shaft CHRYSLER VOYAGER 1996 Service Manual

31TH TORQUE SPECIFICATIONS
DESCRIPTION TORQUE DESCRIPTION TORQUE
Bell Housing Cover Bolts 12 N´m (106 in. lbs.) Output Shaft Nut 271 N´m (200 ft. lbs.)
Cooler Hose To Rad. Conn. 12 N´m (105 in. lbs.) Park/Neutral Switch 34 N´m (25 ft. lbs.)
Cooler Line Conn. 28 N´m (250 in. lbs.) Pressure Check Plug 5 N´m (45 in. lbs.)
Diff. Bear. Ret. To Case Bolt 28 N´m (250 in. lbs.) Pump To Case Bolts 31 N´m (275 in. lbs.)
Diff. Cover To Case Bolt 19 N´m (165 in. lbs.) Reaction Shaft Assembly Bolt 28 N´m (250 in. lbs.)
Exten. Hous. To Case Bolt 28 N´m (250 in. lbs.) Rear Cover To Case Screw 19 N´m (165 in. lbs.)
Flex Plate To Crankshaft Bolts 95 N´m (70 ft. lbs.) Reverse Band Adj. Lock Nut 14 N´m (125 in. lbs.)
Flex Plate To Torque Conv. Bolts 68 N´m (50 ft. lbs.) Reverse Band Shaft Plug 7 N´m (60 in. lbs.)
Fluid Filter Screw 5 N´m (45 in. lbs.) Ring Gear Screw 95 N´m (70 ft. lbs.)
Front Motor Mount Bolt 54 N´m (40 ft. lbs.) Speedo. To Ext. Hous. Screw 7 N´m (60 in. lbs.)
Governor Counterweight Screw 28 N´m (250 in. lbs.) Sprag Ret. To Transfer Case Bolt 28 N´m (250 in. lbs.)
Governor To Support Bolt 7 N´m (60 in. lbs.) Starter To Trans. Bell Bolts 54 N´m (40 ft. lbs.)
Kickdown Band Adj. Lock Nut 47 N´m (35 ft. lbs.) Throttle Cable To Trans. Case
Bolt12 N´m (105 in. lbs.)
Left Motor Mount Bolts 54 N´m (40 ft. lbs.) Throttle Lever To Trans. Shaft
Bolts12 N´m (105 in. lbs.)
Lower Bell Housing Cover Screw 41 N´m (30 ft. lbs.) Trans. To Cyl. Block Bolt 95 N´m (70 ft. lbs.)
Manual Cable To Trans. Case Bolt 28 N´m (250 in. lbs.) Transfer Shaft Nut 271 N´m (200 ft. lbs.)
Manual Control Lever Screw 12 N´m (105 i n. lbs.) Transfer Gear Strap Bolts 23 N´m (17 ft. lbs.)
Oil Pan To Trans. Case Screw 19 N´m (165 in. lbs.) Valve Body Assy. To Case Bolts 12 N´m (105 in. lbs.)
Output Gear Strap Bolts 23 N´m (17 ft. lbs.) Valve Body Screw 5 N´m (45 in. lbs.)
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SPECIFICATIONS (Continued)

Housing Remover Adapter L-4437
Starter Nut L-4439
Transfer Shaft Remover-Installer L-4512
Bearing Cup Remover L-4517
Special Jaw Set L-4518
Installer L-4520
Bearing Splitter P-334
Cooling System Tester 7700
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SPECIAL TOOLS (Continued)

(4) Reverse and LR clutch pressure should read
165 to 235 psi.
(5) This test checks the reverse clutch hydraulic
circuit.
TEST RESULT INDICATIONS
(1) If proper line pressure is found in any one test,
the pump and pressure regulator are working prop-
erly.
(2) Low pressure in all positions indicates a defec-
tive pump, a clogged filter, or a stuck pressure regu-
lator valve.
(3) Clutch circuit leaks are indicated if pressures
do not fall within the specified pressure range.
(4) If the overdrive clutch pressure is greater than
5 psi in Step 4 of Test Three, a worn reaction shaft
seal ring or a defective solenoid assembly is indi-
cated.
(5) If the underdrive clutch pressure is greater
than 5 psi in Step 4 of Test 2A, a defective solenoid
assembly or TCM is the cause.
CLUTCH AIR PRESSURE TESTS
Inoperative clutches can be located using a series
of tests by substituting air pressure for fluid pressure
(Fig. 3) (Fig. 4). The clutches may be tested by apply-
ing air pressure to their respective passages. The
valve body must be removed and Tool 6056 installed.
To make air pressure tests, proceed as follows:
NOTE: The compressed air supply must be free of
all dirt and moisture. Use a pressure of 30 psi.
Remove oil pan and valve body. See Valve body
removal.
OVERDRIVE CLUTCH
Apply air pressure to the overdrive clutch apply
passage and watch for the push/pull piston to move
forward. The piston should return to its starting
position when the air pressure is removed.
PRESSURE CHECK SPECIFICATIONS
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DIAGNOSIS AND TESTING (Continued)

REVERSE CLUTCH
Apply air pressure to the reverse clutch apply pas-
sage and watch for the push/pull piston to move rear-
ward. The piston should return to its starting
position when the air pressure is removed.
2/4 CLUTCH
Apply air pressure to the feed hole located on the
2/4 clutch retainer. Look in the area where the 2/4
piston contacts the first separator plate and watch
carefully for the 2/4 piston to move rearward. The
piston should return to its original position after the
air pressure is removed.
LOW/REVERSE CLUTCH
Apply air pressure to the low/reverse clutch feed
hole (rear of case, between 2 bolt holes). Then, look
in the area where the low/reverse piston contacts thefirst separator plate. Watch carefully for the piston to
move forward. The piston should return to its origi-
nal position after the air pressure is removed.
UNDERDRIVE CLUTCH
Because this clutch piston cannot be seen, its oper-
ation is checked by function. Air pressure is applied
to the low/reverse and the 2/4 clutches. This locks the
output shaft. Use a piece of rubber hose wrapped
around the input shaft and a pair of clamp-on pliers
to turn the input shaft. Next apply air pressure to
the underdrive clutch. The input shaft should not
rotate with hand torque. Release the air pressure
and confirm that the input shaft will rotate.
FLUID LEAKAGE-TORQUE CONVERTER HOUSING
AREA
(1) Check for source of leakage.
(2) Fluid leakage at or around the torque converter
area may originate from an engine oil leak. The area
should be examined closely. Factory fill fluid is red
and, therefore, can be distinguished from engine oil.
(3) Prior to removing the transaxle, perform the
following checks:
(4) When leakage is determined to originate from
the transaxle, check fluid level prior to removal of
the transaxle and torque converter.
(5) High oil level can result in oil leakage out the
vent in the manual shaft. If the fluid level is high,
adjust to proper level.
(6) After performing this operation, inspect for
leakage. If a leak persists, perform the following
operation on the vehicle. This will determine if the
torque converter or transaxle is leaking.
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
²Torque converter weld leaks at the outside
(peripheral) weld.
²Torque converter hub weld.
NOTE: Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter.
SHIFT POSITION INDICATOR
The transmission range sensor (on the valve body)
sends a signal to the TCM on the position of the
transaxle manual valve lever. The TCM receives the
switch signal and processes the data. The TCM sends
the Shift Lever Position (SLP) information to the
BCM via the CCD bus. The BCM then outlines with
a box the appropriate shifter position indicator in the
instrument cluster.
Fig. 3 Air Pressure Test Plate
Fig. 4 Testing Reverse Clutch
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DIAGNOSIS AND TESTING (Continued)

(13) Remove manual shaft seal (Fig. 20).
(14) Slide Transmission Range Sensor up the man-
ual shaft and remove (Fig. 21).
INSTALLATION
(1) For installation, reverse removal procedure.
Tighten TRS retaining screw to 5 N´m (45 in. lbs.)
Reseal transaxle oil pan using RTV.
SPEED SENSOR-INPUT
CAUTION: When disconnecting speed sensor con-
nector, be sure that the weather seal does not fall
off or remain in old sensor.
The input speed sensor is located to the left of the
manual shift lever (Fig. 22).
SPEED SENSOR-OUTPUT
CAUTION: When disconnecting speed sensor con-
nector, be sure that the weather seal does not fall
off or remain in old sensor.
The output speed sensor is located to the right of
the manual shift lever (Fig. 23).
Fig. 17 Gearshift Cable And Manual Valve Lever
Fig. 18 Valve Body W/TRS
Fig. 19 Remove Retaining Screw
Fig. 20 Remove Manual Shaft Seal
Fig. 21 Remove Transmission Range Sensor
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REMOVAL AND INSTALLATION (Continued)

INSTALLATION
To install valve body, reverse removal procedure
CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
NOTE: To ease installation of the valve body, turn
the manual valve lever fully clockwise.
Guide park rod rollers into guide bracket, while
shifting manual lever assembly out of the installation
position.
TRANSAXLE
Transaxle removal does NOT require engine
removal.
See Group 7, Cooling to drain engine cooling sys-
tem and remove coolant return extension (3.0 liter
engine only).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 drive plate during removal.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner duct. Disconnect transaxle
shift linkage at manual valve lever (Fig. 34).
(3) Squeeze grommet clips and remove cable at
transaxle bracket (Fig. 35) (Fig. 36).
(4) Remove 16±way engine harness connector from
dipstick tube bracket. Remove dipstick tube bracket
nut at cylinder head. Remove dipstick tube.
(5) Remove transaxle cooler lines.
(6) Remove connector at transaxle solenoid pack.
(7) Remove input and output speed sensor wiring
connectors (Fig. 37) (Fig. 38).
Fig. 32 Remove Valve Body
Fig. 33 Valve Body Removed
Fig. 34 Shift Linkage At Manual Valve Lever
Fig. 35 Grommet Clips
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REMOVAL AND INSTALLATION (Continued)

(8) Disconnect electrical connector at transmission
range sensor.
(9) Remove upper bellhousing upper bolts.
(10) Remove heater tube mounting bolt.(11) Remove vehicle speed sensor wiring at sensor.
(12) Remove one rear engine mount bolt from top.
(13) Remove rear engine mount shield screw.
(14) Install engine support fixture and support
engine (Fig. 39).
(15) Raise vehicle. Remove front wheels. Refer to
Group 2, Suspension to remove wheel hub nuts 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.
(16) Remove bolts securing exhaust flex joint to
exhaust manifold. Disconnect exhaust pipe from
manifold.
(17) Remove torque converter dust shield to gain
access to torque converter bolts (Fig. 40).
Fig. 36 Remove Cable From Bracket
Fig. 37 Input (Turbine) Speed Sensor
Fig. 38 Output Speed Sensor
Fig. 39 Engine Support Fixture
Fig. 40 Remove Torque Converter Dust Shield
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REMOVAL AND INSTALLATION (Continued)

(18) Rotate engine clockwise to gain access to
torque converter bolts (Fig. 41). Remove torque con-
verter mounting bolts.
(19) Remove front engine mount insulator and
bracket (Fig. 42).
(20) Remove rear engine mount shield.
(21) Remove rear engine mount bracket bolts and
bracket.
(22) Remove starter bolts and set starter aside. Do
not allow the starter to hang from battery cable (Fig.
43).
(23) Position transmission jack securely under
transaxle (Fig. 44).
(24) Remove left fender splash shield.
(25) With transmission jack in position, remove
the left transmission mount.
(26) Lower transaxle to access the crankshaft posi-
tion sensor, remove crankshaft position sensor from
bell housing. For installation procedure refer to sec-
tion 8D of this service manual.CAUTION: Remove the crankshaft position sensor
from the bell housing before transmission removal
or installation.
(27) Remove lower bellhousing bolts.
(28) Carefully lower the transaxle assembly from
vehicle.
INSTALLATION
(1) For installation of transaxle, reverse the above
procedure.
(2) Check and/or adjust gearshift cable.
(3) Refill transaxle with MOPARtATF PLUS 3
(Automatic Transmission Fluid) Type 7176.
Fig. 41 Rotate Engine
Fig. 42 Remove Front Engine Mount
Fig. 43 Starter Assembly
Fig. 44 Position Transmission Jack
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REMOVAL AND INSTALLATION (Continued)

OIL PUMP SEAL
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
VALVE BODY RECONDITION
Fig. 45 Remove Oil Pump Seal
Fig. 46 Install Oil Pump Seal
Fig. 47 Transmission Range Sensor Screw
Fig. 48 Transmission Range Sensor Removed
Fig. 49 Manual Shaft and Rooster Comb
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REMOVAL AND INSTALLATION (Continued)

Fig. 50 2-4 Accumulator Plate
Fig. 51 TRS, Manual Shaft, and 2-4 Accumulator
Fig. 52 Valve Body Screws
Fig. 53 Valve Body and Transfer Plate
Fig. 54 Transfer Plate and Separator Plate
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DISASSEMBLY AND ASSEMBLY (Continued)