CHRYSLER VOYAGER 2001 Service Manual

(14) If equipped, install the power steering cooler
hoses on the cooler inlet and outlet tubes. Install the
clamps.
(15) Install the front tire and wheel assemblies on
vehicle. Install the wheel mounting lug nuts and
tighten to a torque to 135 N´m (100 ft. lbs.).
(16) Lower the vehicle to a level were the interior
of vehicle is accessible (keeping tires off the ground).
(17) Using the intermediate coupler, turn the front
wheels of the vehicle to the left until the intermedi-
ate coupler shaft is properly aligned with the steer-
ing column coupler. Assemble the steering columnshaft coupler onto the steering gear intermediate
coupler (Fig. 1). Install steering column coupler to
intermediate shaft retaining pinch bolt. Tighten the
pinch bolt nut to a torque of 28 N´m (250 in. lbs.).
(18) Perform the POWER STEERING PUMP INI-
TIAL OPERATION procedure to properly fill and
bleed the power steering system. (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE)
(19) Inspect for leaks.
(20) Adjust front wheel toe (Refer to 2 - SUSPEN-
SION/WHEEL ALIGNMENT - STANDARD PROCE-
DURE).
RGGEAR19a-5
GEAR (Continued)

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION............................6
REMOVAL...............................6
INSTALLATION............................6RESERVOIR
DESCRIPTION............................7
REMOVAL...............................7
INSTALLATION............................7
PUMP
DESCRIPTION - PUMP (2.5L DIESEL)
Hydraulic pressure for the operation of the power
steering gear is provided by a belt driven power
steering pump. The power steering pump is mounted
front lower right corner of the engine (Fig. 2).
The pump has a supply fitting for fluid coming
from the reservoir and a pressure port for exiting
fluid that is headed for the steering gear.
REMOVAL - PUMP (2.5L DIESEL)
(1) Remove the negative (-) battery cable from the
battery and isolate cable.
(2) Remove the fill cap from the power steering
fluid reservoir.
(3) Using a siphon pump, remove as much power
steering fluid as possible from the fluid reservoir.
(4) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(5) Remove the splash shields from below the
engine compartment.
(6) Remove the accessory drive belt from the power
steering pump pulley. (Refer to 7 - COOLING/AC-
CESSORY DRIVE/DRIVE BELTS - REMOVAL)
(7) Disconnect the fluid supply hose from the
pump (Fig. 1).
(8) Disconnect the pressure hose from the pump
(Fig. 1).
(9) Remove the bolt fastening the stamped bracket
on the rear of the pump to the cast bracket (Fig. 2).
(10) Remove the three front mounting bolts
through the pulley.
(11) Remove the pump from the cast bracket and
vehicle.
INSTALLATION - PUMP (2.5L DIESEL)
(1) Install the power steering pump on its cast
mounting bracket.
(2) Install the three front power steering pump
mounting bolts. Tighten the mounting bolts to a
torque of 54 N´m (40 ft. lbs.).(3) Install the rear mounting bolt fastening the
stamped bracket to the cast bracket (Fig. 2). Tighten
the mounting bolt to a torque of 54 N´m (40 ft. lbs.).
NOTE: Before installing power steering pressure
hose on power steering pump, inspect the O-ring
on the power steering pressure hose for damage
and replace if required.
(4) Install the power steering fluid pressure hose
fitting into the pressure port of the power steering
pump (Fig. 1). Tighten the pressure line to pump fit-
ting tube nut to a torque of 31 N´m (275 in. lbs.).
(5) Install the power steering fluid supply hose on
the power steering pump supply fitting (Fig. 1).Be
sure hose clamp is properly reinstalled.
(6) Install the accessary drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
Fig. 1 POWER STEERING PUMP - 2.5L DIESEL
1 - PRESSURE HOSE
2 - HOSE CLAMP
3 - SUPPLY HOSE
4 - POWER STEERING PUMP
19a - 6 PUMPRG

(7) Install the splash shields below the engine
compartment.
(8) Lower the vehicle.
(9) Connect the negative (-) battery cable on the
negative battery post.
(10) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
(11) Inspect for leaks.
RESERVOIR
DESCRIPTION - RESERVOIR (2.5L DIESEL)
All vehicles use a remote mounted power steering
fluid reservoir. The power steering fluid reservoir is
mounted to a bracket on the engine manifold (Fig. 3).
REMOVAL - RESERVOIR (2.5L DIESEL)
(1) Open hood.
(2) Remove engine cover.
(3) Remove the filler cap from remote power steer-
ing fluid reservoir.
(4) Siphon as much fluid as possible from the fluid
reservoir.
(5) Remove the clamp attaching the return hose to
the power steering fluid reservoir. Disconnect hose
from reservoir (Fig. 3).
(6) Remove the clamp attaching the supply hose to
the power steering fluid reservoir. Disconnect hose
from reservoir (Fig. 3).(7)
Press the tang on the reservoir mounting bracket
retaining the reservoir to the bracket, then pull upward
on reservoir and remove it from the bracket.
INSTALLATION - RESERVOIR (2.5L DIESEL)
(1) Align the guide on the rear of the reservoir
with the mounting bracket and push reservoir down-
ward until reservoir clicks into place in the bracket.
(2) Install the supply hose onto the reservoir (Fig.
3). Slide the hose clamp into position on the fluid res-
ervoir and attach it.Be sure hose clamp in
installed past bead on fluid reservoir fitting.
(3) Install the return hose onto the reservoir (Fig.
3). Slide the hose clamp into position on the fluid res-
ervoir and attach it.Be sure hose clamp in
installed past bead on fluid reservoir fitting.
(4)
Fill the fluid reservoir to the proper level with
the correct Mopartpower steering fluid or equivalent.
(5) Start the engine and let run for a few seconds,
then turn the engine off.
(6) Add fluid as necessary.
(7) Install the filler cap.
(8) Install engine cover.
Fig. 2 PUMP AND BRACKETS - 2.5L DIESEL
1 - CAST BRACKET
2 - STAMPED BRACKET
3 - POWER STEERING PUMP
Fig. 3 RESERVOIR AND HOSES - 2.5L DIESEL
1 - POWER STEERING FLUID RESERVOIR
2 - RESERVOIR BRACKET
3 - SUPPLY HOSE BRACKET
4 - RETURN HOSE FROM GEAR
5 - ROUTING CLIP
6 - PRESSURE HOSE TO GEAR
7 - SUPPLY HOSE (PUMP END)
8 - PRESSURE HOSE (PUMP END)
9 - SUPPLY HOSE
10 - RETURN HOSE
RGPUMP19a-7
PUMP (Continued)

TRANSMISSION/TRANSAXLE
TABLE OF CONTENTS
page page
POWER TRANSFER UNIT...................1
AUTOMATIC - 31TH.......................21AUTOMATIC - 41TE......................158
POWER TRANSFER UNIT
TABLE OF CONTENTS
page page
POWER TRANSFER UNIT
DESCRIPTION............................1
OPERATION.............................3
DIAGNOSIS AND TESTING..................3
SEAL IDENTIFICATION...................3
FLUID LEAK DIAGNOSIS..................3
STANDARD PROCEDURE...................4
FLUID LEVEL INSPECTION................4
PTU FLUID CHANGE.....................4
REMOVAL...............................5
INSTALLATION............................6
ADJUSTMENTS...........................7
SPECIFICATIONS.........................7
SPECIAL TOOLS..........................8
DIFFERENTIAL CARRIER SEAL
REMOVAL...............................9
INSTALLATION............................9
END COVER BALL BEARING
REMOVAL...............................9
INSTALLATION...........................10
END COVER SEAL
REMOVAL..............................11INSTALLATION...........................11
HALF SHAFT INNER SEAL
REMOVAL..............................12
INSTALLATION...........................12
INPUT SHAFT COVER SEAL
REMOVAL..............................13
INSTALLATION...........................14
INPUT SHAFT END SEAL
REMOVAL..............................16
INSTALLATION...........................16
INPUT SHAFT SEAL
REMOVAL..............................17
INSTALLATION...........................18
OUTER HALF SHAFT SEAL
REMOVAL..............................18
INSTALLATION...........................19
REAR COVER O-RING
REMOVAL..............................20
INSTALLATION...........................20
POWER TRANSFER UNIT
DESCRIPTION
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 Power Transfer Unit is sealed from the trans-
axle and has its own oil sump. The Unit uses
Moparž SAE 80W-90 Gear and Axle Lubricant (MS-
9020) and holds 1.15 liters (1.22 quarts).Service of the Power Transfer Unit is limited to:
²Fluid Change
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.
RSTRANSMISSION/TRANSAXLE21-1

Power Transfer Unit Components
21 - 2 POWER TRANSFER UNITRS
POWER TRANSFER UNIT (Continued)

OPERATION
The Transfer Unit provides the power to the rear
wheels through a hypoid ring gear and pinion set.
DIAGNOSIS AND TESTING - SEAL
IDENTIFICATION
For accurate seal diagnosis, repair seal name and
location is critical. Refer to (Fig. 1), (Fig. 2), (Fig. 3)
and (Fig. 4) for correct seal name and location.
DIAGNOSIS AND TESTING - FLUID LEAK
DIAGNOSIS
When diagnosing fluid leaks on the Power Transfer
Unit two weep holes are provided to diagnose certain
seal leaks. These holes are located on the bottom side
of the assembly (Fig. 5).
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. 5) the
type of fluid leaking will determine which seal needs
to be replaced. If the fluid leaking is red in color
1 - PLUG 18 - CASE-PTU 35 - SHIM
2 - WASHER FLAT 19 - PINION-PTU 36 - TAPERED ROLLER BEARING
3 - SEAL RING 20 - O-RING 37 - SHAFT ASSY. FRONT L.H.
4 - SNAP RING 21 - SHIM 38 - SEAL RING
5 - BALL BEARING 22 - TAPERED ROLLER BEARING 39 - OIL WIPER
6 - SEAL RING 23 - COVER-PTU CASE REAR 40 - RETAINER DIFFERENTIAL BEARING
7 - COVER-PTU
CASE END24 - FLANGE TUBE-PTU-OUTPUT ASSY. 41 - SHAFT DIFFERENTIAL PINION
8 - TAPERED ROLLER BEARING 25 - LOCK NUT-HEX FLANGE 42 - PIN
9 - SEAL RING 26 - O- RING 43 - CASE DIFFERENTIAL
10 - SEAL RING 27 - RETAINER PLATE 44 - TAPERED ROLLER BEARING CONE
11 - HEX HEAD SCREW 28 - O-RING 45 - SEAL RING
12 - SHAFT-PTU INPUT 29 - BRACKET 46 - SEAL RING
13 - GEAR-PTU RING 30 - THRUST WASHER 47 - PLUG
14 - TROUGH-PTU (RT.) 31 - SIDE GEAR-DIFFERENTIAL 48 - O-RING
15 - TROUGH-PTU (LT.) 32 - FINAL DRIVE GEAR 49 - SHIM
16 - TAPERED ROLLER BEARING 33 - PINION DIFFERENTIAL 50 - MAGNET
17 - HEX HEAD SCREW 34 - WASHER DIFFERENTIAL PINION 51 - DOWEL
52 - SHAFT ASSY. FRONT R.H.
53 - HEX HEAD SCREW
Fig. 1 Seal
1 - INPUT SHAFT
2 - P.T.U. CASE
3 - MAGNET
4 - INPUT SHAFT END SEAL
5 - OUTPUT SHAFT
6 - RING GEAR
7 - REAR COVER
Fig. 2 Seal Location
1 - REAR COVER
2 - END COVER
3 - OUTER HALFSHAFT SEAL
4 - P.T.U. CASE
5 - P.T.U. OUTPUT SEAL
RSPOWER TRANSFER UNIT21-3
POWER TRANSFER UNIT (Continued)

(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. 5) 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 innerseal 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.
STANDARD PROCEDURE - FLUID LEVEL
INSPECTION
(1) Raise vehicle on hoist.
(2) Remove PTU inspection plug (Fig. 6).
(3) Fluid level should be within 3/16º from bottom
of inspection hole. Add Moparž Gear and Axle Lubri-
cant 80W-90 as necessary with suitable suction gun
(Fig. 7).
(4) Install inspection plug and torque to 20 N´m
(180 in. lbs.) torque.
(5) Lower vehicle.
STANDARD PROCEDURE - PTU FLUID CHANGE
NOTE: PTU Fluid should be changed upon servic-
ing the unit, or at the unit's regular scheduled inter-
val. (Refer to LUBRICATION & MAINTENANCE/
MAINTENANCE SCHEDULES - DESCRIPTION)
(1) Raise vehicle on hoist.
(2) Remove PTU inspection plug (Fig. 8).
Fig. 3 Seal Location
1 - INPUT SHAFT
2 - OUTPUT SHAFT
3 - REAR COVER
4 - P.T.U. CASE
5 - INPUT SHAFT SEAL
Fig. 4 Seal Location
1 - P.T.U. INPUT SHAFT COVER SEAL
2 - HALF SHAFT INNER SEAL
3 - INSIDE VIEW OF P.T.U. END COVER
Fig. 5 Weep Hole Locations
1 - ENGINE OIL PAN
2 - WEEP HOLE ªAº
3 - TRANSAXLE CASE
4 - P.T.U.
5 - WEEP HOLE ªBº
21 - 4 POWER TRANSFER UNITRS
POWER TRANSFER UNIT (Continued)

(3) Using suitable suction gun, draw fluid from
PTU. Make sure hose contacts bottom of case to
ensure all fluid is removed.
(4) Add 1.15 liters (1.22 quarts) of Moparž Gear
and Axle Lubricant 80W-90 with suction gun (Fig. 9).
(5) Install inspection plug and torque to 20 N´m
(180 in. lbs.) torque.(6) Lower vehicle.
REMOVAL
(1) Raise vehicle and remove front wheels.
CAUTION: A certain amount of oil will drain out of
the transaxle when the drive shaft is removed.
Fig. 6 Inspection Plug
1 - INSPECTION PLUG
Fig. 7 Removing/Adding PTU Fluid
1 - SUCTION GUN
2 - INSPECTION HOLE
Fig. 8 Inspection Plug
1 - INSPECTION PLUG
Fig. 9 Adding Fluid to PTU
1 - SUCTION GUN
2 - INSPECTION HOLE
RSPOWER TRANSFER UNIT21-5
POWER TRANSFER UNIT (Continued)

(2) Remove right front drive shaft. Install a plug
into the right driveshaft seal hole. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/HALF SHAFT -
REMOVAL)
(3) Mark propeller shaft front flange.
CAUTION: Do not let propeller shaft to hang freely.
Damage to the shaft will occur.
(4) Remove propeller shaft assembly (Fig. 10).
(Refer to 3 - DIFFERENTIAL & DRIVELINE/PRO-
PELLER SHAFT - REMOVAL)
(5) Remove cradle plate (Fig. 11).(6) Remove the Power Transfer Unit mounting
bracket bolts at the rear of the unit (Fig. 12).
(7) Remove the right outboard support bracket and
bolts near the right axle shaft.
(8) Remove the four mounting bolts for the P.T.U.
(Fig. 13)and (Fig. 14).
(9) Remove P.T.U. assembly from vehicle.
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.
Fig. 10 Driveshaft Flange
1 - DRIVESHAFT FLANGE
Fig. 11 Cradle Plate
1 - CRADLE PLATE
Fig. 12 Remove Rear P.T.U Bracket Bolts
1 - P.T.U. MOUNT BRACKET
2 - P.T.U.
Fig. 13 P.T.U. Lower Mounting Bolts
1 - P.T.U.
2 - P.T.U. MOUNTING BOLTS
21 - 6 POWER TRANSFER UNITRS
POWER TRANSFER UNIT (Continued)