boot CHRYSLER VOYAGER 1996 Workshop Manual

(8) Remove selector shaft inner C-clip (Fig. 186).
(9) Remove selector shaft outer C-clip (Fig. 187).
Fig. 180 Dust Boot
Fig. 181 Oil Seal
Fig. 182 Vent Cap
Fig. 183 Crossover Lever and Roll Pin
Fig. 184 5th/Reverse Blocker
Fig. 185 Crossover Shaft
21 - 46 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: The C-Clip grooves in the selector shaft will
damage the oil seal. Install oil seal after selector
shaft is installed. Always use a new oil seal when
selector shaft is removed.
(9) Install selector shaft oil seal (Fig. 192).
(10) Install selector shaft dust boot.
(11) Install selector shaft selector lever.
NOTE: Roll pin must be flush with top of lever.
TRANSAXLE CASE
INTERMEDIATE SHAFT FRONT BEARING CUP
REMOVAL
(1) Insert Special Tool 6787 into the intermediate
shaft front bearing cup (Fig. 193).
(2) Tighten the special tool so that the tool fingers
spread out and seat underneath the bearing cup.(3) Install Special Tool 3752 (Slide Hammer) onto
the Special Tool 6787.
(4) Remove the intermediate shaft front bearing
cup (Fig. 194).
(5) Remove the bearing oil feeder (if necessary).
INSTALLATION
(1) Insert the bearing oil feeder (if necessary) into
the transaxle case (Fig. 195).
Fig. 191 5±R Blocker Bolts
Fig. 192 Selector Shaft Oil Seal
Fig. 193 Special Tool 6787 Installed in Bearing Cup
Fig. 194 Remove Intermediate Shaft Front Bearing
Cup
21 - 48 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

be screwed into the housing. This operation locks the
selector shaft in the 3-4 neutral position.
(5) Remove gearshift knob (Fig. 213).
(6) Remove gearshift boot (Fig. 214).
(7) Remove gearshift console screws and remove
the console (Fig. 215).
(8) Loosen crossover cable adjustment screw.
(9) Verify gearshift mechanism is in the neutral
position.CAUTION: Be sure crossover bellcrank does NOT
move when tightening adjusting screw.
Fig. 210 Gearshift Mechanism
Fig. 211 Auxiliary Vent Removal
Fig. 212 Lock Pin Installation
NS/GSA±598 MANUAL TRANSAXLE 21 - 53
ADJUSTMENTS (Continued)

(10) Tighten crossover cable adjuster to 8 N´m (70
in. lbs.) (Fig. 216).CAUTION: Proper torque to the crossover cable
adjusting screw is very important.
(11) Remove lock pin from gearshift housing. Rein-
stall auxiliary vent in gear shift housing (Fig. 217).
Tighten auxiliary vent to 8 N´m (70 in. lbs.).
(12) Check for shift into first and reverse.
(13) Gearshift mechanism and cables are now
functioning properly.
(14) Install gearshift console.
(15) Install gearshift boot.
(16) Install gearshift knob.
(17) Stow gearshift lock pin in glove packet.
Fig. 213 Gearshift Knob
Fig. 214 Gearshift Boot
Fig. 215 Gearshift Console
Fig. 216 Crossover Cable Adjustment
Fig. 217 Auxiliary Vent Installation
21 - 54 A±598 MANUAL TRANSAXLENS/GS
ADJUSTMENTS (Continued)

GEARSHIFT CROSSOVER CABLE
Before replacing the gearshift cables for a hard-
shifting complaint, disconnect both cables at the
transaxle. Then, from the driver's seat, manually
operate the gearshift lever through all gear ranges. If
the gearshift lever moves smoothly, the cable(s)
should NOT be replaced. If the gear lever binds
replace the cable that is causing the binding condi-
tion. If the problem still exists, check the crossover
cable adjustment (Fig. 218).
(1) Working over the left front fender, remove the
auxiliary vent from the selector shaft housing (Fig.
219).
(2) Locate the gearshift lock pin that has been
included in the new vehicle packet located in the
glove box.
(3) Place transaxle gearshift in the neutral posi-
tion.
(4) Insert lock pin (so long end is down) into same
threaded hole (Fig. 220). A hole in the selector shaft
will align with the lock pin, allowing the lock pin to
be screwed into the housing. This operation locks the
selector shaft in the 3-4 neutral position.
(5) Remove gearshift knob (Fig. 221).
(6) Remove gearshift boot (Fig. 222).
(7) Remove gearshift console screws and remove
the console (Fig. 223).(8) Loosen crossover cable adjustment screw.
(9) Verify gearshift mechanism is in the neutral
position.
CAUTION: Be sure crossover bellcrank does NOT
move when tightening adjusting screw.
Fig. 218 Gearshift Mechanism
Fig. 219 Auxiliary Vent Removal
NS/GSA±598 MANUAL TRANSAXLE 21 - 55
ADJUSTMENTS (Continued)

(10) Tighten crossover cable adjuster to 8 N´m (70
in. lbs.) (Fig. 224).
CAUTION: Proper torque to the crossover cable
adjusting screw is very important.
(11) Remove lock pin from gearshift housing. Rein-
stall auxiliary vent in gear shift housing (Fig. 225).
Tighten auxiliary vent to 8 N´m (70 in. lbs.).
(12) Check for shift into first and reverse.
(13) Gearshift mechanism and cables are now
functioning properly.
(14) Install gearshift console.
(15) Install gearshift boot.
(16) Install gearshift knob.(17) Stow gearshift lock pin in glove packet.
BEARING ADJUSTMENT PROCEDURE
The A-598 (T-750) transaxle has two bearing
adjustment procedures that must be performed if the
transaxle case or related components have been
replaced. If the intermediate shaft, and/or bearing
cups and cones have been replaced, you must per-
form the intermediate shaft preload shim adjust-
ment. If the differential case, cups or cones have
Fig. 220 Lock Pin Installation
Fig. 221 Gearshift Knob
Fig. 222 Gearshift Boot
Fig. 223 Gearshift Console
21 - 56 A±598 MANUAL TRANSAXLENS/GS
ADJUSTMENTS (Continued)

BODY COMPONENT SERVICE
INDEX
page page
REMOVAL AND INSTALLATION
GEARSHIFT CONSOLE.................... 3LIFTGATE CHMSL ACCESS PANEL........... 3
REMOVAL AND INSTALLATION
GEARSHIFT CONSOLE
REMOVAL
(1) Lift the parking brake lever to the full up posi-
tion (Fig. 1).
(2) Carefully pull the base of the gearshift boot off
the top of the gearshift console.
(3) Remove the four (4) screws from the top of the
gearshift console (Fig. 2).
(4) Tilt the gearshift boot and carefully push the
boot through the opening in the gearshift console.
(5) Separate console from vehicle.
INSTALLATION
(1) Tilt the gearshift boot and carefully push the
boot through the gearshift console.
(2) Install screws to hold gearshift console to gear-
shift mechanism.
(3) Install gearshift boot and carefully push the
clips into the three (3) slots in the gearshift console.
LIFTGATE CHMSL ACCESS PANEL
REMOVAL
(1) Using a trim stick (C-4755), disengage clip
holding CHMSL access panel to liftgate trim panel
(Fig. 3).
(2) Disengage hooks on CHMSL access cover from
liftgate trim panel.
(3) Separate access panel from vehicle.
Fig. 1 Console, Parking Brake Lever, and Gearshift
Boot
Fig. 2 Gearshift Console and Boot Removal
NS/GSBODY 23 - 3

(10) Disconnect the two upper mounts from the
upper reinforcement and the lower mount from the
tunnel.
(11) Remove the (3) nuts (in the engine compart-
ment) securing the unit to the dash panel (Fig. 46).
(12) Disconnect the HVAC housing wiring harness.
(13) Pull the entire unit rearward until the studs
on the unit clear the dash panel. Drop the unit down.
Pull it rearward to remove it from vehicle.
INSTALLATION
(1) For installation of the assembly, reverse the
above procedures. Install new O-rings on plumbing
inlets
(2) Evacuate and recharge the A/C system.
(3) Perform HVAC control Calibration Diagnostic
and Cooldown test.
HEATER CORE
REMOVAL
(1) Drain coolant system.
(2) Remove left side lower column cover.
(3) Remove steering column assembly. Refer to
Group 19, Steering for service procedure.
(4) Remove ABS module, bracket and wiring (Fig.
47).
(5) Remove I/P to body harness interconnect and
bracket (Fig. 48).
(6) Remove lower silencer boot at base of steering
shaft (Fig. 49)
(7) Pinch off heater lines under the hood.
(8) Remove heater core cover. Insert a small
amount of towels under the heater core tubes.
Remove heater core plate and tubes (Fig. 50).
(9) Depress heater core retaining clips (Fig. 51).
(10) Pull up on accelerator pedal and slide heater
core past (Fig. 52).(11) Depress brake pedal (Fig. 53) and remove
heater core from HVAC housing.
Fig. 46 HVAC Bolt-Up
Fig. 47 ABS MODULE
Fig. 48 Interconnect And Bracket
Fig. 49 Lower Silencer Boot
24 - 30 HEATING AND AIR CONDITIONINGNS
REMOVAL AND INSTALLATION (Continued)

(2) Hand-start the stud into the expansion valve
and torque to7-11N´m(64-96in.lbs.).
(3) Carefully install the expansion valve to the
sealing plate. Install the two screws and tighten 8 to
14 N´m (70 to 130 in. lbs.) torque.
(4) Carefully install the refrigerant lines and seal-
ing plate to the expansion valve. Install the nut and
tighten 20 to 26 N´m (170 to 230 in. lbs.) torque.
(5) Install the ground wire at dash panel.
(6) Pull generator back into the proper position for
bracket mounting.
(7) Install generator field wire connector.
(8) Install the upper generator bracket.
(9) Install accessory drive belt.
(10) Evacuate and recharge system.
(11) After expansion valve is installed, the system
is charged, and leaks have checked repeat the A/C
performance check.
FILTER-DRIER ASSEMBLY
REMOVAL
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
(1) Recover A/C system refrigerant.
(2) Remove liquid line at filter-drier (Fig. 21).
(3) Remove the (2) bolts holding filter-drier bracket
to radiator fan module bracket.
(4) Remove the lower liquid line at condenser.
(5) Remove the upper radiator crossmember.
(6) Pull up on radiator and slide filter-drier from
the mounting location.
INSTALLATION
(1) Before installation, replace both refrigerant
line O-rings. Then reverse the above procedures.
(2) Evacuate and recharge system.
HEATER A/C UNIT HOUSING
REMOVAL
WARNING: IF EQUIPPED WITH AIR CONDITIONING,
THE REFRIGERATION SYSTEM MUST BE COM-
PLETELY EMPTY BEFORE PROCEEDING.
(1) Set parking brake.
(2) Disconnect battery negative cable.
(3) Using a refrigerant recovery machine, remove
refrigerant from the A/C system.
(4) Remove wiper module. Refer to Group 8K,
Windshield Wipers and Washers.
(5) Drain engine coolant. Remove heater hoses at
the heater core, refer to Heater Hoses Removal and
Installation procedures. Plug coolant lines.(6) Remove suction and liquid lines at the expan-
sion valve (Fig. 27).
(7) Remove the Instrument Panel Assembly. Refer
to Group 8E, Instrument Panel and Systems.
(8) Remove heater ducts.
(9) Disconnect the two upper mounts from the
upper reinforcement and the lower mount from the
tunnel.
(10) Remove the (3) nuts (in the engine compart-
ment) securing the unit to the dash panel (Fig. 30).
(11) Disconnect the HVAC housing wiring harness.
(12) Pull the entire unit rearward until the studs
on the unit clear the dash panel. Drop the unit down.
Pull it rearward to remove it from vehicle.
INSTALLATION
(1) For installation of the assembly, reverse the
above procedures. Install new O-rings on plumbing
inlets
(2) Evacuate and recharge the A/C system.
(3) Perform HVAC control Calibration Diagnostic
and Cooldown test.
HEATER CORE
REMOVAL
(1) Drain coolant system.
(2) Remove left side lower column cover.
(3) Remove steering column assembly. Refer to
Group 19, Steering for service procedure.
(4) Remove ABS module, bracket and wiring (Fig.
31).
(5) Remove I/P to body harness interconnect and
bracket (Fig. 32).
(6) Remove lower silencer boot at base of steering
shaft (Fig. 33)
(7) Pinch off heater lines under the hood.
Fig. 30 HVAC Bolt-Up
24 - 26 HEATING AND AIR CONDITIONINGNS/GS
REMOVAL AND INSTALLATION (Continued)

(8) Remove heater core cover. Insert a small
amount of towels under the heater core tubes.
Remove heater core plate and tubes (Fig. 34).
(9) Depress heater core retaining clips (Fig. 35).(10) Pull up on accelerator pedal and slide heater
core past (Fig. 36).
(11) Depress brake pedal (Fig. 37) and remove
heater core from HVAC housing.
Fig. 31 ABS MODULE
Fig. 32 Interconnect And Bracket
Fig. 33 Lower Silencer Boot
Fig. 34 Heater Core Plate And Tubes
Fig. 35 Depress Clips
Fig. 36 Accelerator Pedal
NS/GSHEATING AND AIR CONDITIONING 24 - 27
REMOVAL AND INSTALLATION (Continued)