CHRYSLER VOYAGER 2002 Service Manual

(14) Remove differential bearing cone (Fig. 149).
(15) Remove bearing retainer bearing cup using
Tool 6062A (Fig. 150) (Fig. 151). Remove shim and oil
baffle.
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.
Fig. 149 Remove Differential Bearing Cone
1 - SPECIAL TOOL 5048
2 - RING GEAR
Fig. 150 Position Bearing Cup Remover Tool in
Retainer
1 - SPECIAL TOOL 6062A
2 - DIFFERENTIAL BEARING RETAINER
Fig. 151 Remove Bearing Cup using 6062A
1 - SPECIAL TOOL 6062A
2 - DIFFERENTIAL BEARING RETAINER
Fig. 152 Bearing Retainer Bearing Cup Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5052
3 - DIFFERENTIAL BEARING RETAINER
21 - 94 31TH AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)
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(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.
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
Fig. 156 Checking Side Gear End Play (Typical)
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
RS31TH AUTOMATIC TRANSAXLE21-95
FINAL DRIVE (Continued)
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(4) Apply a bead of MopartSilicone 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.
(7) Apply a bead of MopartSilicone 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).
(10) Install bearing retainer axle seal using Tool
L-4520 (inverted), and driver handle C-4171 (Fig.
160).
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)
Fig. 160 Install Bearing Retainer Axle Seal
1 - SPECIAL TOOL L-4520
2 - SPECIAL TOOL C-4171
21 - 96 31TH AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)
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(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 MopartSilicone 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.ADJUSTMENTS
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.
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
Fig. 163 Tool L-4436 and Torque Wrench
1 - SPECIAL TOOL L-4436±A
2 - TORQUE WRENCH
3 - DIFFERENTIAL BEARING RETAINER
RS31TH AUTOMATIC TRANSAXLE21-97
FINAL DRIVE (Continued)
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(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.
(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 MOPARtSilicone
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. 164 Checking Differential Bearings Turning
Torque
1 - SPECIAL TOOL L-4436±A
2 - TORQUE WRENCH
21 - 98 31TH AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)
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FLUID
STANDARD PROCEDURE
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 thetransaxle dipstick where it may be mistaken for a
leak.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. MopartATF+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.
ATF+4 also has a unique odor that may change with
age. Consequently,odor and color cannot be used
to indicate the fluid condition, or the need for a
fluid change.
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 MoparTATF+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.
(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 MopartSilicone Rubber Adhesive Sealant.
Torque oil pan bolts to 19 N´m (165 in. lbs.).
(7) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid-Type 9602) through the dipstick
opening.
Fig. 165 Fluid Level Indicator Markings
1 - TRANSAXLE DIPSTICK
RS31TH AUTOMATIC TRANSAXLE21-99
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(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 MopartATF+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
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(8) 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).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/FLUID - STANDARD PROCEDURE)
(10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
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
21 - 100 31TH AUTOMATIC TRANSAXLERS
FLUID (Continued)
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GEAR SHIFT CABLE
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect gear shift cable at manual valve
lever (Fig. 169).
(3) Disconnect gear shift cable from upper mount
bracket (Fig. 169).
(4) Remove instrument panel lower silencer (Fig.
170).(5) Remove knee bolster (Fig. 171).
(6) Disconnect PRNDL cable from gear shift lever
(Fig. 172).
Fig. 169 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 170 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 171 Knee Bolster
1 - KNEE BOLSTER
Fig. 172 PRNDL Cable
1 - PRNDL CABLE
2 - GEAR SHIFT LEVER
RS31TH AUTOMATIC TRANSAXLE21 - 101
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(7) Disconnect gear shift cable from gear shift
lever (Fig. 173).
(8) Remove gear shift cable from column bracket
(Fig. 173).
(9) Disengage grommet from dash panel and
remove gear shift cable from inside vehicle (Fig. 174).INSTALLATION
(1) Fish gear shift cable dash panel opening into
engine compartment and secure grommet (Fig. 175).
(2) Install gear shift cable through column bracket
(Fig. 176) until audible ªclickº is heard.
(3) Connect gear shift cable to gear shift lever (Fig.
176).
Fig. 173 Gearshift Cable at Column
1 - GEAR SHIFT CABLE
Fig. 174 Gearshift Cable/Grommet at Dash Panel
1 - CABLE GROMMET
2 - DASH PANEL
Fig. 175 Gearshift Cable/Grommet at Dash Panel
1 - CABLE GROMMET
2 - DASH PANEL
Fig. 176 Gearshift Cable at Column
1 - GEAR SHIFT CABLE
21 - 102 31TH AUTOMATIC TRANSAXLERS
GEAR SHIFT CABLE (Continued)
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(4) Connect PRNDL cable to gear shift lever (Fig.
177). Adjust if necessary.
(5) Install knee bolster (Fig. 178).
(6) Install instrument panel lower silencer (Fig.
179).
(7) Install gear shift cable to transaxle upper
mount bracket (Fig. 180). An audible ªclickº should
be heard.
(8) Connect gear shift cable end to transaxle man-
ual valve lever (Fig. 180).(9) Adjust gearshift cable. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 31TH/GEAR
SHIFT CABLE - ADJUSTMENTS)
Fig. 177 PRNDL Cable
1 - PRNDL CABLE
2 - GEAR SHIFT LEVER
Fig. 178 Knee Bolster
1 - KNEE BOLSTER
Fig. 179 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 180 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
RS31TH AUTOMATIC TRANSAXLE21 - 103
GEAR SHIFT CABLE (Continued)
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