torque CHRYSLER VOYAGER 2001 Service Manual

ASSEMBLY
NOTE: The differential is serviced as an assembly.
Service is limited to bearing cups and cones. Any
other failure must be repaired by differential assem-
bly and transfer shaft replacement.
(1) Install shim and bearing cup using Tool 5052
and driver handle C-4171 (Fig. 152). Install bearing
cup into extension housing using Tool 6536 and
driver handle C-4171.
(2) Position bearing cone onto differential (Fig.
153), and install bearing cone using Tool 6536 and
driver handle C-4171 (Fig. 154).(3) Measure side gear end play using dial indicator
C-3339 and Tool C-4996 (Fig. 155) (Fig. 156).Side
gear end play must be between 0.001 and 0.013
in.
(4) Apply a bead of Moparž Silicone Rubber Adhe-
sive Sealant to the adapter plate. Load differential
assembly into position and install adapter plate .
(5) Using Tool L-4435, index adapter plate until
bolt holes align.
(6) Install adapter plate-to-transaxle case bolts
and torque to 28 N´m (250 in. lbs.) torque.
Fig. 152 Bearing Retainer Bearing Cup Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5052
3 - DIFFERENTIAL BEARING RETAINER
Fig. 153 Position Bearing Cone Onto Differential
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL BEARING
Fig. 154 Install Differential Bearing Cone
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 6536
3 - DIFFERENTIAL ASSEMBLY
Fig. 155 Checking Side Gear End Play
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
4 - SIDE GEAR
21 - 94 AUTOMATIC - 31THRS
FINAL DRIVE (Continued)

(7) Apply a bead of Moparž Silicone Rubber Adhe-
sive Sealant to the differential bearing retainer (Fig.
157).(8) Install bearing retainer and index using Tool
L-4435 until bolt holes align (Fig. 158).
(9) Install and torque bearing retainer bolts to 34
N´m (25 ft. lbs.) torque (Fig. 159).
Fig. 156 Checking Side Gear End Play (Typical)
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
Fig. 157 Differential Bearing Retainer (Typical)
1 - DIFFERENTIAL BEARING CUP
2 - DIFFERENTIAL
3 - DIFFERENTIAL BEARING RETAINER
Fig. 158 Index Bearing Retainer using Tool L-4435
1 - GOVERNOR PRESSURE PLUG
2 - DIFFERENTIAL BEARING RETAINER
3 - SPECIAL TOOL L-4435
Fig. 159 Differential Bearing Retainer Bolts
1 - DIFFERENTIAL BEARING RETAINER
2 - DIFFERENTIAL BEARING RETAINER BOLTS (6)
RSAUTOMATIC - 31TH21-95
FINAL DRIVE (Continued)

(10) Install bearing retainer axle seal using Tool
L-4520 (inverted), and driver handle C-4171 (Fig.
160).
(11) Install adapter plate axle seal using Tool
L-4520 (inverted), and driver handle C-4171.
(12) Check differential turning torque. (Refer to 21
- TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/BEARINGS - ADJUSTMENTS)
(13) Apply an 1/8º bead of Moparž Silicone Rubber
Adhesive Sealant to the differential cover (Fig. 161).(14) Install differential cover-to-transaxle case
bolts and torque to 19 N´m (165 in. lbs.) torque (Fig.
162).
(15) Install transfer shaft and related components.
ADJUSTMENT - DIFFERENTIAL BEARING
NOTE: Transfer shaft MUST be removed from trans-
axle to obtain an accurate differential turning torque
measurement.
Differential turning torque should be measured
and adjusted during any transaxle or differential
teardown/assembly, or if any of the following parts
are replaced:
²Transaxle case
²Differential carrier
²Differential bearing retainer
²Extension housing
²Differential bearing cups and cones
(1) Position the transaxle assembly vertically on
the support stand, differential bearing retainer side
up.
(2) Install Tool L-4436A into the differential and
onto the pinion mate shaft (Fig. 163).
(3) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.
(4) Using Tool L-4436A and an inch-pound torque
wrench, check the turning torque of the differential
(Fig. 164).Turning torque should be within 5±18
in. lbs.
Fig. 160 Install Bearing Retainer Axle Seal
1 - SPECIAL TOOL L-4520
2 - SPECIAL TOOL C-4171
Fig. 161 Install Differential Cover
1 - GOVERNOR PRESSURE PLUG
2 - DIFFERENTIAL COVER
3 - 1/8 INCH BEAD OF R T V SEALANT
4 - DIFFERENTIAL ASSEMBLY
Fig. 162 Differential Cover Bolts
1 - DIFFERENTIAL COVER
2 - DIFFERENTIAL COVER BOLT
21 - 96 AUTOMATIC - 31THRS
FINAL DRIVE (Continued)

(5) If the turning torque is within specifications,
remove tools. Setup is complete.
(6) If turning torque is not within specifications
proceed with the following steps to obtain proper
shim selection:
(a) Remove differential bearing retainer from
the transaxle case.
(b) Remove the bearing cup from the differential
bearing retainer using Tool 6062A.
(c) Remove the existing shim from under the
cup.
(d) Measure the existing shim.NOTE: If the turning torque was too high when
measured, install a 0.05 mm (0.002 inch) thinner
shim. If the turning torque is was too low, install a
0.05 mm (0.002 inch) thicker shim. Repeat until 5 to
18 inch-pounds turning torque is obtained. Refer to
the ªDifferential Bearing Shim Chart.º Oil Baffle is
not required when making shim selection.
(e) Install the proper shim under the bearing
cup. Make sure the oil baffle is installed properly
in the bearing retainer, below the bearing shim
and cup.
(f) Install the differential bearing cup, shim, and
oil baffle using Tool 5052 and C-4171. Seal the
retainer to the housing with MOPARž Silicone
Rubber Adhesive Sealant and torque bolts to 28
N´m (250 in. lbs.).
DIFFERENTIAL BEARING SHIM CHART
SHIM THICKNESS
MM INCH
.980 0.0386
1.02 0.0402
1.06 0.0418
1.10 0.0434
1.14 0.0449
1.18 0.0465
1.22 0.0481
1.26 0.0497
1.30 0.0512
1.34 0.0528
1.38 0.0544
1.42 0.0560
1.46 0.0575
1.50 0.0591
1.54 0.0607
1.58 0.0623
1.62 0.0638
1.66 0.0654
1.70 0.0670
2.02 0.0796
2.06 0.0812
(7) Using Tool L-4436A and an inch-pound torque
wrench, recheck differential turning torque.Turning
torque should be within 5±18 in. lbs.
Fig. 163 Tool L-4436 and Torque Wrench
1 - SPECIAL TOOL L-4436±A
2 - TORQUE WRENCH
3 - DIFFERENTIAL BEARING RETAINER
Fig. 164 Checking Differential Bearings Turning
Torque
1 - SPECIAL TOOL L-4436±A
2 - TORQUE WRENCH
RSAUTOMATIC - 31TH21-97
FINAL DRIVE (Continued)

FLUID
STANDARD PROCEDURE - FLUID LEVEL AND
CONDITION CHECK
NOTE: The transmission and differential sump have
a common oil sump with a communicating opening
between the two.
FLUID LEVEL CHECK
The torque converter fills in both the P Park and N
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate.The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground. This will assure complete oil level sta-
bilization between differential and transmis-
sion.The fluid should be at normal operating
temperature (approximately 82 C. or 180 F.). The
fluid level is correct if it is in the HOT region (cross-
hatched area) on the fluid level indicator (Fig. 165).
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, the air bubbles can cause overheat-
ing, fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and servo operation.
Foaming can also result in fluid escaping from the
transaxle dipstick where it may be mistaken for a
leak.Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
If there is any doubt about its condition, drain out a
sample for a double check.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle recondition is needed.
Be sure to examine the fluid on the dipstick closely.
If there is any doubt about its condition, drain out a
sample for a double check.
Moparž ATF+4 (Automatic Transmission Fluid-
Type 9602) when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
the vehicle such as engine oil or antifreeze. The red
color is not permanent and is not an indicator of fluid
condition. As the vehicle is driven, the ATF will begin
to look darker in color and may eventually become
brown. This is normal. A dark brown/black fluid
accompanied with a burnt odor and/or deterioration
in shift quality may indicate fluid deterioration or
transmission component failure.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
STANDARD PROCEDURE - FLUID AND FILTER
CHANGE
NOTE: For the recommended maintenance (fluid/fil-
ter change) intervals for this transaxle, (Refer to
LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
NOTE: Only fluids of the type labeled Moparž
ATF+4 (Automatic Transmission Fluid) Type 9602
should be used. A filter change should be made at
the time of the transmission oil change. The magnet
(on the inside of the oil pan) should also be cleaned
with a clean, dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Place a drain con-
tainer with a large opening, under transaxle oil pan.
Fig. 165 Fluid Level Indicator Markings
1 - TRANSAXLE DIPSTICK
21 - 98 AUTOMATIC - 31THRS

(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Remove oil filter-to-valve body screws (Fig.
166).
(4) Remove oil filter and gasket (Fig. 167).
(5) Install a new filter and gasket (Fig. 167).
(6) Clean the oil pan and magnet. Reinstall pan
using new Moparž Silicone Rubber Adhesive Sealant.
Torque oil pan bolts to 19 N´m (165 in. lbs.).(7) Pour four quarts of Moparž ATF+4 (Automatic
Transmission Fluid-Type 9602) through the dipstick
opening.
(8) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(9) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ªADDº mark on the dip-
stick (Fig. 168).
(10) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/FLUID - STANDARD PROCEDURE)
(11) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
DIPSTICK TUBE FLUID SUCTION METHOD
(ALTERNATIVE)
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (VaculaŸ
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Pour four quarts of Moparž ATF+4 (Automatic
Transmission FluidÐType 9602) through the dipstick
opening.
(7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
Fig. 166 Oil Filter Screws
1 - SCREWDRIVER HANDLE
2 - SPECIAL TOOL L-4553
3 - OIL FILTER SCREWS (2)
4 - OIL FILTER
Fig. 167 Oil Filter and Gasket
1 - OIL FILTER
2 - GASKET
3 - VALVE BODY
Fig. 168 Dipstick Markings
1 - TRANSAXLE DIPSTICK
RSAUTOMATIC - 31TH21-99
FLUID (Continued)

pressure. Generally governor pressure ranges from
0-100 psi from idle to maximum speed, and rises pro-
portionally with the increase in output shaft speed.
Governor pressure and throttle pressure are acting
upon the shift valves to determine when a shift will
occur. Governor pressure is a direct indication of road
speed, and throttle pressure is an indication of
engine load. When both parameters have been met
by the throttle and governor pressures, an upshift or
downshift will occur.
CLEANING
Thoroughly clean all the governor parts in a suit-
able cleaning solution but do not use any type of
caustic cleaning agents.
The governor weight components and the governor
valve, must slide freely in their bores when clean and
dry. Minor surface scratches and burrs can be
smoothed with crocus cloth.
INSPECTION
The aluminum governor valve and outer weight
have a hard coating on them. Check condition of this
coating carefully. Do not reuse either part if the coat-
ing is damaged.
Inspect the governor weight spring for distortion.
Replace the spring, if distorted, collapsed, or broken.
Clean the filter in solvent and dry it with compressedair. Replace the filter, if damaged. Inspect the park
gear for chipped or worn gear teeth or damaged ring
grooves. Replace the gear, if damaged.
Check the teeth on the park gear for wear or dam-
age. Replace the gear if necessary. Inspect the metal
seal rings on the park gear hub. Replace the rings
only if severely worn, or broken.
OIL PUMP
DESCRIPTION
The oil pump is located in the pump housing inside
the bell housing of the transmission case. The oil
pump consists of an inner and outer gear, a housing,
and a cover that also serves as the reaction shaft
support (Fig. 182).
OPERATION
As the torque converter rotates, the converter hub
rotates the inner and outer gears. As the gears
rotate, the clearance between the gear teeth
increases in the crescent area, and creates a suction
at the inlet side of the pump. This suction draws
fluid through the pump inlet from the oil pan. As the
clearance between the gear teeth in the crescent area
decreases, it forces pressurized fluid into the pump
outlet and to the valve body.
Fig. 182 Oil Pump Assembly
1 - REACTION SHAFT SUPPORT
2 - INNER GEAR
3 - PUMP BODY4 - PUMP BUSHING
5 - OUTER GEAR
21 - 104 AUTOMATIC - 31THRS
GOVERNOR (Continued)

STANDARD PROCEDURE - OIL PUMP VOLUME
CHECK
Measuring the oil pump output volume will deter-
mine if sufficient oil flow to the transmission oil
cooler exists, and whether or not an internal trans-
mission failure is present.
Verify that the transmission fluid is at the proper
level. Refer to the Fluid Level Check procedure in
this section. If necessary, fill the transmission to the
proper level with Moparž ATF +4, type 9602, Auto-
matic Transmission Fluid.
(1) Using hose cutters or a suitable blade, cut the
To coolerline off flush with the cooler inlet fitting
and place a collecting container under the open line.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engineat curb idle speed, with the
shift selector in neutral.
(3) If one quart of transmission fluid is collected in
the container in 20 seconds or less, oil pump flow vol-
ume is within acceptable limits. If fluid flow is inter-
mittent, or it takes more than 20 seconds to collect
one quart of fluid, (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 31TH - DIAGNOSIS
AND TESTING) for further diagnosis.
(4) Re-connect theTo coolerline to the transmis-
sion cooler inlet using a service splice kit. Refer to
instructions included with the kit.
(5) Refill the transmission to proper level. (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 31TH/FLUID - STANDARD PROCEDURE)
DISASSEMBLY
(1) Remove reaction shaft support-to-pump body
bolts.
(2) Remove reaction shaft support, and the inner
and outer pump gears (Fig. 183).
CLEANING
Clean pump and support components with solvent
and dry them with compressed air.
INSPECTION
(1) Check condition of the seal rings and thrust
washer on the reaction shaft support. The seal rings
do not need to be replaced unless cracked, broken, or
severely worn.
(2) Visually inspect the pump and support compo-
nents. Replace the pump assembly if the seal ring
grooves or machined surfaces are worn, scored, pit-
ted, or damaged. Replace the pump assembly if the
gears if pitted, worn chipped, or damaged.
(3) Inspect the pump bushing. Then check the
reaction shaft support bushing. Replace the pump
assembly if either bushing is heavily worn, scored or
damaged.
(4) Clearance between outer gear and reaction
shaft housing should be 0.010 to 0.063 mm (0.0004 to
0.0025 in.). Clearance between inner gear and reac-
tion shaft housing should be 0.010 to 0.063 mm
(0.0004 to 0.0025 in.). Both clearances can be mea-
sured at the same time by installing the gears in the
pump body and measure pump component clearances
as follows:
(5) Reinstall gears to pump body and measure
outer gear-to-pocket clearance with a feeler gauge
(Fig. 184).Outer gear-to-pocket clearance should
be within 0.045-0.141 mm (0.0018-0.0056 in.).
(6) Measure both inner and outer gear side clear-
ance with PlastigageŸ. If PlastigageŸ is not avail-
able, measure across the pump body with a straight
edge and feeler gauge.
(a) Position an appropriate piece of PlastigageŸ
across both gears.
(b) Align the plastigage to a flat area on the
reaction shaft housing.
(c) Install the reaction shaft support to the
pump housing and torque to 28 N´m (250 in. lbs.).
(d) Separate the reaction shaft housing from the
pump housing and measure the PlastigageŸ fol-
lowing the instructions supplied with it.Inner
and outer gear side clearance should be
within 0.020-0.046 mm (0.0008-0.0018 in.).
ASSEMBLY
(1) Install inner and outer gears to pump body
(Fig. 183). Lubricate gears with Moparž ATF+4
(Automatic Transmission Fluid-Type 9602).
(2) Install reaction shaft support to pump body
and align holes.
(3) Install and torque reaction shaft support-to-
pump body bolts to 28 N´m (250 in. lbs.).
RSAUTOMATIC - 31TH21 - 105
OIL PUMP (Continued)

(2) Verify gearshift lever is in PARK (P) and con-
nect solenoid connector (Fig. 219).
(3) Install steering column lower shroud.
(4) Install knee bolster (Fig. 220).
(5) Install instrument panel lower silencer (Fig.
221).
(6) Connect battery negative cable.
(7) Verify proper shift interlock system operation.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-MATIC - 31TH/SHIFT INTERLOCK SOLENOID -
OPERATION)
SOLENOID - TCC
DESCRIPTION
The torque converter clutch (TCC) solenoid is fas-
tened to the transaxle valve body, and its connector
protrudes through the transaxle case (Fig. 222).
OPERATION
The torque converter clutch solenoid is responsible
for controlling application of the torque converter
clutch. It is controlled by the Powertrain Control
Module (PCM), which determines when conditions
are acceptable for torque converter lock-up.
Fig. 219 BTSI Solenoid Connector
1 - BTSI SOLENOID
2 - SOLENOID CONNECTOR
Fig. 220 Knee Bolster
1 - KNEE BOLSTER
Fig. 221 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 222 Torque Converter Clutch Solenoid
1 - TCC SOLENOID WIRING CONNECTOR
RSAUTOMATIC - 31TH21 - 117
SHIFT INTERLOCK SOLENOID (Continued)

REMOVAL
(1) Remove valve body from transaxle. (Refer to 21
- TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/VALVE BODY - REMOVAL)
(2) Remove three (3) torque converter clutch sole-
noid-to-valve body screws (Fig. 223).
(3) Remove torque converter clutch solenoid (Fig.
223). Note orientation of plug and spring.
INSTALLATION
(1) Install plug and spring as shown in (Fig. 223).
(2) Install torque converter clutch solenoid to valve
body (Fig. 223) and torque screws to 5 N´m (45 in.
lbs.).
(3) Install valve body to transaxle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/VALVE BODY - INSTALLATION)
THROTTLE VALVE CABLE
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect cable core from throttle lever pin
(Fig. 224).
(3) Disconnect cable retainer from throttle body
bracket (Fig. 224).
(4) Disconnect cable from throttle valve lever at
transaxle (Fig. 225).
(5) Disconnect cable retainer at transaxle bracket
(Fig. 225).
INSTALLATION
(1) Install throttle valve cable to bracket at trans-
axle (Fig. 226). Connect cable to transaxle throttle
valve lever.
(2) Route cable through center of intake manifold
(#2 & #3) runners.
Fig. 223 Torque Converter Clutch Solenoid and Regulator/Control Valves
1 - CONVERTER PRESSURE CONTROL VALVE
2 - END COVER
3 - SCREW (3)4 - REGULATOR VALVE THROTTLE PRESSURE PLUG SPRING
5 - REGULATOR VALVE THROTTLE PRESSURE PLUG
6 - SWITCH VALVE
21 - 118 AUTOMATIC - 31THRS
SOLENOID - TCC (Continued)