shaft CHRYSLER VOYAGER 1996 Service Manual

NOTE: Use screw-in dowels or phillips-head screw-
drivers to align pump to case.CAUTION: Be sure to reinstall O-ring on oil pump
after selecting the proper No. 4 thrust plate.
Measure the input shaft end play with the tran-
saxle in the vertical position. This will ensure that
the measurement will be accurate.
NOTE: Input shaft end play must be .005 to .025
inch.
For example, if end play reading is .055 inch, select
No. 4 Thrust Plate which is .071 to .074 thick. This
should provide an input shaft end play reading of
.020 inch which is within specifications.
Fig. 262 Install Front Sun Gear Assembly
Fig. 263 Select Thinnest No. 4 Thrust Plate
Fig. 264 View Through Input Speed Sensor Hole
Fig. 265 Remove Oil Pump O-Ring
Fig. 266 Measure Input Shaft End Play
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 135
DISASSEMBLY AND ASSEMBLY (Continued)

(1) Install transaxle solenoid pack (Fig. 284).
(2) Install input and output speed sensors.
This concludes the assembly of the transaxle cen-
terline.
DIFFERENTIAL REPAIR
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.
DISASSEMBLE
The transfer shaft should be removed for differen-
tial repair and bearing turning torque checking.
(1) Remove the differential cover and bolts (Fig.
285) (Fig. 286).
(2) Remove the differential bearing retainer and
bolts (Fig. 287) (Fig. 288).(3) Using a plastic hammer, remove extension
housing/adapter plate on the right side of the tran-
saxle.
Fig. 283 Install Pan Bolts
Fig. 284 Install Solenoid Pack
Fig. 285 Differential Cover Bolts
Fig. 286 Remove Differential Cover
Fig. 287 Differential Retainer Bolts
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 139
DISASSEMBLY AND ASSEMBLY (Continued)

(2) Using Miller Special Tool 5052 and C-4171,
install differential bearing to differential (bearing
retainer side).
(3) Using Miller Special Tool 6061 and C-4171,
install differential bearing race to bearing retainer
(Fig. 297).
(4) Using Miller Special Tool L±4520 and C-4171,
install differential bearing to extension housing.
DIFFERENTIAL BEARING PRELOAD
ADJUSTMENT
NOTE: Perform all differential bearing preload mea-
surements with the transfer shaft and gear
removed.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING
EXISTING SHIM
(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 (Fig. 298).
(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
(Fig. 299).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.
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 to be installed 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.).
Fig. 297 Differential Bearing Retainer
Fig. 298 Tool L-4436 and Torque Wrench
Fig. 299 Checking Differential Bearings Turning
Torque
21 - 142 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

SPECIFICATIONS
41TE AUTOMATIC TRANSAXLE
Type..........................Fully adaptive,
electronically controlled,
four speed automatic 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 3Type 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..............................2.84
Second Gear.............................1.57
Direct Gear.............................1.00
Overdrive Gear..........................0.69
Reverse Gear............................2.21
Overall Top Gear Ratio
3.8 Liter................................2.38
3.3 Liter................................2.49
2.4 Liter................................2.69
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 . . .5 to 18 in. lbs. Drag Torque
Output Hub............3to8in.lbs. Drag Torque
Transfer Shaft.........0.002 to 0.004 in. End Play
Overall Drag At Output Hub........3to16in.lbs.
Drag Torque
Clutch Pack Clearances
Low/Rev Clutch
(Select Reaction Plate)............0.89-1.04mm
(0.035-0.042 in.)
Two/Four Clutch
(No Selection)...................0.76-2.64mm
(0.030-0.104 in.)Reverse Clutch (Select Snap Ring).....0.76-1.24mm
(0.030-0.049 in.)
Overdrive Clutch
(No Selection)...................0.96-2.26mm
(0.038-0.089 in.)
Underdrive Clutch
Select Pressure Plate)............0.91-1.47mm
(0.036-0.058 in.)
Transmission End Play.............0.12-0.63mm
(0.005-0.025 in.)
41TE TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Cooler Line Fittings..........12N´m(105 in. lbs.)
Differential Cover............19N´m(165 in. lbs.)
Differential Ring Gear.........95N´m(70ft.lbs.)
Differential Bearing Ret........28N´m(21ft.lbs.)
Driveplate To Crank. Bolts......95N´m(70ft.lbs.)
Driveplate To Torque Conv.......75N´m(55ft.lbs.)
Eight Way Solenoid Conn........4N´m(35in.lbs.)
Extension Housing............28N´m(21ft.lbs.)
Input Speed Sensor............27N´m(20ft.lbs.)
L/R Clutch Retainer............5N´m(45in.lbs.)
Oil Pan To Trans. Case........19N´m(165 in. lbs.)
Output Gear Bolt...........271 N´m (200 ft. lbs.)
Output Gear Stirrup Ret........23N´m(17ft.lbs.)
Output Speed Sensor..........27N´m(20ft.lbs.)
Pressure Taps................5N´m(45in.lbs.)
Pump To Case Bolts...........27N´m(20ft.lbs.)
Reaction Shaft Bolts...........27N´m(20ft.lbs.)
Rear End Cover..............19N´m(14ft.lbs.)
Sixty-Way Connector...........4N´m(35in.lbs.)
Solenoid Assembly To Case.....12N´m(105 in. lbs.)
Transmission Range Sensor......5N´m(45in.lbs.)
Transfer Gear Nut..........271 N´m (200 ft. lbs.)
Transfer Plate To Case........12N´m(105 in. lbs.)
Valve Body To Case Bolts......12N´m(105 in. lbs.)
Valve Body Bolts..............5N´m(45in.lbs.)
Vent Assembly..............12N´m(105 in. lbs.)
21 - 158 TRANSAXLE AND POWER TRANSFER UNITNS

POWER TRANSFER UNIT
INDEX
page page
GENERAL INFORMATION
POWER TRANSFER UNIT................ 165
DIAGNOSIS AND TESTING
FLUID LEAK DIAGNOSIS................. 167
SEAL IDENTIFICATION................... 165
REMOVAL AND INSTALLATION
DIFFERENTIAL CARRIER SEAL............ 170
END COVER BALL BEARING.............. 178
END COVER SEAL...................... 169
HALF SHAFT INNER SEAL................ 175
INPUT SHAFT COVER SEAL.............. 174
INPUT SHAFT END SEAL................. 177INPUT SHAFT SEAL..................... 169
OUTER HALF SHAFT SEAL............... 177
POWER TRANSFER UNIT (P.T.U.).......... 167
POWER TRANSFER UNIT OUTPUT SEAL.... 171
REAR COVER O-RING................... 171
ADJUSTMENTS
OUTPUT FLANGE SHIM SELECTION........ 180
SPECIFICATIONS
TORQUE............................. 180
SPECIAL TOOLS
SDP POWER TRANSFER UNIT............ 181
GENERAL INFORMATION
POWER TRANSFER UNIT
The Power Transfer Unit (P.T.U.) is attached to a
modified automatic transaxle case where the right
half shaft extension housing would normally be
located. The Transfer Unit provides the power to the
rear wheels through a hypoid ring gear and pinion
set.
The Power Transfer Unit is sealed from the tran-
saxle and has its own oil sump. The Unit uses SAE
85W-90 gear lubricant and holds 1.15 liters (1.22
quarts).
The Power Transfer Unit fill plug is located on the
end cover (Fig. 1).Do not mistake the black plas-
tic inspection plug located on the P.T.U. case
for the fill plug.Service of the Power Transfer Unit is limited to:
²Seals
²Gaskets
²One ball bearing
²Output flange
If the ring gear and pinion, any tapered roller
bearings, case, covers, or pinion carrier fail the entire
unit must be replaced.
DIAGNOSIS AND TESTING
SEAL IDENTIFICATION
For accurate seal diagnosis, repair seal name and
location is critical. Refer to (Fig. 2), (Fig. 3), (Fig. 4)
and (Fig. 5) for correct seal name and location.
Fig. 1 Fill Plug LocationFig. 2 Seal Location
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 165

FLUID LEAK DIAGNOSIS
When diagnosing fluid leaks on the Power Transfer
Unit two weep holes are provided to diagnose certainseal leaks. These holes are located on the bottom side
of the assembly (Fig. 6).
If fluid leak is detected from either weep hole, seal
replacement is necessary.Do not attempt to repair
the leak by sealing weep holes,they must be kept
clear of sealants for proper seal operation.
If fluid is leaking from weep hole A (Fig. 6) the
type of fluid leaking will determine which seal needs
to be replaced. If the fluid leaking is red in color
(transmission fluid) this indicates that the Transmis-
sion differential carrier seal should be replaced. If
the fluid leaking is light brown (gear lube) this indi-
cates that the Power Transfer Unit input seal should
be replaced. For replacement of these seals refer to
Power Transfer Unit Service Procedures.
If fluid is leaking from weep hole B (Fig. 6) the
type of fluid leaking will determine which seal is
leaking. If the fluid leaking is red in color (transmis-
sion fluid) this indicates that the input shaft end seal
should be replaced. If the fluid leaking is light brown
(gear lube) this indicates that the half shaft inner
seal and P.T.U. input shaft cover seal should be
replaced. For replacement of these seals refer to
Power Transfer Unit Service Procedures.
Before condemning any seal or gasket be sure that
the rear rocker arm cover on the engine is not the
cause of the oil leak. Oil leaking from the rocker arm
cover is easily mistaken for a leaking Power Transfer
Unit.
REMOVAL AND INSTALLATION
POWER TRANSFER UNIT (P.T.U.)
REMOVAL
(1) Raise vehicle and remove front wheels.
Fig. 3 Seal Location
Fig. 4 Seal Location
Fig. 5 Seal Location
Fig. 6 Weep Hole Locations
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 167
DIAGNOSIS AND TESTING (Continued)

CAUTION: A certain amount of oil will drain out of
the transaxle when the drive shaft is removed.
(2) Remove right front drive shaft. Install a plug
into the right driveshaft seal hole. Refer to Group 2,
Suspension to remove or install wheel hub nut and
right drive shaft.
(3) Mark propeller shaft front flange.
(4) Separate propeller shaft from P.T.U. assembly
(Fig. 7).
CAUTION: Do not let propeller shaft to hang freely.
Damage to the shaft will occur.
(5) Suspend propeller shaft from underbody of
vehicle.
(6) Remove cradle plate (Fig. 8).
(7) Remove the Power Transfer Unit mounting
bracket bolts at the rear of the unit (Fig. 9).
(8) Remove the right outboard support bracket and
bolts near the right axle shaft.(9) Remove the four mounting bolts for the P.T.U.
(Fig. 10) and (Fig. 11).
(10) Remove P.T.U. assembly from vehicle.
Fig. 7 Driveshaft Flange
Fig. 8 Cradle Plate
Fig. 9 Remove Rear P.T.U Bracket Bolts
Fig. 10 P.T.U. Lower Mounting Bolts
Fig. 11 P.T.U. Upper Mounting Bolts
21 - 168 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) To install, reverse removal procedure. Check
transaxle fluid and P.T.U. fluid and fill to level.
(2) Refer to the Specifications section for the
proper torque specifications.
END COVER SEAL
The Power Transfer Unit must be removed from
the vehicle to perform this operation. Refer to Power
Transfer Unit Removal in this section for procedures.
(1) Remove P.T.U. end cover bolts (Fig. 12).
(2) Gently tap on end cover ears with a hammer to
separate end cover from the case (Fig. 13).
(3) Clean and inspect sealer surfaces.
(4) Apply MopartGasket Maker, Loctite Gasket
Eliminator No.518 or equivalent to sealing surfaces.
(5) Reinstall cover and tighten bolts to 28 N´m
(250 in. lbs.) in the sequence shown in (Fig. 14).
Retighten first bolt after all others are tight.
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. into vehicle.
(7) Check and fill fluids as required.
INPUT SHAFT SEAL
The Power Transfer Unit must be removed from
the vehicle to service this seal. Refer to Power Trans-
fer Unit Removal in this section for procedures.
REMOVAL
(1) Remove P.T.U. end cover bolts (Fig. 15).(2) Gently tap on end cover ears to separate cover
from case (Fig. 16).
(3) Remove ring gear oil trough (Fig. 17).
(4) Remove input shaft and ring gear from case
(Fig. 18).
(5) Use Special Tool No. 7794-A (seal puller) to
remove seal (Fig. 19).
Fig. 12 P.T.U. End Cover Bolts
Fig. 13 End Cover Removal
Fig. 14 Bolt Tightening Sequence
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 169
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Clean and inspect seal area.
(2) Lay housing on bench and install new seal with
seal driver C-4657 and handle C-4171 (Fig. 20). The
seal must be installed with the spring side facing
towards the ring gear. Drive the seal in until it bot-
toms against the case shoulder.
(3) Install input shaft.
(4) Install oil trough.(5) Apply MopartGasket Maker or equivalent to
sealing surfaces of end cover and reinstall. Tighten
bolts to 28 N´m (250 in. lbs.).
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly into vehicle.
(7) Check and fill fluids as required.
DIFFERENTIAL CARRIER SEAL
The Power Transfer Unit must be removed from
the vehicle to replace this seal.
REMOVAL
(1) Remove P.T.U. from vehicle.
Fig. 15 P.T.U. End Cover Bolts
Fig. 16 End Cover Removal
Fig. 17 Oil Trough
Fig. 18 Input Shaft and Ring Gear Removal
21 - 170 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) Raise vehicle on hoist.
(2) Remove propeller shaft.
(3) Remove rear cover retaining bolts (Fig. 26).(4) Index rear cover to the case for later reassem-
bly (Fig. 27).
(5) Pull rear cover out of the P.T.U. case (Fig. 28).
Fig. 23 Mark Rear Cover
Fig. 24 Rear Cover Removal
Fig. 25 O-Ring Removal
Fig. 26 Rear Cover Bolts
Fig. 27 Mark Rear Cover
Fig. 28 Rear Cover Removal
21 - 172 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)