shaft CHRYSLER VOYAGER 1996 Service Manual

NOTE: The input shaft is serviced as an assembly.
The only serviceable components of the input shaft
are the bearings.To disassemble the intermediate shaft, differential,
synchronizers, or transaxle case, refer to the appro-
priate procedure in this section (Fig. 108).
ASSEMBLY
If the transaxle housing, intermediate shaft, bear-
ing plate, or bearings were replaced, you must adjust
the intermediate shaft bearing preload. To adjust
intermediate shaft preload, refer to Intermediate
Shaft Preload Adjustment.
(1) Install geartrain set.
CAUTION: The 5th gear shift rail has a small inter-
lock pin that is contained within the shift lug and
rail. Use caution when installing shift rail.
(2) Carefully install 5th gear shift rail (Fig. 109)
(Fig. 110).
(3) Install 5th gear shift rail C-clip.
(4) Install reverse shift rail.
(5) Install reverse idler gear (Fig. 111).
Fig. 105 Reverse Shift Rail Removed
Fig. 106 Reposition Shift Rail Lugs
Fig. 107 Geartrain Removal
Fig. 108 Geartrain Components
Fig. 109 5th Gear Shift Rail and Interlock
21 - 28 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Verify that the rear oil trough is properly
installed and retained in the bearing support plate
before installing support plate.
(6) Apply a bead of MopartGasket Maker or
equivalent onto bearing support plate. Install bearing
support plate (Fig. 112).
(7) Install interlock plate (Fig. 113) and shuttles
(Fig. 114).
(8) Install input shaft bearing snap ring (Fig. 115).
(9) Install preload shim at intermediate shaft (Fig.
116).
(10) Install bearing retainer plate. Tighten bearing
retainer plate to 17 N´m (250 in. lbs.).
NOTE: If the transaxle housing, intermediate shaft,
bearing retainer plate, or bearings are replaced, you
must perform the intermediate shaft bearing pre-
load procedure. Refer to Intermediate Shaft Bearing
Preload Adjustment procedure in the ADJUST-
MENTS section.(11) Install 5th gear.
(12) Use Special Tool 6252 to hold 5th gear and
install 5th gear nut at input shaft. Tighten the
retaining nut to 176 N´m (130 ft. lbs.).
Fig. 110 5th Gear Shift Rail
Fig. 111 Reverse Idler Gear
Fig. 112 Support Plate
Fig. 113 Interlock Plate
Fig. 114 Shuttles
NS/GSA±598 MANUAL TRANSAXLE 21 - 29
DISASSEMBLY AND ASSEMBLY (Continued)

(13) Use Special Tool 6930 to stake the 5th gear
retaining nut onto the input shaft (Fig. 117).
(14) Install 5th gear shift fork, synchro, and plate
(Fig. 118).(15) Install snap ring at 5th gear synchro (Fig.
119).
(16) Install 5th gear shift fork roll pin (Fig. 120).
Fig. 115 Input Shaft Bearing Snap Ring
Fig. 116 Bearing Preload Shim
Fig. 117 Staking 5th Gear Retaining Nut
Fig. 118 5th Gear Shift Fork, Rail, and Synchronizer
Fig. 119 5th Gear Synchronizer Snap Ring
Fig. 120 5th Gear Shift Fork Roll Pin
21 - 30 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Two of the bolts retaining the shift cover are
shouldered (Fig. 127).
(23) Apply a bead of MopartGasket Maker or
equivalent onto shift cover. Line up the shift detent
springs so the springs are aligned with the shift
cover spring pockets. Install shift cover. Tighten shift
cover bolts to 28 N´m (250 in. lbs.).
(24) Install differential assembly.
(25) Apply a bead of MopartGasket Maker or
equivalent onto differential cover. Install differential
cover. Tighten differential cover bolts to 61 N´m (45
ft. lbs.).
(26) Apply a bead of RTV silicone to the differen-
tial bearing retainer. Install differential bearing
retainer. Tighten differential bearing retainer bolts to
61 N´m (45 ft. lbs.).
(27) Apply a bead of RTV silicone to the extension
housing. Install extension housing. Tighten extension
housing bolts to 28 N´m (250 in. lbs.).
(28) Install engine mount bracket.
INPUT SHAFT
The input shaft is serviced as an assembly. The
only serviceable component of the input shaft is the
rear bearing.
DISASSEMBLY
(1) Install the bearing splitter 1130 under the rear
bearing.
(2) Position the input shaft into a shop press (Fig.
128).
(3) Remove the rear bearing (Fig. 129).
ASSEMBLY
(1) Position replacement bearing onto the input
shaft (Fig. 130).
(2) Place input shaft into shop press.
(3) Position Special Tool 6950 over input shaft on
top of bearing.
(4) Press input shaft bearing into position (Fig.
131).
Fig. 126 Shift Cover Splash Shield
Fig. 127 Gearshift Cover Shouldered Bolts
Fig. 128 Input Shaft
Fig. 129 Remove Bearing
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DISASSEMBLY AND ASSEMBLY (Continued)

INTERMEDIATE SHAFT
DISASSEMBLY
(1) Install intermediate shaft into shop press.
(2) Install bearing splitter 1130 under the 4th
speed gear clutch teeth (Fig. 132).
(3) Remove intermediate shaft rear bearing snap
ring (Fig. 133).
(4) Position Special Tool 6792±1 over intermediate
shaft.
CAUTION: To prevent damaging the intermediate
shaft, grasp the bottom of the shaft when doing
shop press procedures.
(5) Using Special Tool 6792±1 as a driver, press off
and remove 4th speed gear (Fig. 134).
(6) Remove intermediate shaft from shop press.
(7) Install Special Tool 6938 onto front intermedi-
ate bearing for protection.
(8) Remove 3±4 synchro snap ring (Fig. 135) (Fig.
136).NOTE: The 3±4 synchro has a master spline (Fig.
137).
Fig. 130 Position Bearing
Fig. 131 Press Input Bearing Onto Shaft
Fig. 132 Bearing Splitter Installed
Fig. 133 Intermediate Shaft Rear Bearing Snap Ring
Fig. 134 Press Off 4th Speed Gear
NS/GSA±598 MANUAL TRANSAXLE 21 - 33
DISASSEMBLY AND ASSEMBLY (Continued)

(15) Remove 1±2 dual cone synchro assembly and
1st speed gear (Fig. 144).
(16) Install Special Tool 1130 bearing splitter
under the plastic intermediate shaft front bearing
(17) Position shaft into shop press.
(18) Position Special Tool MD998802±01 over the
intermediate shaft.
(19) Remove the intermediate shaft front bearing
(Fig. 145).
Fig. 143 Snap Ring Removed
Fig. 142 1±2 Synchro Snap Ring
Fig. 144 1±2 Dual Cone Synchro
21 - 36 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
(1) Position intermediate shaft front bearing onto
intermediate shaft. Install Special Tool 6938 over
bearing and shaft. Install the intermediate shaft
front bearing (Fig. 146).
(2) Remove intermediate shaft from shop press.
(3) Position intermediate shaft bearing side down.
Place intermediate shaft into Special Tool 6938 to
protect front bearing. Install 1±2 dual cone synchro
assembly and 1st speed gear.
(4) Install 1±2 synchro snap ring (precision
ground) (Fig. 147).
(5) Install 2nd speed gear (Fig. 148).
(6) Install the anti-spin pin (Fig. 149).
(7) Install the two split washers.
(8) Install thrust washer outer retainer (Fig. 150).
NOTE: The 3±4 synchro has a master spline (Fig.
151).
(9) Install 3±4 synchro assembly and 3rd speed
gear.(10) Install 3±4 synchro snap ring (Fig. 152).
(11) Install 4th speed gear over the 3±4 synchro.
Fig. 145 Intermediate Shaft Front Bearing
Fig. 146 Install Intermediate Shaft Front Bearing
Fig. 147 1±2 Synchro Snap Ring
NS/GSA±598 MANUAL TRANSAXLE 21 - 37
DISASSEMBLY AND ASSEMBLY (Continued)

(12) Position the intermediate shaft rear bearing
onto the intermediate shaft.
(13) Install the intermediate shaft into a shop
press.
(14) Position Special Tool MD998323 over the
intermediate shaft rear bearing
(15) Press on the intermediate shaft rear bearing
(Fig. 153).
(16) Install intermediate shaft rear bearing snap
ring.
DIFFERENTIAL
NOTE: The differential is typically serviced as an
assembly. The only parts that are serviceable within
the differential are the differential bearing cups and
cones. If any other part fails within the differential,
you should replace the differential assembly.Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle gear case
²Differential case
²Differential bearings
²Differential cover
Refer toBearing Adjustment Procedurein the
Adjustments section at the end of this section to
determine proper shim thickness. This will provide
correct bearing preload and proper bearing turning
torque.DIFFERENTIAL BEARINGS
Differential bearings are usually serviced as pairs.
If one differential bearing fails, you should replace
both bearing cups and cones
Fig. 152 3±4 Synchro Snap RingFig. 153 Intermediate Shaft Rear Bearing Installation
NS/GSA±598 MANUAL TRANSAXLE 21 - 39
DISASSEMBLY AND ASSEMBLY (Continued)

RING GEAR
CAUTION: Always install new ring gear bolts.
Tighten ring gear bolts to 94 N´m (70 ft. lbs.) torque.
DIFFERENTIAL GEARS
REMOVAL
(1) Remove pinion shaft retaining pin (Fig. 167)
(Fig. 168).
(2) Remove pinion shaft (Fig. 169).
(3) Rotate side gears to opening in differential
(Fig. 170).
(4) Remove differential gears (Fig. 171).
Fig. 165 Install Extension Bearing Cup
Fig. 166 Remove or Install Ring Gear Bolts and
Ring Gear
Fig. 167 Remove Pinion Shaft Retaining Pin
Fig. 168 Retaining Pin Removed
Fig. 169 Pinion Shaft Removal
21 - 42 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

INSTALLATION
(1) Assemble the differential side gears, pinion
gears and pinion gears with the pinion gear washers.
(2) Install pinion shaft retaining pin (Fig. 172).
(3) Stake pinion shaft retaining pin with a suitable
chisel (Fig. 173).
(4) Rotate the assembly two full revolutions both
clockwise and counterclockwise. Set up dial indicator
as shown and record end play (Fig. 174) (Fig. 175).
Rotate side gear 90 degrees and record another end
play. Again, rotate side gear 90 degrees and record a
final end play.(5) Using the smallest end play recorded, shim
that side gear to within .02540 mm to .3302 mm
(0.001 to 0.013 inch). The other side gear should be
checked using the same procedure.
CAUTION: Side gear end play must be within 02540
mm to .3302 mm (0.001 to 0.013 inch). Five select
thrust washers are available: 0.027, 0.032, 0.037,
0.042, and 0.047 inch.
SYNCHRONIZER
The 1±2 synchronizer is a dual-cone synchronizer
(Fig. 176). The disassembly and assembly procedures
are the same as the 3±4 synchronizer (Fig. 177)
Fig. 171 Differential Gears
Fig. 170 Remove Pinion Gears, Side Gears, and
Thrust Washers by Rotating Side Gears to Opening
in CaseFig. 172 Install Retaining Pin
NS/GSA±598 MANUAL TRANSAXLE 21 - 43
DISASSEMBLY AND ASSEMBLY (Continued)