lock CHRYSLER VOYAGER 1996 Service Manual

NOTE: To ease removal of the valve body, turn the
manual valve fully clockwise.
CAUTION: Do not handle the valve body from the
manual valve. Damage could result.
Fig. 63 Remove Valve Body Attaching Bolts
Fig. 64 Push Park Rod Rollers from Guide Bracket
Fig. 65 Remove Valve Body
Fig. 66 Valve Body Removed
Fig. 67 Remove Accumulators
21 - 96 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 231 Install Strap Bolts
Fig. 232 Turn Stirrup Clockwise Against Flats Of
Output Gear Retaining Bolt
Fig. 233 Tighten Stirrup Strap Bolts To 23 N´m
(200 in. lbs.)
Fig. 234 Bend Tabs On Strap Up Against Flats Of
Bolts
Fig. 235 Install Transfer Shaft Bearing Cone
Fig. 236 Install Bearing Cup To Shaft
21 - 128 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Dependent on engine application, some
accumulators will have two springs and others will
have one spring. The springs are color coded for
application and year.NOTE: To ease installation of the valve body, turn
the manual valve fully clockwise.
Fig. 271 Install Oil Pump
Fig. 272 Install Pump Attaching Bolts
Fig. 273 Install Low/Reverse Accumulator
Fig. 274 Install Low/Reverse Accumulator Plug
(Cover)
Fig. 275 Install Low/Reverse Accumulator Snap
Ring
Fig. 276 Accumulator (Underdrive)
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 137
DISASSEMBLY AND ASSEMBLY (Continued)

(11) Install the oil baffle. Install the proper shim
combination under the bearing cup.
(12) Install the differential bearing retainer. Seal
the retainer to the housing with MopartSilicone
Rubber Adhesive Sealant. Torque bolts to 28 N´m
(250 in. lbs.).
(13) Using Miller Special Tool L-4436-A and an
inch-pound torque wrench, check the turning torque
of the differential (Fig. 299). The turning torque
should be between 5-18 inch-pounds.
NOTE: If turning torque is too high install a .05mm
(.002 inch) thicker shim. If the turning torque is too
low, install a .05mm (.002 inch) thinner shim. Repeat
until 5-18 inch-pounds of turning torque is
obtained.
CLEANING AND INSPECTION
CLEANING VALVE BODY
Prior to removing any transaxle parts, plug all
openings and clean unit, preferably by steam. Clean-
liness through entire disassembly and assembly can-
not be overemphasized. When disassembling, each
part should be washed in a suitable solvent, then
dried by compressed air.Do not wipe parts with
shop towels.All mating surfaces in the transaxles
are accurately machined; therefore, careful handling
of all parts must be exercised to avoid nicks or burrs.
NOTE: Tag all springs, as they are removed, for
reassembly identification.
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT
Lift and rotate the gearshift hand lever into the
park (P) gate position and remove the ignition key.This confirms the shift lever is in the gated park (P)
position.
After confirming the park gate position, turn the
ignition switch. If the starter will operate, the park
gate position is correct. Move the shift lever into the
neutral (N) position. If the starter will operate in this
position, the linkage is properly adjusted. If the
starter fails to operate in either position, linkage
adjustment is required.
(1) Park the vehicle on level ground and set the
parking brake.
(2) Place the gearshift lever in park (P) gate posi-
tion and remove key.
(3) Loosen the cable adjustment screw at the tran-
saxle operating lever (Fig. 300).
(4) Pull the transaxle operating lever fully forward
to the park detent position.
(5) Release the park brake, then rock the vehicle
to assure it is in park lock. Reset the park brake.
(6) Tighten the cable adjustment screw to 8 N´m
(70 in. lbs.). Gearshift cable should now be properly
adjusted.
(7) Check adjustment by using the preceding pro-
cedure.
Fig. 300 Gearshift Cable Adjustment
21 - 144 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (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)

(22) Remove input shaft bearing snap ring (Fig.
91) (Fig. 92).
(23) Remove interlock plate (Fig. 93) and shuttles
(Fig. 94).NOTE: The shift rails are positioned as shown (Fig.
95).
Fig. 87 Bearing Retainer Plate Bolts
Fig. 88 Bearing Retainer Plate
Fig. 89 Retainer Plate Removed
Fig. 90 Bearing Preload Shim
Fig. 91 Input Shaft Bearing Snap Ring
Fig. 92 Snap Ring Removed
NS/GSA±598 MANUAL TRANSAXLE 21 - 25
DISASSEMBLY AND ASSEMBLY (Continued)

(24) Remove bearing support plate (Fig. 96) (Fig.
97).
(25) Remove reverse idler gear (Fig. 98) (Fig. 99).
(26) Remove 5th gear shift rail C-clip (Fig. 100).CAUTION: The 5th gear shift rail has a small inter-
lock pin that is contained within the shift lug and
rail. Use caution when removing shift rail.
Fig. 93 Interlock Plate
Fig. 94 Shuttles
Fig. 95 Shift Rail Identification
Fig. 96 Bearing Support Plate
Fig. 97 Support Plate Removed
Fig. 98 Reverse Idler Gear
21 - 26 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

(27) Carefully remove 5th gear shift rail (Fig. 101)
(Fig. 102) (Fig. 103).
(28) Remove reverse shift rail (Fig. 104) (Fig. 105).(29) Move the 1±2 and 3±4 shift rail lugs out of
the way (Fig. 106).
(30) Remove geartrain set (Fig. 107).
Fig. 99 Reverse Idler Removed
Fig. 100 Shift Rail C-clip
Fig. 101 5th Gear Shift Rail
Fig. 102 5th Gear Shift Rail Removed
Fig. 103 5th Gear Shift Rail, Interlock, and Pin
Fig. 104 Reverse Shift Rail
NS/GSA±598 MANUAL TRANSAXLE 21 - 27
DISASSEMBLY AND ASSEMBLY (Continued)

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)