CHRYSLER VOYAGER 2001 Service Manual

(6) Using Miller Special Tool L-4518, remove the
differential bearing race from the extension housing.
(7) Using Miller Special Tool 6062A, remove the
differential bearing race from the bearing retainer
(Fig. 185) (Fig. 186).
(8) Remove ring gear-to-differential case bolts and
floating pinion shaft retainers (Fig. 187).
(9) Separate ring gear from differential case (Fig.
188).
Fig. 185 Position Bearing Cup Remover Tool in
Retainer
1 - SPECIAL TOOL 6062A
2 - DIFFERENTIAL BEARING RETAINER
Fig. 186 Remove Bearing Cup
1 - SPECIAL TOOL 6062A
2 - DIFFERENTIAL BEARING RETAINER
Fig. 187 Ring Gear-to-Case Bolts
1 - DIFFERENTIAL CASE
2 - PINION SHAFT RETAINER
3 - RING GEAR
4 - RING GEAR-TO-CASE BOLT
Fig. 188 Ring Gear Removal
1 - DIFFERENTIAL CASE
2 - RING GEAR
RSAUTOMATIC - 41TE21 - 237
FINAL DRIVE (Continued)

(10) Separate differential cover from case using
suitable screwdrivers at position shown in (Fig. 189)
(11) Lift support from case (Fig. 190).(12) Remove side gear thrust washer (Fig. 191).
(13) Remove side gear (Fig. 192).
Fig. 189 Separating Differential Support with
Screwdrivers
1 - DIFFERENTIAL SUPPORT
2 - DIFFERENTIAL CASE
3 - SCREWDRIVER
4 - RELIEF (2 @ 180É APART)
Fig. 190 Differential Support Removal
1 - DIFFERENTIAL SUPPORT
2 - DIFFERENTIAL CASE
Fig. 191 Side Gear Thrust Washer Removal
1 - SIDE GEAR THRUST WASHER
Fig. 192 Side Gear Removal
1 - DIFFERENTIAL SIDE GEAR
21 - 238 AUTOMATIC - 41TERS
FINAL DRIVE (Continued)

(14) Remove pinion shaft (Fig. 193).
(15) Remove pinion gears and tabbed washers
(Fig. 194).(16) Remove differential side gear (Fig. 195).
(17) Remove side gear thrust washer (Fig. 196).
(18) Inspect all components for excessive wear.
Fig. 193 Pinion Shaft Removal
1 - PINION SHAFT
Fig. 194 Pinion Gear and Washer Removal
1 - PINION GEAR
2 - TABBED WASHER
3 - LOCATING TAB
4 - NOTCH
Fig. 195 Side Gear Removal
1 - DIFFERENTIAL SIDE GEAR
Fig. 196 Side Gear Thrust Washer Removal
1 - THRUST WASHER
RSAUTOMATIC - 41TE21 - 239
FINAL DRIVE (Continued)

ASSEMBLY
NOTE: The differential is serviced as an assembly.
Differential service is limited to bearing cups and
cones. Any other differential component failure
must be remedied by differential assembly and
transfer shaft replacement.
(1) Install side gear thrust washer to differential
case (Fig. 197).
(2) Install side gear to differential case (Fig. 198).(3) Install both pinion gears and washers to case,
while orientating washer tabs to notch in case (Fig.
199).
(4) Install pinion shaft (Fig. 200).
Fig. 197 Thrust Washer Installation
1 - THRUST WASHER
Fig. 198 Side Gear Installation
1 - DIFFERENTIAL SIDE GEAR
Fig. 199 Pinion Gear and Washer Installation
1 - PINION GEAR
2 - TABBED WASHER
3 - LOCATING TAB
4 - NOTCH
Fig. 200 Pinion Shaft Installation
1 - PINION SHAFT
21 - 240 AUTOMATIC - 41TERS
FINAL DRIVE (Continued)

(5) Install side gear to case (Fig. 201).
(6) Install side gear thrust washer to case (Fig.
202).(7) Install differential support into position, while
aligning through-holes (Fig. 203).
(8) Install differential ring gear to case (Fig. 204).
Fig. 201 Side Gear Installation
1 - DIFFERENTIAL SIDE GEAR
Fig. 202 Side Gear Thrust Washer
1 - SIDE GEAR THRUST WASHER
Fig. 203 Diff Support Installation
1 - DIFFERENTIAL SUPPORT
2 - DIFFERENTIAL CASE
Fig. 204 Ring Gear Installation
1 - DIFFERENTIAL CASE
2 - RING GEAR
RSAUTOMATIC - 41TE21 - 241
FINAL DRIVE (Continued)

(9) Install ring gear-to-case bolts, with pinion shaft
retainers (Fig. 205), and torque bolts to 95 N´m (70
ft. lbs.).
(10) Using Miller Special Tool L-4410, and C-4171,
install differential bearing to differential (extension
housing side) (Fig. 206).
(11) Using Miller Special Tool 5052 and C-4171,
install differential bearing to differential (bearing
retainer side).(12) Using Miller Special Tool 6061 and C-4171,
install differential bearing race to bearing retainer
(Fig. 207).
(13) Using Miller Special Tool L±4520 and C-4171,
install differential bearing to extension housing.
NOTE: Use Moparž Silicone Rubber Adhesive Seal-
ant, or equivalent, on retainer and extension hous-
ing/adapter plate to seal to case.
(14) Install differential assembly into transaxle
case. Install differential bearing retainer (Fig.
208)and torque retainer-to-case bolts (Fig. 209)to 28
N´m (21 ft. lbs.).
Fig. 205 Ring Gear-to-Case Bolts
1 - DIFFERENTIAL CASE
2 - PINION SHAFT RETAINER
3 - RING GEAR
4 - RING GEAR-TO-CASE BOLT
Fig. 206 Position Bearing Cone Onto DifferentialÐ
Typical
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL BEARING
Fig. 207 Differential Bearing Retainer
1 - DIFFERENTIAL BEARING CUP
2 - DIFFERENTIAL BEARING RETAINER
Fig. 208 Differential Bearing Retainer
1 - DIFFERENTIAL BEARING CUP
2 - DIFFERENTIAL BEARING RETAINER
21 - 242 AUTOMATIC - 41TERS
FINAL DRIVE (Continued)

(15) Apply a bead of Moparž Silicone Rubber
Adhesive Sealant to extension housing/adapter plate
and install into position. Install and torque bolts to
28 N´m (21 ft. lbs.).
(16) Measure and adjust differential bearing pre-
load. (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 41TE/FINAL DRIVE -
ADJUSTMENTS)
(17) Apply a bead of Moparž Silicone Rubber
Adhesive Sealant to differential cover and install to
case (Fig. 210).(18) Install and torque cover-to-case bolts to 19
N´m (165 in. lbs.) (Fig. 211).
ADJUSTMENT - DIFFERENTIAL BEARING
PRELOAD
NOTE: Perform all differential bearing preload mea-
surements with the transfer shaft and gear
removed.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT
USING EXISTING SHIM
(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. 212).
(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. 213).The turning torque should be
between 5 and 18 inch-pounds.
(5) If the turning torque is within specifications,
remove tools. Setup is complete.
Fig. 209 Differential Retainer Bolts
1 - DIFFERENTIAL RETAINER BOLTS
Fig. 210 Install Differential Cover
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL COVER
Fig. 211 Differential Cover Bolts
1 - DIFFERENTIAL COVER BOLTS
2 - DIFFERENTIAL COVER
RSAUTOMATIC - 41TE21 - 243
FINAL DRIVE (Continued)

(6) If turning torque is not within specifications
proceed with the following steps.
(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.
(e) If the turning torque was too high when mea-
sured, 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 5-18
inch-pounds turning torque is obtained. Oil Baffle
is not required to be installed when making shim
selection.
(f) 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.
(g) Install the differential bearing retainer 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.).
(7) Using Tool L-4436A and an inch-pound torque
wrench, recheck the turning torque of the differential
(Fig. 213).The turning torque should be within
5-18 inch-pounds.
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Differential carrier
²Differential bearing retainer
²Extension housing
²Differential bearing cups and cones
Fig. 212 Tool L-4436 and Torque Wrench
1 - SPECIAL TOOL L-4436±A
2 - TORQUE WRENCH
3 - DIFFERENTIAL BEARING RETAINER
Fig. 213 Checking Differential Bearings Turning
Torque
1 - SPECIAL TOOL L-4436±A
2 - TORQUE WRENCH
21 - 244 AUTOMATIC - 41TERS
FINAL DRIVE (Continued)

DIFFERENTIAL BEARING SHIM CHART
PART NUMBER SHIM THICKNESS
MM INCH
4659257 .980 0.0386
4659258 1.02 0.0402
4659259 1.06 0.0418
4659260 1.10 0.0434
4659261 1.14 0.0449
4659262 1.18 0.0465
4659263 1.22 0.0481
4659264 1.26 0.0497
4659265 1.30 0.0512
4659266 1.34 0.0528
4659267 1.38 0.0544
4659268 1.42 0.0560
4659269 1.46 0.0575
4659270 1.50 0.0591
4659271 1.54 0.0607
4659272 1.58 0.0623
4659273 1.62 0.0638
4659274 1.66 0.0654
4659275 1.70 0.0670
4659283 2.02 0.0796
4659284 2.06 0.0812
PRELOAD ADJUSTMENT W/O SHIM
(1) Remove the bearing cup from the differential
bearing retainer using Miller special Tool 6062A.
(2) Remove existing shim from under bearing cup.
(3) Reinstall the bearing cup into the retainer
using Miller Special Tool 6061, and C-4171.
NOTE: Oil baffle is not required when making the
shim calculation.
(4) Install the bearing retainer into the case.
Torque bolts to 28 N´m (250 in. lbs.).
(5) Position the transaxle assembly vertically on
the support stand and install Miller Special Tool
L-4436-A into the bearing retainer.
(6)
Rotate the differential at least one full revolution
to ensure the tapered roller bearings are fully seated.
(7)Attach a dial indicator to the case and zero the
dial. Place the tip on the end of Special Tool L-4436-A.
(8) Place a large screwdriver to each side of the
ring gear and lift. Check the dial indicator for the
amount of end play.
CAUTION: Do not damage the transaxle case and/or
differential retainer sealing surface.(9) Using the end play measurement that was
determined, add 0.18mm (0.007 inch). This should
give you between 5-18 inch pounds of bearing pre-
load. Refer to the Differential Bearing Shim Chart to
determine which shim to use.
(10) Remove the differential bearing retainer.
Remove the bearing cup.
(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 Moparž Silicone
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. 213). The turning torque
should be between 5-18 inch-pounds.
NOTE: If turning torque is too high install a 0.05mm
(0.002 inch) thicker shim. If the turning torque is too
low, install a 0.05mm (0.002 inch) thinner shim.
Repeat until 5-18 inch-pounds of turning torque is
obtained.
RSAUTOMATIC - 41TE21 - 245
FINAL DRIVE (Continued)

FLUID
STANDARD PROCEDURE - FLUID LEVEL AND
CONDITION CHECK
NOTE: Only transmission fluid of the type labeled
Mopar ATF+4 (Automatic Transmission Fluid±Type
9602) should be used in this transaxle.
FLUID LEVEL CHECK
The transmission sump has a fluid level indicator
(dipstick) to check oil similar to most automatic
transmissions. It is located on the left side of the
engine. Be sure to wipe all dirt from dipstick handle
before removing.
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.At normal operating temperature (approxi-
mately 82 C. or 180 F.), the fluid level is correct if it
is in the HOT region (cross-hatched area) on the oil
level indicator (Fig. 214). The fluid level should be
within the WARM range of the dipstick at 70É F fluid
temperature.
FLUID LEVEL CHECK USING DRB
NOTE: Engine and Transaxle should be at normal
operating temperature before performing this proce-
dure.
(1) Start engine and apply parking brake.
(2) Hook up DRB scan tool and select transmis-
sion.(3) Select sensors.
(4) Read the transmission temperature value.
(5) Compare the fluid temperature value with the
fluid temperature chart (Fig. 215).
(6) Adjust transmission fluid level shown on the
indicator according to the chart.
(7) Check transmission for leaks.
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, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transaxle vent where it may be mistaken
for a leak.
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 proba-
bly required. Be sure to examine the fluid on the dip-
stick 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
SERVICE
NOTE: Refer to the maintenance schedules in
LUBRICATION and MAINTENANCE, or the vehicle
owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
Fig. 214 Transaxle Fluid Level Indicator
1 - TRANSAXLE DIPSTICK
21 - 246 AUTOMATIC - 41TERS