shaft CHRYSLER VOYAGER 1996 Service Manual

Measure the input shaft end play with the tran-
saxle in the vertical position. This will ensure that
the measurement will be accurate.
Measuring input shaft end play before disassembly
will usually indicate when a #4 thrust plate change
is required. The #4 thrust plate is located behind the
overdrive clutch hub.
Attach a dial indicator to transaxle bell housing
with its plunger seated against end of input shaft
(Fig. 74).
Move input shaft in and out to obtain end play
reading. End play specifications are .13 to .64 mm
(.005 to .025 inch).
Record indicator reading for reference when reas-
sembling the transaxle.
CAUTION: Be sure input speed sensor is removed
before removing oil pump.
OIL PUMP INSPECTION
When disassembling the transaxle it is necessary
to inspect the oil pump for wear and damage.
(1) Remove the reaction shaft support bolts.
Fig. 74 Measure Input Shaft End Play
Fig. 75 Remove Pump Attaching Bolts
Fig. 76 Install Tool C-3752
Fig. 77 Remove Oil Pump
Fig. 78 Oil Pump Removed
21 - 98 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

(2) Remove reaction shaft support from pump
housing (Fig. 80).
(3) Remove the pump gears and check for wear
and damage.
(4) Install the gears and check clearances.
(5) Measure the clearance between the outer gear
and the pump pocket (Fig. 81). Clearance should be
0.045-0.141mm (0.0018-0.0056 in.).
(6) Measure the clearance between the outer gear
and the pump crescent. Clearance should be 0.020-
0.046mm (0.0008-0.0018 in.) (Fig. 82).
(7) Measure the clearance between the inner gear
and the pump crescent. Clearance should be 0.020-
0.046mm (0.0008-0.0018 in.) (Fig. 83).
Fig. 79 Remove Oil Pump Gasket
Fig. 80 Reaction Shaft Support
Fig. 81 Measure Outer Gear to Pocket
Fig. 82 Measure Outer Gear To Crescent
Fig. 83 Measure Inner Gear To Crescent
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 99
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Tag low/reverse clutch pack for reassembly
identification.
Fig. 101 Remove Rear Cover Bolts
Fig. 102 Remove Rear Cover
Fig. 103 Remove Transfer Shaft Gear Nut
Fig. 104 Transfer Shaft Gear Nut and Coned Washer
Fig. 105 Remove Transfer Shaft Gear
Fig. 106 Remove Transfer Shaft Gear and (Select)
Shim
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 103
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Screw Tool 5049-A onto transfer shaft.
Remove transfer shaft.
Fig. 107 Remove Bearing Cup Retainer
Fig. 108 Remove Transfer Gear Bearing Cone
Fig. 109 Remove Transfer Shaft Bearing Cup
Fig. 110 Remove Transfer Shaft Bearing Snap Ring
Fig. 111 Remove Transfer Shaft
Fig. 112 Bearing Cup Removed
21 - 104 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Remove output gear stirrup and strap bolts.
All transaxles utilize a stirrup and retaining strap
that is attached to the output gear. The stirrup pre-
vents the output gear retaining bolt from turning
and backing out of the rear carrier. The strap is used
to hold the stirrup to the output gear and prevent
the stirrup retaining bolts from backing out.
CAUTION: When installing, be sure guide bracket
and split sleeve touch the rear of the transaxle
case.
Fig. 113 Remove Transfer Shaft Bearing Cone
Fig. 114 Loosen Stirrup Strap Bolts
Fig. 115 Remove Strap Bolts
Fig. 116 Remove Stirrup Strap
Fig. 117 Remove Stirrup
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 105
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 124 Remove Rear Carrier Bearing Cone
Fig. 125 Low/Reverse Spring Compressor Tool
Fig. 126 Compressor Tool in Use
Fig. 127 Remove Snap Ring
Fig. 128 Low/Reverse Piston Return Spring
Fig. 129 Drive Out Anchor Shaft
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 107
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 130 Remove Anchor Shaft and Plug
Fig. 131 Remove Guide Bracket Pivot Shaft
Fig. 132 Pivot Shaft and Guide Bracket
Fig. 133 Guide Bracket
Fig. 134 Guide Bracket Disassembled
Fig. 135 Remove Low/Reverse Clutch Piston
21 - 108 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Tag overdrive clutch pack for reassembly
identification.
Fig. 147 OD/Reverse Pressure Plate
Fig. 148 Waved Snap Ring
Fig. 149 Remove OD Clutch Pack
Fig. 150 Overdrive Clutch Pack
Fig. 151 Overdrive Shaft Assembly
Fig. 152 Underdrive Shaft Assembly
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 111
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 164 Input Hub Removed
Fig. 165 Pull Retainer from Piston
Fig. 166 Remove Snap Ring
Fig. 167 Snap Ring and Return Spring
Fig. 168 Remove Input Shaft Snap Ring
Fig. 169 Remove Input Shaft
21 - 114 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
Use petrolatum on all seals to ease assembly of
components.
Fig. 170 Install Input Shaft
Fig. 171 Install Input Shaft Snap Ring
Fig. 172 Return Spring and Snap Ring
Fig. 173 Install Snap Ring
Fig. 174 Install OD/Reverse Piston
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 115
DISASSEMBLY AND ASSEMBLY (Continued)