (Typical)
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 49
DISASSEMBLY AND ASSEMBLY (Continued)

To remove the differential bearing cup from the
extension housing/adapter side, use Special Tool6062A, Remover. To install the differential bearing
cup on the extension housing/adapter side, use Spe-
cial Tool 6536, Driver and Special Tool C-4171, Han-
dle.
DETERMINING SHIM THICKNESS
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
Refer to Bearing Adjustment Procedure in rear of
this section to determine proper shim thickness.
CLEANING AND INSPECTION
VALVE BODY
Allow all parts to soak a few minutes in a suitable
clean solvent. Wash thoroughly and blow dry with
compressed air. Make sure all passages are clean and
free from obstructions.
Inspect manual and throttle valve operating levers
and shafts for being bent, worn or loose. If a lever is
loose on its shaft, it should be replaced. Do not
attempt to straighten bent levers.
Inspect all mating surfaces for burrs, nicks and
scratches. Minor blemishes may be removed with cro-
cus cloth, using only a very light pressure. Using a
straightedge, inspect all mating surfaces for warpage
or distortion. Slight distortion may be corrected,
using a surface plate. Make sure all metering holes
in steel plate are open. Using a pen light, inspect
bores in valve body for scores, scratches, pits and
irregularities.
Fig. 156 Differential Bearing Retainer
Fig. 157 Position Bearing Cup Remover Tool in
Retainer
Fig. 158 Remove Bearing Cup
Fig. 159 Install Bearing Cup
21 - 50 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

(3) Back off adjusting screw the number of turns
listed in Specifications. Hold adjusting screw in this
position and tighten locknut to 47 N´m (35ft. lbs.)
LOW/REVERSE BAND (REAR)
To adjust low-reverse band, proceed as follows:
(1) Loosen and back off locknut approximately 5
turns.
(2) Using an inch-pound torque wrench, tighten
adjusting screw to 5 N´m (41 in. lbs.) true torque.
(3) Back off adjusting screw the number of turns
listed under Specifications. This chart is located at
the rear of this section.
(4) Tighten locknut to 14 N´m (10 ft. lbs.).
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
LINE PRESSURE
An incorrect throttle pressure setting will cause
incorrect line pressure readings even though line
pressure adjustment is correct. Always inspect and
correct throttle pressure adjustment before adjusting
the line pressure.
The approximate adjustment for line pressure is
1-5/16 inches, measured from valve body to inner
edge of adjusting nut. However, due to manufactur-
ing tolerances, the adjustment can be varied to
obtain specified line pressure.
The adjusting screw may be turned with an Allen
wrench. One complete turn of adjusting screw
changes closed throttle line pressure approximately
1-2/3 psi. Turning adjusting screw counterclockwise
increases pressure, and clockwise decreases pressure.
THROTTLE PRESSURE
Throttle pressures cannot be tested accurately;
therefore, the adjustment should be measured if a
malfunction is evident.
(1) Insert gauge pin of Tool C-3763 between the
throttle lever cam and kickdown valve.
(2) By pushing in on tool, compress kickdown
valve against its spring so throttle valve is com-
pletely bottomed inside the valve body.
(3) While compressing spring, turn throttle lever
stop screw with adapter C-4553. Turn until head of
screw touches throttle lever tang, with throttle lever
cam touching tool and throttle valve bottomed. Be
sure adjustment is made with spring fully com-
pressed and valve bottomed in the valve body.
BEARING ADJUSTMENT PROCEDURES
(1) Take extreme care when removing and install-
ing bearing cups and cones.Use only an arbor
press for installation, as a hammer may not
properly align the bearing cup or cone.Burrs or
nicks on the bearing seat will give a false end play
reading, while gauging for proper shims. Improperlyseated bearing cup and cones are subject to low-mile-
age failure.
(2) Bearing cups and cones should be replaced if
they show signs of pitting or heat distress.
(3) If distress is seen on either the cup or bearing
rollers, both cup and cone must be replaced.
NOTE: Bearing end play and drag torque specifica-
tions must be maintained to avoid premature bear-
ing failures.
(4) Used (original) bearing may lose up to 50 per-
cent of the original drag torque after break-in.
NOTE: All bearing adjustments must be made with
no other component interference or gear inter-
mesh, except the transfer gear bearing.
(5) Refer to the conversion chart in specifications
to convert inches to millimeter measurements. Refer
to bearing shim chart for proper shim thicknesses.
OUTPUT SHAFT BEARING
(1) With output shaft gear removed, install a 13.65
mm (.537 inch) and a 1.34 mm (.053 inch) gauging
shims on the planetary rear annulus gear hub using
grease to hold the shims in place. The 13.65 mm
shim has a larger inside diameter and must be
installed over the output shaft first. The 1.34 mm
shim pilots on the output shaft.
(2) Install output shaft gear and bearing assembly,
torque to 271 N´m (200 ft. lbs.).
(3) To measure bearing end play:
(4) Attach Tool L-4432 to the output shaft gear.
(5) Mount a steel ball with grease into the end of
the output shaft.
(6) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
(7) Using a dial indicator, mounted to the tran-
saxle case, measure output shaft end play.
(8) Once bearing end play has been determined,
refer to the output shaft bearing shim chart.
(9) The 12.65 mm (.498 inch), 13.15 mm (.518
inch) or 13.65 mm (.537 inch) shims are always
installed first.These shims have lubrication slots
which are necessary for proper bearing lubrica-
tion.
(10) Shims thinner than 12.65 mm listed in the
chart are common to both the transfer shaft and out-
put shaft bearings.
(11) Use Tool L-4434 to remove the retaining nut
and washer. To remove the output shaft gear use Tool
L-4407.
(12) Remove the two gauging shims and install the
proper shim combination, making sure to install the
12.65, 13.15, or 13.65 mm shim first. Use grease to
21 - 52 TRANSAXLE AND POWER TRANSFER UNITNS
ADJUSTMENTS (Continued)

hold the shims in place. Install the output shaft gear
and bearing assembly.
(13) Install the retaining nut and washer and
torque to 271 N´m (200 ft. lbs.).
(14) Using an inch-pound torque wrench, check the
turning torque.The torque should be between 3
and 8 inch-pounds.
(15) If the turning torque is too high, install a
.05mm (.002 inch) thicker shim. If the turning torque
is too low, install a .05 mm (.002 inch) thinner shim.
Repeat until the proper turning torque is 3 to 8 inch
pounds.
DIFFERENTIAL BEARING
(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 .
(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.
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.
OUTPUT SHAFT BEARING SHIM CHART
Fig. 161 Tool L-4436 and Torque Wrench
Fig. 162 Checking Differential Bearings Turning
Torque
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 53
ADJUSTMENTS (Continued)

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 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.).(7) Using Tool L-4436A and an inch-pound torque
wrench, recheck the turning torque of the differen-
tial.The turning torque should be between 5
and 18 inch-pounds.
TRANSFER SHAFT BEARING
(1) Use Tool L-4434 to remove the retaining nut
and washer. Remove the transfer shaft gear using
Tool L-4407.
(2) Install a 2.29 mm (.090 inch) and a 1.39 mm
(.055 inch) gauging shims on the transfer shaft
behind the governor support.
(3) Install transfer shaft gear and bearing assem-
bly and torque the nut to 271 N´m (200 ft. lbs.).
(4) To measure bearing end play:
(5) Attach Tool L-4432 to the transfer gear.
(6) Mount a steel ball with grease into the end of
the transfer shaft.
(7) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
(8) Using a dial indicator, measure transfer shaft
end play.
(9) Refer to the Transfer Bearing Shim Chart for
the required shim combination to obtain the proper
bearing setting.
(10) Use Tool L-4434 to remove the retaining nut
and washer. Remove the transfer shaft gear using
Tool L-4407.
(11) Remove the two gauging shims and install the
correct shim combination. Install the transfer gear
and bearing assembly.
(12) Install the retaining nut and washer and
torque to 271 N´m (200 ft. lbs.). Measure transfer
shaft end play, end play should be .05 to .25 mm
(.002 to .010 inch).
(13) Measure bearing end play as outlined in Step
(4). End play should be between .05 mm and .25 mm
(.002 to .010 inch).
DIFFERENTIAL BEARING SHIM CHART
SHIM THICKNESS
MM INCH
.980 0.0386
1.02 0.0402
1.06 0.0418
1.10 0.0434
1.14 0.0449
1.18 0.0465
1.22 0.0481
1.26 0.0497
1.30 0.0512
1.34 0.0528
1.38 0.0544
1.42 0.0560
1.46 0.0575
1.50 0.0591
1.54 0.0607
1.58 0.0623
1.62 0.0638
1.66 0.0654
1.70 0.0670
2.02 0.0796
2.06 0.0812
21 - 54 TRANSAXLE AND POWER TRANSFER UNITNS
ADJUSTMENTS (Continued)

SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE
Type ................Automatic three speed 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 3 Type 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..............................2.69
Second Gear.............................1.55
Third Gear..............................1.00
Reverse Gear............................2.10
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 . . .6 to 12 in. lbs. Drag Torque
Output Hub............0to3in.lbs. Drag Torque
Transfer Shaft.........0.002 to 0.010 in. End Play
Overall Drag At Output
Hub.............3to16in.lbs. Drag Torque
Clutch Pack Clearances
Front Clutch (Not Adjustable)........1.27-2.79mm
(0.050-0.110 in.)
Rear Clutch.........0.71-1.10mm (0.028-0.043 in.)
Band Adjustment
Kickdown, Backed Off From 8 N´m
(72 in. lbs.).....................21/4Turns
Low-Reverse, Backed Off From 5 N´m
(41 in. lbs.)......................31/2Turns
21 - 64 TRANSAXLE AND POWER TRANSFER UNITNS