shaft CHRYSLER VOYAGER 1996 Service Manual

NOTE: The OD/UD Reaction Plate, Snap Rings, and
Input Clutches Retainer is not interchangeable with
previous year 41TE components. The snap rings
are thicker and the position of the ring lands have
changed.
Fig. 175 Install Input Shaft Hub Assembly
Fig. 176 Install Input Hub Tapered Snap Ring
Fig. 177 Underdrive Clutch Piston
Fig. 178 Seal Compressor Special Tool 5067
Fig. 179 UD Return Spring and Retainer
21 - 116 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

The reverse clutch pack clearance is 0.76 to
1.24 mm (.030 to .049 inch).Select the proper
reverse clutch snap ring to achieve specifications:
All clutch clearances in the input clutch retainer
have now been checked and approved.
To complete the assembly of the input clutch
retainer, the reverse clutch and the overdrive clutch
must be removed from the retainer.
CAUTION: Do not intermix clutch parts. Keep in
exact same order.
Now proceed with the next phase of the assembly:
REVERSE CLUTCH SNAP RING CHART
Fig. 200 Install No. 2 Needle Bearing
Fig. 201 Install Underdrive Shaft Assembly
Fig. 202 Install No. 3 Thrust Washer
Fig. 203 Install No. 3 Thrust Plate
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 121
DISASSEMBLY AND ASSEMBLY (Continued)

Reinstall overdrive clutch and reverse clutch as
shown.Rechecking these clutch clearances is
not necessary, as they were set and approved
previously.
TRANSAXLE ASSEMBLE
To assemble the transaxle centerline, refer to the
following procedures.
Fig. 204 Install Overdrive Shaft Assembly
Fig. 205 Input Clutch Assembly
Fig. 206 Install Both Output Bearing Cups
Fig. 207 Install Piston Retainer Gasket
Fig. 208 Install Piston Retainer
21 - 122 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 209 Install Retainer Attaching Screws
Fig. 210 Install Low/Reverse Clutch Piston
Fig. 211 Guide Bracket Disassembled
Fig. 212 Guide Bracket
Fig. 213 Pivot Shaft and Guide Bracket
Fig. 214 Install Guide Bracket Pivot Shaft
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 123
DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: When installing, be sure guide bracket
and split sleeve touch the rear of the transaxle case.
Fig. 215 Install Anchor Shaft and Plug
Fig. 216 Install Low/Reverse Piston Return Spring
Fig. 217 Low/Reverse Spring Compressor Tool
Fig. 218 Compressor Tool in Use
Fig. 219 Install Snap Ring
Fig. 220 Install Rear Carrier Bearing Cone
21 - 124 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 231 Install Strap Bolts
Fig. 232 Turn Stirrup Clockwise Against Flats Of
Output Gear Retaining Bolt
Fig. 233 Tighten Stirrup Strap Bolts To 23 N´m
(200 in. lbs.)
Fig. 234 Bend Tabs On Strap Up Against Flats Of
Bolts
Fig. 235 Install Transfer Shaft Bearing Cone
Fig. 236 Install Bearing Cup To Shaft
21 - 128 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Screw Tool 5049-A onto transfer shaft.
Install transfer shaft.
TRANSFER SHAFT BEARING
(1) Install a 4.66 mm (.184 inch) gauging shim on
the transfer shaft.
(2) Install transfer shaft gear and bearing assem-
bly and torque the nut to 271 N´m (200 ft. lbs.).
To measure bearing end play:
²Attach Tool L-4432 to the transfer gear.
²Mount a steel ball with grease into the end of
the transfer shaft.
²Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
²Using a dial indicator, measure transfer shaft
end play.
(3) Refer to the Transfer Bearing Shim Chart for
the required shim combination to obtain the proper
bearing setting.
(4) Use Tool 6259 to remove the retaining nut and
washer. Remove the transfer shaft gear using Tool
L-4407.
Fig. 237 Install Transfer Shaft
Fig. 238 Install Transfer Shaft Bearing Snap Ring
Fig. 239 Install Transfer Shaft Bearing Cup Into
Retainer
Fig. 240 Install Bearing Cup Retainer
Fig. 241 Install Transfer Gear Bearing Cone
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 129
DISASSEMBLY AND ASSEMBLY (Continued)

TRANSFER SHAFT BEARING SHIM CHART
End Play Shim Needed Part Number End Play Shim Needed Part Number
.05mm .002 in. 4.66mm .183 in. 4505588 .76mm .030 in. 3.94mm .155 in. 4412818
.08mm .003 in. 4.62mm .182 in. 4412835 .79mm .031 in. 3.90mm .154 in. 4412817
.10mm .004 in. 4.58mm .180 in. 4412834 .81mm .032 in. 3.90mm .154 in. 4412817
.13mm .005 in. 4.58mm .180 in. 4412834 .84mm .033 in. 3.86mm .152 in. 4412816
.15mm .006 in. 4.54mm .178 in. 4412833 .86mm .034 in. 3.82mm .150 in. 4412815
.18mm .007 in. 4.50mm .177 in. 4412832 .89mm .035 in. 3.82mm .150 in. 4412815
.20mm .008 in. 4.50mm .177 in. 4412832 .91mm .036 in. 3.78mm .149 in. 4412814
.23mm .009 in. 4.46mm .175 in. 4412831 .94mm .037 in. 3.74mm .147 in. 4412813
.25mm .010 in. 4.46mm .175 in. 4412831 .97mm .038 in. 3.74mm .147 in. 4412813
.28mm .011 in. 4.42mm .174 in. 4412830 .99mm .039 in. 3.70mm .146 in. 4412812
.30mm .012 in. 4.38mm .172 in. 4412829 1.02mm .040 in. 3.66mm .144 in. 4412811
.33mm .013 in. 4.38mm .172 in. 4412829 1.04mm .041 in. 3.66mm .144 in. 4412811
.36mm .014 in. 4.34mm .171 in. 4412828 1.07mm .042 in. 3.62mm .143 in. 4412810
.38mm .015 in. 4.30mm .169 in. 4412827 1.08mm .043 in. 3.62mm .143 in. 4412810
.41mm .016 in. 4.30mm .169 in. 4412827 1.12mm .044 in. 3.58mm .141 in. 4412809
.43mm .017 in. 4.26mm .168 in. 4412826 1.14mm .045 in. 3.54mm .139 in. 4412808
.46mm .018 in. 4.22mm .166 in. 4412825 1.17mm .046 in. 3.54mm .139 in. 4412808
.48mm .019 in. 4.22mm .166 in. 4412825 1.19mm .047 in. 3.50mm .138 in. 4412807
.50mm .020 in. 4.18mm .165 in. 4412824 1.22mm .048 in. 3.46mm .136 in. 4412806
.53mm .021 in. 4.18mm .165 in. 4412824 1.24mm .049 in. 3.46mm .136 in. 4412806
.56mm .022 in. 4.14mm .163 in. 4412823 1.27mm .050 in. 3.42mm .135 in. 4412805
.58mm .023 in. 4.10mm .161 in. 4412822 1.30mm .051 in. 3.38mm .133 in. 4412804
.61mm .024 in. 4.10mm .161 in. 4412822 1.32mm .052 in. 3.38mm .133 in. 4412804
.64mm .025 in. 4.06mm .160 in. 4412821 1.35mm .053 in. 3.34mm .132 in. 4412803
.66mm .026 in. 4.02mm .158 in. 4412820 1.37mm .054 in. 3.34mm .132 in. 4412803
.69mm .027 in. 4.02mm .158 in. 4412820 1.40mm .055 in. 3.30mm .130 in. 4412802
.71mm .028 in. 3.98mm .157 in. 4412819 1.45mm .057 in 3.26mm .128 in. 4412801
.74mm .029 in. 3.94mm .155 in. 4412818 1.47mm .058 in. 2.22mm .127 in. 4505570
21 - 130 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

(5) Remove the gauging shim and install the cor-
rect shim (Fig. 242). Install the transfer gear and
bearing assembly (Fig. 243).
CAUTION: Original retaining nut may not be
reused. Always use a new retaining nut when reas-
sembling.
(6) Install the new retaining nut and washer and
torque to 271 N´m (200 ft. lbs.) (Fig. 244).Measure
transfer shaft end play, end play should be .05
to .10 mm (.002 to .004 inch).
(7) Measure bearing end play as outlined in . End
play should be between .05 mm and .10 mm (.002 to
.004 inch).
NOTE: If end play is too high, install a .04 mm
(.0016 inch) thinner shim. If end play is too low,
install a .04 mm (.0016 inch) thicker shim combina-
tion. Repeat until .05 to .10 mm (.002 to .004 inch)
end play is obtained.NOTE: Install the low/reverse reaction plate
stepped side up.
Fig. 242 Transfer Shaft Gear and (Select) Shim
Fig. 243 Install Transfer Shaft Gear
Fig. 244 Tighten Nut to 271 N´m (200 ft. lbs.)
Fig. 245 Install Rear Cover
Fig. 246 Install Rear Cover Bolts
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 131
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Verify that Miller Tool 5058 is centered prop-
erly to the 2/4 clutch retainer before depressing the
tool.Press down clutch pack with finger and zero dial
indicator.The 2/4 clutch pack clearance is 0.76 to
2.64mm (.030 to .104 inch).If not within specifica-
tions, the clutch is not assembled properly.There is
no adjustment for the 2/4 clutch clearance.
DETERMINING No. 4 THRUST PLATE
THICKNESSÐINPUT SHAFT END PLAY
To determine the proper thickness of the No. 4
thrust plate, select the thinnest No. 4 thrust plate.
Using petrolatum (Fig. 263) to hold thrust plate in
position, install input clutch assembly. Be sure the
input clutch assembly is completely seated (Fig. 264).
CAUTION: If view through input speed sensor hole
is not as shown above, the input clutches assembly
is not seated properly.
Remove the oil pump O-ring (Fig. 265). You will be
able to install and remove the oil pump and gasket
very easily to select the proper No. 4 thrust plate.
Fig. 257 Install 2/4 Clutch Retainer
Fig. 258 Install 2/4 Clutch Retainer Snap Ring
Fig. 259 Check 2/4 Clutch Clearance
Fig. 260 Install Rear Sun Gear
Fig. 261 Install Front Carrier and Rear Annulus
Assembly
21 - 134 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)