shaft CHRYSLER VOYAGER 1996 Service Manual

(6) Remove output flange nut (Fig. 29).
(7) Index the pinion to the flange (Fig. 30).
(8) Using a hydraulic press, press off output flange
from pinion.
(9) Use a hammer and chisel to remove output
seal (Fig. 31).
CAUTION: If the output flange requires replace-
ment, a new shim may be required. Refer to Output
Flange Shim Selection procedure in this section to
determine correct shim requirements.
INSTALLATION
(1) Install new seal with Seal Installer 5049 (Fig.
32).
(2) If the original flange is used, align index marks
and press flange onto pinion. If a new flange is used
disregard the alignment marks on the pinion and
press flange onto the pinion.(3) Install flange nut and tighten to 244 N´m (180
ft. lbs.).
Fig. 29 Output Flange Nut
Fig. 30 Mark Flange and Shaft
Fig. 31 Seal Removal
Fig. 32 Seal Installation
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 173
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)

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.
HALF SHAFT INNER SEAL
The power transfer unit half shaft inner seal is the
smaller of the two seals located on the inside of the
end cover.
REMOVAL
(1) Remove power transfer unit from the vehicle.
(2) Remove end cover bolts (Fig. 41).
(3) Tap on end cover ears to separate cover from
case (Fig. 42).
(4) Drive seal out with a hammer and small chisel
(Fig. 43).
Fig. 36 Seal Removal
Fig. 37 Seal Installation
Fig. 38 Bearing Shim and Race
Fig. 39 Installing Bearing Race
Fig. 40 Bolt Tightening Sequence
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 175
REMOVAL AND INSTALLATION (Continued)

sequence shown in (Fig. 45). Retighten first bolt after
all other bolts are tight.
(5) Reinstall P.T.U. assembly.
(6) Check and fill fluids as required.
INPUT SHAFT END SEAL
The input shaft end seal is located on the end of
the input shaft.
REMOVAL
(1) Remove power transfer unit from the vehicle.
(2) Remove end cover bolts (Fig. 46).
(3) Tap on end cover ears to separate end cover
from case (Fig. 47).
(4) Pry out seal with a pry bar (Fig. 48).
INSTALLATION
(1) Clean and inspect seal area.
(2) Remove input shaft from housing and stand on
soft block of wood. Install input shaft end seal with
seal installer 5065 and handle C-4171.
(3) Lubricate seal lip after installing seal into
input shaft.
(4) Clean sealing surfaces of the end cover and
P.T.U. case. Apply a bead of MopartGasket Maker,
Loctite Gasket Eliminator No. 518 or equivalent.
(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. 49). 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. assembly.
(7) Check and fill fluids as required.
OUTER HALF SHAFT SEAL
The outer half shaft seal is located on the outside
of the end cover. The P.T.U. does not have to be
removed to replace this seal.
Fig. 45 Bolt Tightening Sequence
Fig. 46 End Cover Bolts
Fig. 47 Side Cover Removal
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 177
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) Lift vehicle on hoist.
(2) Remove right front half shaft from vehicle.
(3) Remove seal with a chisel and hammer (Fig.
50).
INSTALLATION
(1) Clean and inspect seal area.
(2) Install new seal with seal installer MD998334
(Fig. 51).
(3) Reinstall right front half shaft.
(4) Check and fill fluids as required.
END COVER BALL BEARING
The end cover ball bearing can be removed and
installed without removing the Power Transfer Unit
from the vehicle. When replacing the bearing the out-
put seal must be removed to gain access to the bear-
ing.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove right front half shaft from vehicle.
(3) Remove output seal with a hammer and chisel
(Fig. 52).
(4) Remove bearing retaining snap ring (Fig. 53).
(5) Use bearing puller MD998346 to remove bear-
ing (Fig. 54).
Fig. 48 Seal Removal
Fig. 49 Bolt Tightening Sequence
Fig. 50 Seal Removal
Fig. 51 Seal Installation
21 - 178 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Use bearing driver L-4530 and handle C-4171-2
to install bearing (Fig. 55).
(2) Install bearing retaining snap ring.
CAUTION: When installing bearing retaining snap
ring, be sure to index the snap ring so that the
snap ring does not cover bearing oil passage.
(3) Install new outer half shaft seal using
MD998334 seal installer (Fig. 56).Do not reuse the
old seal.
(4) Reinstall right front half shaft.
(5) Check and fill fluids as required.
Fig. 52 Output Seal Removal
Fig. 53 Bearing Snap Ring
Fig. 54 Bearing Removal
Fig. 55 Bearing Installation
Fig. 56 Installing New Seal
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 179
REMOVAL AND INSTALLATION (Continued)

A±598 MANUAL TRANSAXLE
CONTENTS
page page
GENERAL INFORMATION
A-598 MANUAL TRANSAXLE............... 2
A-558 MANUAL TRANSAXLEÐRHD
VEHICLES............................ 2
GEAR RATIOS........................... 3
GEAR RATIOSÐRHD VEHICLES............ 3
GEARSHIFT PATTERN..................... 3
GEARSHIFT PATTERNÐRHD VEHICLES...... 3
SELECTION OF LUBRICANT................ 2
SELECTION OF LUBRICANTÐRHD VEHICLES . 2
SPECIAL ADDITIVES..................... 2
SPECIAL ADDITIVESÐRHD VEHICLES....... 3
TRANSAXLE IDENTIFICATION INFORMATION . . 2
TRANSAXLE IDENTIFICATION
INFORMATIONÐRHD VEHICLES.......... 2
DESCRIPTION AND OPERATION
AXLE SEALS............................ 3
GEARSHIFT LEVERS...................... 3
DIAGNOSIS AND TESTING
CLUTCH PROBLEMS..................... 4
COMMON PROBLEM CAUSES.............. 3
HARD SHIFTING......................... 4
LOW LUBRICANT LEVEL.................. 4
NOISY OPERATION....................... 4
SLIPS OUT OF GEAR..................... 4
SERVICE PROCEDURES
FLUID DRAIN AND FILL................... 4
FLUID DRAIN AND FILLÐRHD VEHICLES.... 4
REMOVAL AND INSTALLATION
A-558 TRANSAXLE ASSEMBLYÐRHD
VEHICLES........................... 16
AXLE SEALS........................... 11
BACK-UP LAMP SWITCH.................. 9
CRANKSHAFT POSITION SENSOR Ð
2.5L VM DIESEL...................... 10
CROSSOVER LEVER..................... 11
GEARSHIFT BOOT....................... 5GEARSHIFT BOOT....................... 5
GEARSHIFT CABLES...................... 5
GEARSHIFT CABLESÐRHD VEHICLES....... 7
GEARSHIFT KNOB....................... 5
GEARSHIFT MECHANISM REPLACEMENT..... 7
GEARSHIFT MECHANISM REPLACEMENTÐ
RHD VEHICLES........................ 8
INPUT SHAFT FRONT BEARING RETAINER . . . 15
INPUT SHAFT SEAL..................... 16
SELECTOR LEVER...................... 11
SHIFT SHAFT SEALS.................... 12
TRANSAXLE........................... 12
VEHICLE SPEED SENSOR DRIVE GEAR...... 9
DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL......................... 39
INPUT SHAFT.......................... 32
INTERMEDIATE SHAFT................... 33
SHIFT COVER.......................... 45
SYNCHRONIZER........................ 43
TRANSAXLE........................... 20
TRANSAXLE CASE...................... 48
CLEANING AND INSPECTION
SYNCHRONIZER........................ 52
TRANSAXLE........................... 52
ADJUSTMENTS
BEARING ADJUSTMENT PROCEDURE....... 56
GEARSHIFT CROSSOVER CABLE........... 52
GEARSHIFT CROSSOVER CABLE........... 55
INTERMEDIATE SHAFT BEARING PRELOAD . . 57
SPECIFICATIONS
A-558 MANUAL TRANSAXLEÐRHD
VEHICLES........................... 59
A-598 (T-750) MANUAL TRANSAXLE....... 59
SPECIAL TOOLS
A-558 MANUAL TRANSAXLEÐRHD
VEHICLES........................... 60
A-598 (T-750) MANUAL TRANSAXLE....... 60
NS/GSA±598 MANUAL TRANSAXLE 21 - 1

sealers should be avoided, since they may adversely
affect seals.
SPECIAL ADDITIVESÐRHD VEHICLES
The addition of any fluids to the transaxle, other
than the fluid listed above, is not recommended. An
exception to this policy is the use of special dyes to
aid in detecting fluid leaks. The use of transmission
sealers should be avoided, since they may adversely
affect seals.
GEAR RATIOS
Gear ratios for the 2.4L gasoline engine and 2.5L
Turbo Diesel MTX are as follows:
²1stÐ3.36
²2ndÐ1.90
²3rdÐ1.28
²4thÐ0.92
²5thÐ0.71
²ReverseÐ3.17
Final drive ratio of 3.88 was selected for maximum
performance. All forward gears are synchronized.
Gear ratios for the 2.0L GAS MTX are as follows:
²1stÐ3.69
²2ndÐ2.24
²3rdÐ1.45
²4thÐ1.03
²5thÐ0.81
²ReverseÐ3.17
Final drive ratio of 4.08 was selected for maximum
performance. All forward gears are synchronized.
GEAR RATIOSÐRHD VEHICLES
Gear ratios for the 2.0L GAS MTX are as follows:
²1stÐ3.69
²2ndÐ2.24
²3rdÐ1.45
²4thÐ0.1.03
²5thÐ0.81
²ReverseÐ3.17
Final drive ratio of 4.08 was selected for maximum
performance. All forward gears are synchronized.
GEARSHIFT PATTERN
The A-598 transaxle shift pattern is a H±pattern
(Fig. 3). Overdrive fifth and reverse gears are in±line
and to the right of the first through fourth gear posi-
tions.
GEARSHIFT PATTERNÐRHD VEHICLES
The A-558 transaxle shift pattern is a H±pattern
(Fig. 4). Overdrive fifth and reverse gears are in±line
and to the right of the first through fourth gear posi-
tions.
DESCRIPTION AND OPERATION
GEARSHIFT LEVERS
The gear shift levers at the transaxle are service-
able in the vehicle. The shift levers are different from
each other and do not interchange. The select lever is
not interchangeable with model years earlier than 96
(length is different).
AXLE SEALS
The axle shaft seals are identical for both sides of
the differential and will interchange.
DIAGNOSIS AND TESTING
COMMON PROBLEM CAUSES
The majority of transaxle malfunctions are a result
of:
²Insufficient lubrication
²Incorrect lubricant
²Misassembled or damaged internal components
Fig. 3 A-598 Shift Pattern
Fig. 4 A-558 Shift Pattern
NS/GSA±598 MANUAL TRANSAXLE 21 - 3
GENERAL INFORMATION (Continued)

INSTALLATION
(1) To install, reverse removal procedure. Teflon
tape or equivalent must be used on switch threads.
CAUTION: Do not overtighten switch.
(2) Confirm back-up lamps are functioning prop-
erly following installation.
CRANKSHAFT POSITION SENSOR Ð 2.5L VM
DIESEL
The crankshaft position sensor is located on the
transaxle bellhousing. The sensor measures the posi-
tion of the crankshaft and relays that information to
the Powertrain Control Module.
Fig. 22 Gearshift Cables
Fig. 23 Vehicle Speed SensorFig. 24 Back-Up Lamp Switch Location
21 - 10 A±598 MANUAL TRANSAXLENS/GS
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) Remove electrical connector at crankshaft posi-
tion sensor (Fig. 25).
(2) Remove screw retaining the crankshaft position
sensor to the bellhousing.
(3) Remove the crankshaft position sensor.
INSTALLATION
(1) For installation, reverse removal procedure.
CROSSOVER LEVER
REMOVAL
(1) Remove crossover cable. Refer to Gearshift
Cable removal.
(2) Using a pin punch, remove the crossover roll
pin from lever.
(3) Pull up and remove the crossover lever from
the transaxle crossover shaft.
INSTALLATION
(1) For installation, reverse removal procedure.
Replace the roll pin that was removed with a new
one.
SELECTOR LEVER
REMOVAL
(1) Remove the selector cable. Refer to Gearshift
Cable removal.
(2) Using a pin punch, remove the roll pin from
the lever.
(3) Remove the selector lever from the transaxle
selector shaft
INSTALLATION
(1) For installation, reverse removal procedure.
Replace the roll pin with a new one.
AXLE SEALS
The axle shaft seals are identical for both sides of
the differential and will interchange.
EXTENSION HOUSING AXLE SEAL
REMOVAL
(1) Remove axle shaft. Refer to Group 2, Suspen-
sion and Driveshafts for service procedures.
(2) Insert a flat±blade pry tool into the axle seal
bore (Fig. 26).
(3) Using the pry tool, carefully pop out the seal
taking care not to nick the seal bore.
INSTALLATION
(1) Clean axle shaft seal bore of any excess seal-
ant.
(2) Align axle shaft seal with axle shaft seal bore.
(3) Position axle seal at extension housing.
(4) Using Tool L-4520 and Tool C-4171, tap seal
into position (Fig. 27).
Fig. 25 Crankshaft Position Sensor
Fig. 26 Extension Housing Axle Seal
Fig. 27 Install Seal
NS/GSA±598 MANUAL TRANSAXLE 21 - 11
REMOVAL AND INSTALLATION (Continued)