service CHRYSLER VOYAGER 1996 Service Manual

(11) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range. Drive the vehicle a minimum of
10 miles.
(12) Raise the vehicle on the hoist.
(13) Remove the pan and clean all sealant from
the pan and transaxle mating surfaces. Clean the
magnet and the inside of the pan.
(14) Separate the filter from the valve body to
allow additional fluid to drain from the transaxle.
Inspect the filter O-ring for any damage and replace
as necessary.
(15) After the transaxle has stopped draining,
reinstall the filter and O-ring.
(16) Apply a 1/8 inch bead of Mopar RTV Sealant
to the mounting flange of the transaxle oil pan.
Apply RTV Sealant to the underside of the attaching
bolts. Attach the oil pan to the transaxle. Tighten the
bolts to 19 N´m (165 in. lbs.).
(17) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(18) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(19) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(20) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range.
FLUID DRAIN AND REFILL
(1) Raise vehicle on a hoist (See Group 0, Lubrica-
tion). Place a drain container with a large opening,
under transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and O-ring on bottom of the
valve body.
(4) Clean the oil pan and magnet. Reinstall pan
using new MOPARtRTV sealant. Tighten oil pan
bolts to 19 N´m (165 in. lbs.).
(5) Pour four quarts of MOPARtATF PLUS 3
(Automatic Transmission Fluid) Type 7176 through
the fill tube.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.(7) Add sufficient fluid to bring level to 1/8 inch
below the ADD mark.
CAUTION: Do not overfill transaxle. Do not add oil
if level is between: Lower holes for warm oil
(100ÉF). Upper holes for hot oil (180ÉF).
(8) Recheck fluid level after transaxle is at normal
operating temperature. The level should be in the
HOT region (Fig. 5).
(9) To prevent dirt from entering transaxle, make
certain that dipstick is seated into the dipstick fill
tube.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum tran-
saxle case and valve body can be repaired by the use
of Heli-Coils, or equivalent. This repair consists of
drilling out the worn-out damaged threads. Then tap
the hole with a special Heli-Coil tap, or equivalent,
and installing a Heli-Coil insert, or equivalent, into
the hole. This brings the hole back to its original
thread size.
Heli-Coil, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
FLUSHING COOLERS AND TUBES
When a transaxle failure has contaminated the
fluid, the oil cooler(s) must be flushed. The cooler
bypass valve in the transaxle must be replaced also.
The torque converter must also be replaced with an
exchange unit. This will insure that metal particles
or sludged oil are not later transferred back into the
reconditioned (or replaced) transaxle.
The recommended procedure for flushing the tran-
saxle cooler is to use Tool 6906A Cooler Flusher.
Fig. 5 Oil Level Indicator
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 81
SERVICE PROCEDURES (Continued)

WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover plate filler plug on Tool 6906A.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906A.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines. Monitor pressure readings
and clear return lines. Pressure readings should sta-
bilize below 20 psi. for vehicles equipped with a sin-
gle cooler and 30 psi. for vehicles equipped with dual
coolers. If flow is intermittent or exceeds these pres-
sures, replace cooler.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(11) Place CLEAR suction line into a one quart
container of MopartATF PLUS 3 Type 7176 auto-
matic transmission fluid.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. Thispurges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
OIL PUMP VOLUME CHECK
After the new or repaired transmission has been
installed, fill to the proper level with Mopar ATF
PLUS 3 (Type 7176) automatic transmission fluid.
The volume should be checked using the following
procedure:
(1) Disconnect theFrom coolerline at the trans-
mission and place a collecting container under the
disconnected line.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engineat curb idle speed, with the
shift selector in neutral.
(3) If fluid flow is intermittent or it takes more
than 20 seconds to collect one quart of ATF, discon-
nect theTo Coolerline at the transaxle.
(4) Refill the transaxle to proper level and recheck
pump volume.
(5) If flow is found to be within acceptable limits,
replace the cooler. Then fill transmission to the
proper level, using Mopar ATF PLUS 3 (Type 7176)
automatic transmission fluid.
(6) If fluid flow is still found to be inadequate,
check the line pressure using the Transaxle Hydrau-
lic Pressure Test procedure.
(7) Check the cooler for debris on the external sur-
faces. Clean as necessary.
TRANSAXLE QUICK LEARN PROCEDURE
The quick learn procedure requires the use of the
DRBIII scan tool.
This program allows the electronic transaxle sys-
tem to recalibrate itself. This will provide the best
possible transaxle operation. The quick learn proce-
dure should be performed if any of the following pro-
cedures are performed:
²Transaxle Assembly Replacement
²Transmission Control Module Replacement
²Solenoid Pack Replacement
²Clutch Plate and/or Seal Replacement
²Valve Body Replacement or Recondition
To perform the Quick Learn Procedure, the follow-
ing conditions must be met:
²The brakes must be applied
²The engine speed must be above 500 rpm
²The throttle angle (TPS) must be less than 3
degrees
21 - 82 TRANSAXLE AND POWER TRANSFER UNITNS
SERVICE PROCEDURES (Continued)

²The shift lever position must stay until
prompted to shift to overdrive
²The shift lever position must stay in overdrive
after the Shift to Overdrive prompt until the DRBIII
indicates the procedure is complete
²The calculated oil temperature must be above
60É and below 200É
(1) Plug the DRBIII scan tool into the data link
connector. The connector is located under the instru-
ment panel.
(2) Go to the Transmission screen.
(3) Go to the Miscellaneous screen.
(4) Select Quick Learn Procedure. Follow the
instructions of the DRBIII to perform the Quick
Learn Procedure.
PINION FACTOR PROCEDURE
The vehicle speed readings for the speedometer are
taken from the output speed sensor. The TCM must
be calibrated to the different combinations of equip-
ment available. A procedure has been developed
called Pinion Factor. It allows the technician to set
the Transmission Control Module initial setting so
that the speedometer readings will be correct.
Failure to perform this procedure will cause a No
Speedometer Operation condition.
This procedure must be performed if the Transmis-
sion Control Module has been replaced.
To properly read or reset the Pinion Factor, it is
necessary to use a DRBIII scan tool. Perform the fol-
lowing steps with the DRBIII scan tool to read or
reset the Pinion Factor:
(1) Plug the DRBIII scan tool into the data link
connector located under the instrument panel.
(2) Select the Transmission menu.
(3) Select the Miscellaneous menu.
(4) Select Pinion Factor. Then follow the instruc-
tions on the DRBIII scan tool screen.
REMOVAL AND INSTALLATION
GEARSHIFT CABLE
REMOVAL
(1) Remove cable eyelet attachment from transaxle
operating lever pin (Fig. 6).
(2) Using pliers, squeeze ears of cable conduit
attachment at mounting bracket (Fig. 7) and push
through hole to remove (Fig. 8).
(3) Remove the under instrument panel silencer
(Fig. 9). Refer to Group 8E, Instrument Panel And
Gauges for more information.
(4) At the steering column attachment, remove the
cable eyelet attachment from the shift lever pin.(5) Using pliers, squeeze ears of cable attachment
at mounting bracket then push through hole to
remove.
(6) Unseat the dash grommet and remove the
cable from the vehicle.
INSTALLATION
(1) Install cable into steering column attachment
bracket. Verify conduit ears are fully engaged. Verify
cable does not interfere with brake pedal actuation.
(2) Attach cable eyelet fitting onto shift lever pin.
(3) Insert transaxle end of cable through dash
panel hole and fully seat grommet.
(4) Install instrument panel silencer. Verify gear-
shift cable is routed through the slot in the silencer.
CAUTION: Failure to route the cable properly at the
silencer may cause brake pedal interference.
(5) Attach transaxle end of cable to the mounting
bracket on the transaxle. Assure the conduit attach-
ment ears are fully seated.
Fig. 6 Gearshift Cable
Fig. 7 Grommet Clips
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 83
SERVICE PROCEDURES (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
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 91
REMOVAL AND INSTALLATION (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)

CHECKING SIDE GEAR END PLAY
Check side gear end play whenever the differential
is removed for service.
NOTE: Side gear end play must be BETWEEN 0.001
to 0.013 inch.
ASSEMBLE
NOTE: Use MoparTSilicone Rubber Adhesive Seal-
ant, or equivalent, on retainer and extension hous-
ing/adapter plate to seal to case.
(1) Using Miller Special Tool L-4410, and C-4171,
install differential bearing to differential (extension
housing side) (Fig. 296).
Fig. 293 Remove Bearing Cup
DIFFERENTIAL SERVICE TOOLS
COMPONENT REMOVER INSTALLER
Diff. Bear. On
Retainer Side5048, 5048-4
Collets,
L-4539-2
Button5052, C-4171
Diff. Bear. On
Ext. Hous. Side5048, 5048-3
Collets,
L-4539-2
ButtonL-4410, C-4171
Diff. Race. On
Retainer Side6062-A 6061, C-4171
Diff. Race. On
Ext. Hous. SideL-4518 L-4520, C-4171
Extension
Housing Seal7794-A, C-637
Slide HammerL-4520, C-4171
Bearing
Retainer Seal794-A, C-637
Slide HammerL-4520, C-4171
Fig. 294 Checking Side Gear End Play (Extension
Housing Side)
Fig. 295 Checking Side Gear End Play (Bearing
Retainer Side)
Fig. 296 Position Bearing Cone Onto Differential
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 141
DISASSEMBLY AND ASSEMBLY (Continued)

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)

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)

(4) Install rear cover. Use care not to cut rear
cover O-Ring when installing rear cover into P.T.U.
housing.
(5) Install rear cover retaining bolts and tighten to
28 N´m (250 in. lbs.).
(6) Install propeller shaft.
(7) Check and fill fluids as required.
INPUT SHAFT COVER SEAL
The power transfer unit input shaft cover seal is
the larger of the two seals located on the inside of
the end cover. The differential bearing cup must be
removed to service this seal.
The Power Transfer Unit must be removed from
vehicle to perform this operation.
REMOVAL
(1) Remove P.T.U. end cover bolts (Fig. 33).
(2) Gently tap on end cover ears to separate cover
from case (Fig. 34).
(3) Use special tool No. 6514 and remove the dif-
ferential bearing race located in the end cover (Fig.
35). The race must be removed to gain access to the
seal.
(4) Use special tool No. 7794-A to remove seal (Fig.
36).
INSTALLATION
(1) Clean and inspect seal area.
(2) Use special tool No. MD998803 and install seal
(Fig. 37). When installing seal the spring side of the
seal must face toward the special tool.(3) Reinstall the original bearing race and shim
using special tool No. 6522 (Fig. 38) and (Fig. 39).
CAUTION: The original shim must be installed
behind the bearing cup to maintain proper bearing
preload.
(4) Apply MopartGasket Maker, Loctite Gasket
Eliminator No. 518 or equivalent to sealing surfaces
of end cover.
(5) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N´m (250 in. lbs.) in the
sequence shown in (Fig. 40). Retighten first bolt after
all others are tight.
Fig. 33 P.T.U. End Cover Bolts
Fig. 34 End Cover Removal
Fig. 35 Bearing Race Removal
21 - 174 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)