CHRYSLER VOYAGER 2001 Service Manual

(15) Remove transfer shaft/bearing retainer assem-
bly (Fig. 277).
(16) Separate bearing retainer from transfer shaft
(Fig. 278).
(17) Remove transfer shaft bearing cone from shaft
using Tool C-293-PA and adapters C-293-52 (Fig.
279).
(18) Remove transfer shaft bearing cup from bear-
ing retainer (Fig. 280).
INSTALLATION
(1) Install transfer shaft bearing cup to bearing
retainer using Tool L-4520 (Fig. 281).
(2) Install transfer shaft bearing cone to transfer
shaft using Tool L-4111 (Fig. 282).
(3) Assemble transfer shaft to bearing retainer
(Fig. 283).
Fig. 279 Remove Transfer Shaft Bearing Cone
1 - TOOL C-293-52
2 - TRANSFER SHAFT
3 - TOOL C-293-PA
4 - VISE
Fig. 280 Remove Transfer Shaft Bearing Cup
1 - SPECIAL TOOL L-4518
2 - TRANSFER SHAFT BEARING RETAINER
3-88O'' RING
4 - BEARING CUP
Fig. 277 Remove or Install Transfer Shaft and
Bearing Retainer Assembly Using Tool L-4512
1 - OUTPUT SHAFT GEAR
2 - O-RING
3 - SPECIAL TOOL L-4512
4 - BEARING RETAINER ASSEMBLY
5 - TRANSFER SHAFT
Fig. 278 Transfer Shaft and Bearing Retainer
1 - O-RING
2 - TRANSFER SHAFT
3 - BEARING CONE
4 - TRANSFER SHAFT BEARING RETAINER
RSAUTOMATIC - 31TH21 - 137
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)

(4) Install transfer shaft/bearing retainer assembly
using tool L-4512 (Fig. 284).
(5) Install transfer shaft bearing retainer snap
ring (Fig. 285).
(6) Install governor assembly (Fig. 286).
Fig. 281 Install Transfer Shaft Bearing Cup
1 - PRESS
2 - HANDLE C-4171
3 - SPECIAL TOOL L-4520
4 - TRANSFER SHAFT BEARING RETAINER
5 - ªOº RING
Fig. 282 Install Transfer Shaft Bearing Cone
1 - PRESS
2 - SPECIAL TOOL L-4411
3 - BEARING CONE
4 - TRANSFER SHAFT
Fig. 283 Transfer Shaft and Bearing Retainer
1 - O-RING
2 - TRANSFER SHAFT
3 - BEARING CONE
4 - TRANSFER SHAFT BEARING RETAINER
Fig. 284 Transfer Shaft and Bearing Retainer
1 - O-RING
2 - TRANSFER SHAFT
3 - BEARING CONE
4 - TRANSFER SHAFT BEARING RETAINER
21 - 138 AUTOMATIC - 31THRS
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)

(7) Install low/reverse band anchor pin if previ-
ously removed (Fig. 287).
(8) Install governor support retainer bearing cup
using Tool L-4520 (Fig. 288).
Fig. 285 Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS
2 - SNAP RING
3 - OUTPUT SHAFT GEAR
4 - TRANSFER SHAFT
Fig. 286 Governor Assembly
1 - TRANSFER SHAFT
2 - OUTPUT SHAFT GEAR
3 - GOVERNOR ASSEMBLY
Fig. 287 Low/Reverse Band Anchor Pin
1 - LOW-REVERSE BAND ANCHOR PIN
2 - OUTPUT SHAFT GEAR
Fig. 288 Install Governor Support Retainer Bearing
Cup
1 - PRESS
2 - HANDLE C-4171
3 - SPECIAL TOOL L-4520
4 - GOVERNOR SUPPORT RETAINER
5 - BEARING CUP
RSAUTOMATIC - 31TH21 - 139
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)

(9) Install governor support retainer (Fig. 289).
(10) Install transfer shaft gear bearing cone using
Tool L-4410 (Fig. 290).
(11) Determine transfer shaft bearing shim thick-
ness. (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 31TH/TRANSFER SYSTEM -
ADJUSTMENTS) Shim thickness need be deter-
mined only if any of the following parts are replaced:
²Transaxle case
²Transfer shaft²Transfer shaft gear
²Transfer shaft bearings
²Governor support retainer
²Transfer shaft bearing retainer
²Retainer snap ring
²Governor support
(12) Install transfer shaft gear and select shim
(Fig. 291).
(13) Install transfer shaft gear nut and washer
(Fig. 292).
Fig. 289 Governor Support Retainer
1 - TRANSFER SHAFT
2 - OUTPUT SHAFT GEAR
3 - BEARING CUP
4 - GOVERNOR SUPPORT RETAINER
Fig. 290 Install Transfer Shaft Gear Bearing Cone
1 - PRESS
2 - HANDLE C-4171
3 - SPECIAL TOOL L-4410
4 - TRANSFER SHAFT GEAR
5 - BEARING CONE
Fig. 291 Transfer Shaft Gear and (Select) Shim
1 - TRANSFER SHAFT GEAR
2 - OUTPUT SHAFT GEAR
3 - SHIM (SELECT)
4 - BEARING CONE
Fig. 292 Transfer Shaft Gear Nut and Washer
1 - OUTPUT SHAFT GEAR
2 - TRANSFER SHAFT GEAR
3 - WASHER
4 - NUT
21 - 140 AUTOMATIC - 31THRS
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)

(14) Using Tool L-4434 and adapter C-4658 (Fig.
293), torque transfer shaft gear retaining nut to 271
N´m (200 ft. lbs.).
(15) Measure transfer shaft end play. Set up Tool
L-4432 and C-4658 as shown in (Fig. 294). Measure
end play with dial indicator.
(16) Position stirrup and strap on transfer gear.
(17) Install bolts but do not tighten.
(18) Rotate stirrup clockwise until it contacts
transfer gear retaining nut flat.(19) Torque stirrup and strap-to-transfer gear bolts
to 23 N´m (200 in. lbs.).
(20) Bend tabs of strap up against ªflatsº of retain-
ing bolts.
(21) Install a bead of Moparž Silicone Rubber
Adhesive Sealant to transfer gear cover (Fig. 295).
Immediately install to transaxle case.
(22) Install and torque transfer gear cover-to-case
bolts (Fig. 296) to 19 N´m (165 in. lbs.) .
Fig. 293 Tighten Transfer Shaft Gear Retaining Nut
to 271 N´m (200 ft. lbs.)
1 - TRANSFER SHAFT GEAR
2 - TORQUE WRENCH
3 - SPECIAL TOOL L-4434 AND ADAPTER C-4658
Fig. 294 Measuring Transfer Shaft End-Play
1 - SPECIAL TOOL L-4432 AND C-4658
2 - TRANSFER SHAFT GEAR
3 - STEEL BALL (USE GREASE TO HOLD IN PLACE)
4 - DIAL INDICATOR
5 - SCREW (2)
Fig. 295 Install Rear Cover
1 - OUTPUT SHAFT GEAR
2 - USE MOPAR SILICONE RUBBER ADHESIVE SEALER
3 - REAR COVER
4 - TRANSFER SHAFT GEAR
Fig. 296 Rear Cover Bolts
1 - REAR COVER
2 - REAR COVER BOLTS (10)
RSAUTOMATIC - 31TH21 - 141
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)

ADJUSTMENT - TRANSFER SHAFT BEARING
(1) Use Tool L-4434 to remove the retaining nut
and washer. Remove the transfer shaft gear using
Tool L-4407.
(2) Install a 2.29 mm (0.090 inch) and a 1.39 mm
(0.055 inch) gauging shims on the transfer shaft
behind the governor support.
(3) Install transfer shaft gear and bearing assem-
bly and torque the nut to 271 N´m (200 ft. lbs.).
(4) To measure bearing end play:Attach Tool
L-4432 to the transfer gear.
(5) Mount a steel ball with grease into the end of
the transfer shaft.
(6) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
(7) Using a dial indicator, measure transfer shaft
end play.
(8) Refer to the Transfer Bearing Shim Chart for
the required shim combination to obtain the proper
bearing setting.
(9) Use Tool L-4434 to remove the retaining nut
and washer. Remove the transfer shaft gear using
Tool L-4407.
(10) Remove the two gauging shims and install the
correct shim combination. Install the transfer gear
and bearing assembly.
(11) Install the retaining nut and washer and
torque to 271 N´m (200 ft. lbs.). Measure transfer
shaft end play, end play should be 0.05 to 0.25 mm
(0.002 to 0.010 inch).
(12) Measure bearing end play as outlined in Step
(4). End play should be between 0.05 mm and 0.25
mm (0.002 to 0.010 inch).
NOTE: If end play is too high, install a 0.05 mm
(0.002 inch) thinner shim combination. If end play is
too low, install a 0.05 mm (0.002 inch) thicker shim
combination. Repeat until 0.05 to 0.25 mm (0.002 to
0.010 inch) end play is obtained.
End Play
(with 2.29
mm and 1.39
mm gauging
shims
installed)Required Shim
CombinationTotal
Thickness
mm inch mm mm inch
.0 .0 2.29 + 1.39 3.68 .145
.05 .002 2.29 + 1.39 3.68 .145
.10 .004 2.29 + 1.39 3.68 .145
.15 .006 2.29 + 1.39 3.68 .145
.20 .008 2.29 + 1.34 3.63 .143
.25 .010 2.29 + 1.29 3.58 .141
End Play
(with 2.29
mm and 1.39
mm gauging
shims
installed)Required Shim
CombinationTotal
Thickness
mm inch mm mm inch
.30 .012 2.29 + 1.24 3.53 .139
.35 .014 2.29 + 1.19 3.48 .137
.40 .016 2.29 + 1.14 3.43 .135
.45 .018 2.29 + 1.09 3.38 .133
.50 .020 2.29 + 1.04 3.33 .131
.55 .022 2.29 + .99 3.28 .129
.60 .024 1.84 + 1.39 3.23 .127
.65 .026 1.84 + 1.34 3.18 .125
.70 .028 1.84 + 1.29 3.13 .123
.75 .030 1.84 + 1.24 3.08 .121
.80 .032 1.84 + 1.19 3.03 .119
.85 .034 1.84 + 1.14 2.98 .117
.90 .036 1.84 + 1.09 2.93 .115
.95 .038 1.84 + 1.04 2.88 .113
1.00 .040 1.84 + .99 2.83 .111
1.05 .042 1.39 + 1.39 2.78 .109
1.10 .044 1.39 + 1.34 2.73 .107
1.15 .046 1.39 + 1.29 2.68 .105
1.20 .048 1.39 + 1.24 2.63 .103
1.25 .049 1.39 + 1.19 2.58 .101
1.30 .050 1.39 + 1.14 2.53 .099
1.35 .052 1.39 + 1.09 2.48 .097
1.40 .055 1.39 + 1.04 2.43 .095
1.45 .057 1.39 + .99 2.38 .093
1.50 .059 .94 + 1.39 2.33 .091
1.55 .061 .94 + 1.34 2.28 .089
1.60 .063 .94 + 1.29 2.23 .087
VALVE BODY
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect throttle valve cable from throttle
valve lever at transaxle.
(3) Disconnect gearshift cable from gearshift lever
at transaxle.
(4) Disconnect torque converter clutch solenoid
connector.
(5) Raise vehicle on hoist.
21 - 142 AUTOMATIC - 31THRS
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)

(6) Remove transaxle oil pan bolts (Fig. 297).
(7) Separate oil pan from case and drain fluid into
suitable container (Fig. 298).(8) Remove oil filter-to-valve body screws (Fig.
299).
(9) Remove oil filter and gasket (Fig. 300).
Fig. 297 Transaxle Oil Pan Bolts
1 - TRANSAXLE OIL PAN
2 - OIL PAN BOLTS
Fig. 298 Transaxle Oil Pan
1 - TRANSAXLE OIL PAN
2 - OIL FILTER
Fig. 299 Oil Filter Screws
1 - SCREWDRIVER HANDLE
2 - SPECIAL TOOL L-4553
3 - OIL FILTER SCREWS (2)
4 - OIL FILTER
Fig. 300 Oil Filter and Gasket
1 - OIL FILTER
2 - GASKET
3 - VALVE BODY
RSAUTOMATIC - 31TH21 - 143
VALVE BODY (Continued)

(10) Remove cooler bypass valve from valve body
(Fig. 301).
(11) Remove park rod e-clip (Fig. 302).(12) Remove park rod from valve body (Fig. 303).
(13) Remove valve body-to-transaxle case bolts
(Fig. 304).
(14) Remove valve body from transaxle. Note ori-
entation of governor tubes (Fig. 305).
Fig. 301 Cooler Bypass Valve and Seal
1 - TRANSFER PLATE
2 - BYPASS VALVE
3 - SEAL
Fig. 302 Parking Rod E-Clip
1 - VALVE BODY
2 - SCREWDRIVER
3 - ªEº CLIP
4 - PARKING ROD
Fig. 303 Parking Rod
1 - VALVE BODY
2 - PARKING ROD
Fig. 304 Valve Body Attaching Bolts
1 - VALVE BODY
2 - VALVE BODY ATTACHING BOLTS (7)
3 - GOVERNOR TUBES
21 - 144 AUTOMATIC - 31THRS
VALVE BODY (Continued)

DISASSEMBLY
CAUTION: Do not clamp any portion of valve body
or transfer plate in a vise. Any slight distortion of
the aluminum body or transfer plate will result in
sticking valves, excessive leakage, or both. When
removing or installing valves or plugs, slide them in
or out carefully. Do not use force.
NOTE: TAG ALL SPRINGS AS THEY ARE REMOVED
FOR REASSEMBLY IDENTIFICATION.
(1) Remove detent spring-to-valve body screws and
remove spring (Fig. 306).(2) Remove valve body-to-separator plate screws
(Fig. 307) (Fig. 308).
(3) Separate transfer and separator plate from
valve body assembly (Fig. 309). Note check ball loca-
tions (Fig. 310) for proper reassembly.
(4) Remove throttle valve shaft-to-manual valve
shaft e-clip (Fig. 311). Note orientation of washer and
seal (Fig. 312).
Fig. 305 Valve Body and Governor Tubes
1 - VALVE BODY ASSEMBLY
2 - GOVERNOR TUBES
Fig. 306 Detent Spring Attaching Screw and Spring
1 - SPECIAL TOOL L-4553
2 - DETENT SPRING SCREW
3 - SCREWDRIVER HANDLE
Fig. 307 Using Tool L-4553 on Valve Body Screw
1 - SCREWDRIVER HANDLE
2 - VALVE BODY ASSEMBLY
3 - SPECIAL TOOL L-4553
Fig. 308 Remove Valve Body-to-Transfer Plate
Screws
1 - SCREWDRIVER HANDLE
2 - VALVE BODY SCREWS (16)
3 - VALVE BODY
4 - SPECIAL TOOL L-4553
RSAUTOMATIC - 31TH21 - 145
VALVE BODY (Continued)

Fig. 309 Separate Transfer Plate and Separator
Plate from Valve Body
1 - SEPARATOR PLATE
2 - TRANSFER PLATE
3 - OIL SCREEN
4 - VALVE BODY
Fig. 310 Steel Ball Locations
1 - MANUAL VALVE
2 - STEEL BALLS (8)
3 - STEEL BALLS
Fig. 311 Remove Throttle Shaft E-Clip
1 - MANUAL VALVE LEVER ASSEMBLY
2 - THROTTLE VALVE LEVER ASSEMBLY
3 - SCREWDRIVER
4 - ªEº CLIP
Fig. 312 Throttle Shaft E-Clip, Washer, and Seal
1 - MANUAL VALVE LEVER ASSEMBLY
2 - OIL SEAL
3 - ªEº CLIP
4 - THROTTLE VALVE LEVER ASSEMBLY
5 - WASHER
21 - 146 AUTOMATIC - 31THRS
VALVE BODY (Continued)