CHRYSLER VOYAGER 2001 Service Manual

(4) Remove stirrup (Fig. 241).
(5) Using Tool L-4434, remove output shaft retain-
ing nut and washer (Fig. 242).(6) Using Tool L-4407 as shown in (Fig. 243),
remove output shaft gear and select shim (Fig. 244).
Fig. 241 Remove Stirrup From Gear
1 - OUTPUT GEAR
2 - STIRRUP
Fig. 242 Remove Output Shaft Retaining Nut and
Washer
1 - SPECIAL TOOL L-4434
2 - OUTPUT SHAFT GEAR
Fig. 243 Remove Output Shaft Gear
1 - OUTPUT GEAR
2 - TOOL L-4407A
Fig. 244 Output Shaft Gear and (Select) Shim
1 - BEARING CUP
2 - SHIM (SELECT)
3 - BEARING CONE
4 - OUTPUT SHAFT GEAR
5 - OUTPUT SHAFT
RSAUTOMATIC - 31TH21 - 127
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)

(7) Remove output shaft/rear annulus gear assem-
bly (Fig. 245).
(8) Remove output shaft gear bearing cone using
Tool L-4406-1 and adapters L-4406-2 (Fig. 246).(9) Using an arbor press, remove output shaft from
rear annulus gear (Fig. 247).
(10) Using Tool L-4406-1 and adapters L-4406-2,
remove rear planetary annulus gear bearing cone
(Fig. 248).
Fig. 245 Remove Output Shaft and Rear Annulus
Gear Assembly
1 - BEARING CUP
2 - REAR ANNULUS GEAR
3 - OUTPUT SHAFT
Fig. 246 Remove Output Shaft Gear Bearing Cone
1 - SPECIAL TOOL L-4406-1 WITH ADAPTERS L-4406-2
2 - OUTPUT SHAFT GEAR
Fig. 247 Remove Output Shaft
1 - ARBOR PRESS RAM
2 - CAUTION: SUPPORT ANNULUS GEAR UNDERNEATH, NEAR
GEAR CENTER.
3 - BEARING CONE
4 - REAR ANNULUS GEAR
5 - OUTPUT SHAFT
Fig. 248 Remove Rear Planetary Annulus Gear
Bearing Cone
1 - SPECIAL TOOL L-4406-1 WITH ADAPTERS L-4406-2
2 - REAR PLANETARY ANNULUS GEAR
21 - 128 AUTOMATIC - 31THRS
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)

(11) Using Tool L-4518, remove output shaft gear
bearing cup from rear of transaxle case (Fig. 249).
(12) Using Tool L-4518, remove output shaft gear
bearing cup from inside transaxle case (Fig. 250).
INSTALLATION
(1) Install output shaft bearing cone using Tool
L-4408, C-4171, and a suitable press (Fig. 251).
(2) Install rear planetary annulus gear bearing
cone using tool C-4637 and cup from Tool L-4518
(Fig. 252).
Fig. 249 Remove Output Shaft Gear Bearing Cup
1 - OUTPUT SHAFT GEAR BEARING CUP
2 - SPECIAL TOOL L-4518
Fig. 250 Remove Rear Planetary Annulus Gear
Bearing Cup
1 - REAR PLANETARY ANNULUS GEAR BEARING CUP
2 - SPECIAL TOOL L-4518
Fig. 251 Install Output Shaft Gear Bearing Cone
1 - PRESS
2 - HANDLE C-4171
3 - SPECIAL TOOL L-4408
4 - OUTPUT SHAFT GEAR
5 - BEARING CONE
Fig. 252 Install Rear Planetary Annulus Gear
Bearing Cone
1 - ARBOR PRESS RAM
2 - SPECIAL TOOL C-4637
3 - REAR PLANETARY ANNULUS GEAR
4 - CUP FROM TOOL L-4518
5 - BEARING CONE
RSAUTOMATIC - 31TH21 - 129
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)

(3) Using a press and a º socket to protect the
shaft, install output shaft into rear planetary annu-
lus gear (Fig. 253).
(4) Using Tool L-4429-3, install both output shaft
bearing cups to transaxle case (Fig. 254) (Fig. 255).
(5) Determine output shaft bearing shim thick-
ness. Shim thickness need be determined only if any
of the following parts are replaced:
²Transaxle case
²Output shaft²Rear planetary annulus gear
²Output shaft gear
²Rear annulus and output shaft gear bearing
cones
²Overrunning clutch race cups
To determine proper shim thickness, Refer to Output
Shaft Bearing Adjustment.Check output shaft
bearing turning torque, using an inch-pound
torque wrench. If turning torque is 3-8 in. lbs.,
the proper shim has been installed.
(6) Install output shaft assembly with appropriate
shim (Fig. 256) (Fig. 257).
Fig. 253 Install Output Shaft into Rear Planetary
Annulus Gear
1 - PRESS
2 - 1/2 INCH SOCKET
3 - OUTPUT SHAFT
4 - REAR ANNULUS GEAR
5 - SPACER
Fig. 254 Install Output Shaft Gear Bearing Cup
1 - OUTPUT SHAFT GEAR BEARING CUP
2 - SPECIAL TOOL L-4429-3
Fig. 255 Install Rear Planetary Annulus Gear
Bearing Cup
1 - SPECIAL TOOL L-4429-3
Fig. 256 Install Output Shaft Assembly
1 - OUTPUT SHAFT ASSEMBLY
2 - USE GREASE TO HOLD SHIMS IN POSITION
3 - BEARING CONE
4 - LUBRICATION HOLE
5 - SELECT SHIMS
21 - 130 AUTOMATIC - 31THRS
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)

(7) Install output shaft gear onto shaft. Use Tool
L-4439 to get gear started (Fig. 258).
(8) Install Tool L-4434 and C-4658. Install washer
and nut (Fig. 259).
(9) Torque output shaft retaining nut to 271 N´m
(200 ft. lbs.) (Fig. 260).
(10) Set up Tool L-4432 and C-4658 as shown in
(Fig. 261). Install dial indicator and measure output
shaft end play.
(11) Using an in. lb. torque wrench, measure out-
put shaft bearing turning torque (Fig. 262).
(12) Install stirrup and strap. Install bolts but do
not tighten.
NOTE: Once the stirrup assembly is positioned
onto the output gear, it is necessary to ªclockº the
stirrup against the flats of the output gear retaining
nut.(13) Rotate stirrup clockwise against flats of gear
retaining nut (Fig. 263).
(14) Torque stirrup and strap bolts to 23 N´m (200
in. lbs..) (Fig. 264).
(15) Bend tabs of strap up against ªflatsºof retain-
ing bolts to prevent bolts from backing out of gear in
the event they come loose.
(16) Install transfer shaft and gear. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/TRANSFER SYSTEM - INSTALLATION)
(17) Assemble transaxle geartrain. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC - 31TH
- ASSEMBLY)
Fig. 257 Output Shaft and (Select) Shims in Position
1 - BEARING CUP
2 - (SELECT) SHIM
3 - OUTPUT SHAFT ASSEMBLY
Fig. 258 Start Output Shaft Gear onto Output Shaft
1 - OUTPUT SHAFT GEAR
2 - OUTPUT SHAFT
3 - SPECIAL TOOL L-4439
Fig. 259 Holding Output Shaft Gear
1 - OUTPUT SHAFT
2 - SCREW (2)
3 - SPECIAL TOOL L-4434 AND C-4658
4 - WASHER
5 - NUT
Fig. 260 Tighten Output Shaft Retaining Nut
1 - OUTPUT SHAFT GEAR
2 - SPECIAL TOOL L-4434 AND C-4658
3 - SCREW (2)
RSAUTOMATIC - 31TH21 - 131
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)

ADJUSTMENT - OUTPUT SHAFT BEARING
(1) With output shaft gear removed, install a 13.65
mm (0.537 inch) and a 1.34 mm (0.053 inch) gauging
shims on the planetary rear annulus gear hub using
grease to hold the shims in place. The 13.65 mm
shim has a larger inside diameter and must be
installed over the output shaft first. The 1.34 mm
shim pilots on the output shaft.
(2) Install output shaft gear and bearing assembly,
torque to 271 N´m (200 ft. lbs.).
(3) To measure bearing end play:
(4) Attach Tool L-4432 to the output shaft gear.(5) Mount a steel ball with grease into the end of
the output shaft.
(6) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
(7) Using a dial indicator, mounted to the trans-
axle case, measure output shaft end play.
(8) Once bearing end play has been determined,
refer to the output shaft bearing shim chart.
(9) The 12.65 mm (0.498 inch), 13.15 mm (0.518
inch) or 13.65 mm (0.537 inch) shims are always
installed first.These shims have lubrication slots
which are necessary for proper bearing lubrica-
tion.
Fig. 261 Checking Output Shaft End Play
1 - SPECIAL TOOL L-4432 AND C-4658
2 - SCREW (2)
3 - OUTPUT SHAFT GEAR
4 - STEEL BALL (GREASE IN PLACE)
5 - SPECIAL TOOL L-4438
6 - DIAL INDICATOR
Fig. 262 Checking Bearing Turning Torque
1 - OUTPUT SHAFT GEAR
2 - TORQUE WRENCH
Fig. 263 Turn Stirrup Clockwise Against Flats of
Retaining Nut
1 - TURN STIRRUP CLOCKWISE
2 - STRAP
Fig. 264 Tighten Strap Retaining Nuts
1 - STRAP
2 - OUTPUT GEAR
3 - STIRRUP
21 - 132 AUTOMATIC - 31THRS
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)

(10) Shims thinner than 12.65 mm listed in the
chart are common to both the transfer shaft and out-
put shaft bearings.
(11) Use Tool L-4434 to remove the retaining nut
and washer. To remove the output shaft gear use Tool
L-4407.
(12) Remove the two gauging shims and install the
proper shim combination, making sure to install the
12.65, 13.15, or 13.65 mm shim first. Use grease to
hold the shims in place. Install the output shaft gear
and bearing assembly.(13) Install the retaining nut and washer and
torque to 271 N´m (200 ft. lbs.).
(14) Using an inch-pound torque wrench, check the
turning torque.The torque should be between 3
and 8 inch-pounds.
(15) If the turning torque is too high, install a
0.05mm (0.002 inch) thicker shim. If the turning
torque is too low, install a 0.05 mm (0.002 inch) thin-
ner shim. Repeat until the proper turning torque is 3
to 8 inch pounds.
OUTPUT SHAFT BEARING SHIM CHART
End Play (with 13.65 mm and
1.34 mm gauging shims
installed)Required Shim Combination Total Thickness
mm inch mm mm inch
.0 .0 13.65 + 1.34 14.99 .590
.05 .002 13.65 + 1.24 14.89 .586
.10 .004 13.65 + 1.19 14.84 .584
.15 .006 13.65 + 1.14 14.79 .582
.20 .008 13.65 + 1.09 14.74 .580
.25 .010 13.65 + 1.04 14.69 .578
.30 .012 13.65 + .99 14.64 .576
.35 .014 13.65 + .94 14.59 .574
.40 .016 13.15 + 1.39 14.54 .572
.45 .018 13.15 + 1.34 14.49 .570
.50 .020 13.15 + 1.29 14.44 .568
.55 .022 13.15 + 1.24 14.39 .566
.60 .024 13.15 + 1.19 14.34 .564
.65 .026 13.15 + 1.14 14.29 .562
.70 .028 13.15 + 1.09 14.24 .560
.75 .030 13.15 + 1.04 14.19 .558
.80 .032 13.15 + .99 14.14 .556
.85 .034 13.15 + .94 14.09 .554
.90 .036 12.65 + 1.39 14.04 .552
.95 .038 12.65 + 1.34 13.99 .550
1.00 .040 12.65 + 1.29 13.94 .548
1.05 .042 12.65 + 1.24 13.89 .547
1.10 .044 12.65 + 1.19 13.84 .545
1.15 .046 12.65 + 1.14 13.79 .543
1.20 .048 12.65 + 1.09 13.74 .541
1.25 .049 12.65 + 1.04 13.69 .539
1.30 .051 12.65 + .99 13.64 .537
1.35 .053 12.65 + .94 13.59 .535
RSAUTOMATIC - 31TH21 - 133
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)

TRANSFER SYSTEM -
TRANSFER SHAFT/GEAR/
BEARING
REMOVAL
(1) Remove transfer gear cover bolts (Fig. 265).
(2) Separate transfer gear cover from transaxle
(Fig. 266). Repair any cover imperfections. Clean
cover and case of old adhesive sealant.(3) Using a suitable punch, bend retaining strap
tabs to facilitate bolt removal.
(4) Remove stirrup and retaining strap-to-transfer
gear bolts.
(5) Remove stirrup and retaining strap.
(6) Using Tool L-4434 (Fig. 267), remove transfer
shaft gear retaining nut and washer (Fig. 268).
Fig. 265 Rear Cover Bolts
1 - REAR COVER
2 - REAR COVER BOLTS (10)
Fig. 266 Remove Rear Cover
1 - OUTPUT SHAFT GEAR
2 - USE MOPAR SILICONE RUBBER ADHESIVE SEALER
3 - REAR COVER
4 - TRANSFER SHAFT GEAR
Fig. 267 Remove Transfer Shaft Gear Retaining Nut
1 - TRANSFER SHAFT GEAR
2 - SCREW (2)
3 - OUTPUT SHAFT GEAR
4 - SPECIAL TOOL L-4434
Fig. 268 Transfer Shaft Gear Nut and Washer
1 - OUTPUT SHAFT GEAR
2 - TRANSFER SHAFT GEAR
3 - WASHER
4 - NUT
21 - 134 AUTOMATIC - 31THRS

(7) Using Tool L-4407A, remove transfer shaft gear
and select shim (Fig. 269).
(8) Using Tool L-4406-1 and adapter L-4406-3,
remove transfer shaft gear bearing cone (Fig. 270).(9) Remove governor support retainer (Fig. 271).
(10) Remove governor support retainer bearing cup
(Fig. 272).
Fig. 269 Remove Transfer Shaft Gear using L-4407A
1 - TRANSFER GEAR
2 - TOOL L-4407A
Fig. 270 Using Tool L-4406-1 with Adapter L-4406-3,
Remove Transfer Shaft Gear Bearing Cone
1 - SPECIAL TOOL L-4406-1
2 - TRANSFER SHAFT GEAR
Fig. 271 Governor Support Retainer
1 - TRANSFER SHAFT
2 - OUTPUT SHAFT GEAR
3 - BEARING CUP
4 - GOVERNOR SUPPORT RETAINER
Fig. 272 Remove Governor Support Retainer
Bearing Cup
1 - PRESS
2 - HANDLE C-4171 (WITH SPECIAL TOOL L-4517)
3 - GOVERNOR SUPPORT RETAINER
RSAUTOMATIC - 31TH21 - 135
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)

(11) If necessary, remove low/reverse band anchor
pin (Fig. 273).
(12) Remove governor assembly (Fig. 274).(13) Remove transfer shaft bearing retainer snap
ring (Fig. 275).
(14) Set up tools as shown in (Fig. 276).
Fig. 273 Low/Reverse Band Anchor Pin
1 - LOW-REVERSE BAND ANCHOR PIN
2 - OUTPUT SHAFT GEAR
Fig. 274 Governor Assembly
1 - TRANSFER SHAFT
2 - OUTPUT SHAFT GEAR
3 - GOVERNOR ASSEMBLY
Fig. 275 Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS
2 - SNAP RING
3 - OUTPUT SHAFT GEAR
4 - TRANSFER SHAFT
Fig. 276 Remove Transfer Shaft and Bearing
Retainer Assembly
1 - SPECIAL TOOL L-4512
2 - SPECIAL TOOL L-4437
3 - SPECIAL TOOL C-3752
21 - 136 AUTOMATIC - 31THRS
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)