torque CHRYSLER VOYAGER 2002 Service Manual

(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).
Fig. 260 Tighten Output Shaft Retaining Nut
1 - OUTPUT SHAFT GEAR
2 - SPECIAL TOOL L-4434 AND C-4658
3 - SCREW (2)
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
21 - 134 31TH AUTOMATIC TRANSAXLERS
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)
ProCarManuals.com

(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)
ADJUSTMENTS
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 usinggrease 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.
(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.
Fig. 264 Tighten Strap Retaining Nuts
1 - STRAP
2 - OUTPUT GEAR
3 - STIRRUP
RS31TH AUTOMATIC TRANSAXLE21 - 135
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)
ProCarManuals.com

(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 MopartSilicone 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
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)
21 - 144 31TH AUTOMATIC TRANSAXLERS
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)
ProCarManuals.com

ADJUSTMENTS
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
.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
RS31TH AUTOMATIC TRANSAXLE21 - 145
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)
ProCarManuals.com

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.
(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
21 - 146 31TH AUTOMATIC TRANSAXLERS
ProCarManuals.com

(11) Remove torque converter clutch solenoid,
spring, and plug as shown in (Fig. 319).
Fig. 319 Torque Converter Clutch Solenoid and Regulator/Control Valves
1 - CONVERTER PRESSURE CONTROL
VA LV E3 - SCREW (3) 5 - REGULATOR VALVE THROTTLE
PRESSURE PLUG
2 - END COVER4 - REGULATOR VALVE THROTTLE
PRESSURE PLUG SPRING 6 - SWITCH VALVE
RS31TH AUTOMATIC TRANSAXLE21 - 153
VALVE BODY (Continued)
ProCarManuals.com

(12) Remove shift/shuttle valves and springs as
shown in (Fig. 320).
CLEANING
Clean the valve body components in a parts clean-
ing solution only. Do not use gasoline, kerosene, or
any type of caustic solution. Dry the parts with com-
pressed air. Make sure all passages are clean and
free from obstructions.
NOTE: Do not use rags or shop towels to wipe off
valve body components. Lint from these materials
will adhere to the valve body components. Lint will
interfere with valve operation and may clog filters
and fluid passages.
Minor distortion of a valve body mating surface
may be corrected by smoothing the surface with cro-
cus cloth. The cloth should be in sheet form and bepositioned on a surface plate, sheet of plate glass, or
equally flat surface. However, if distortion is severe
or any surfaces are heavily scored, the valve body
will have to be replaced.
CAUTION: Many of the valve body valves and plugs
are made of coated aluminum. Aluminum compo-
nents can be identified by the dark color of the spe-
cial coating applied to the surface (or by testing
with a magnet). DO NOT polish or sand aluminum
valves or plugs with any type of material, or under
any circumstances. This practice might damage the
special coating and cause the valves and plugs to
stick and bind.
Aluminum valves and plugs should not be sanded
or polished under any circumstances. However, minor
burrs or scratches on steel valves and plugs can be
removed with crocus cloth but do not round off the
Fig. 320 Shift Valves and Shuttle Valve
1 - SHUTTLE VALVE E-CLIP 9 - BY-PASS VALVE SPRING
2 - SHUTTLE VALVE SECONDARY SPRING 10 - 1±2 SHIFT VALVE SPRING
3 - SHUTTLE VALVE 11 - 1±2 SHIFT VALVE
4 - 2±3 SHIFT VALVE 12 - BY-PASS VALVE
5 - SHUTTLE VALVE PRIMARY SPRING 13 - TORQUE CONVERTER CLUTCH SOLENOID
6 - 2±3 SHIFT VALVE SPRING 14 - VALVE BODY
7 - SHUTTLE VALVE PLUG 15 - SPRING GUIDES (2)
8 - SCREWS
21 - 154 31TH AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
ProCarManuals.com

valve or plug edges. Squareness of these edges is
vitally important. These edges prevent foreign matter
from lodging between the valves, plugs and bore.
INSPECTION
Inspect the throttle and manual valve levers and
shafts. Do not attempt to straighten a bent shaft or
correct a loose lever. Replace these components if
worn, bent, loose or damaged in any way.
Inspect all of the valve body mating surfaces for
scratches, nicks, burrs, or distortion. Use a straight-
edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light
pressure.
Inspect the valves and plugs for scratches, burrs,
nicks, or scores. Also inspect the coating on the alu-
minum valves and plugs. If the coating is damaged
or worn through, the valve (or valve body) should be
replaced.
Inspect all the valve and plug bores in the valve
body. Use a penlight to view the bore interiors.
Replace the valve body if any bores are distorted or
scored. Inspect all of the valve body springs. The
springs must be free of distortion, warpage or broken
coils.
Trial fit each valve and plug in its bore to check
freedom of operation. When clean and dry, the valves
and plugs should drop freely into the bores. Valve
body bores do not change dimensionally with use. If
the valve body functioned correctly when new, it will
continue to operate properly after cleaning and
inspection. It should not be necessary to replace a
valve body assembly unless it is damaged in han-
dling.
ASSEMBLY
(1) Install shift/shuttle valves and springs as
shown in (Fig. 320).
(2) Install torque converter clutch solenoid, spring,
and plug as shown in (Fig. 319).
(3) Install governor plugs as shown in (Fig. 318).
(4) Install pressure regulator and manual control
springs and valves as shown in (Fig. 317).
(5) Install pressure regulator spring retainer/ad-
justing screw bracket (Fig. 321).
(6) Install manual valve from valve body (Fig.
322).
Fig. 321 Pressure Regulator and Adjusting Screw
Bracket
1 - SCREWDRIVER HANDLE
2 - PRESSURE REGULATOR SPRING RETAINER AND
ADJUSTING SCREW BRACKET
3 - VALVE BODY
4 - SCREWS
Fig. 322 Install Manual Valve
1 - MANUAL VALVE
2 - VALVE BODY
RS31TH AUTOMATIC TRANSAXLE21 - 155
VALVE BODY (Continued)
ProCarManuals.com

(11) Install transfer and separator plate to valve
body assembly (Fig. 327).
(12) Using Tool L-4553 or equivalent (Fig. 328),
install and torque valve body-to-transfer plate screws
(Fig. 329) to 5 N´m (40 in. lbs.) torque.(13) Install detent spring into position. Install and
torque detent spring-to-valve body screws to 5 N´m
(40 in. lbs.) torque (Fig. 330).
Fig. 327 Install Transfer Plate and Separator Plate to
Valve Body
1 - SEPARATOR PLATE
2 - TRANSFER PLATE
3 - OIL SCREEN
4 - VALVE BODY
Fig. 328 Using Tool L-4553 on Valve Body Screw
1 - SCREWDRIVER HANDLE
2 - VALVE BODY ASSEMBLY
3 - SPECIAL TOOL L-4553
Fig. 329 Install Valve Body-to-Transfer Plate Screws
1 - SCREWDRIVER HANDLE
2 - VALVE BODY SCREWS (16)
3 - VALVE BODY
4 - SPECIAL TOOL L-4553
Fig. 330 Detent Spring Attaching Screw and Spring
1 - SPECIAL TOOL L-4553
2 - DETENT SPRING SCREW
3 - SCREWDRIVER HANDLE
RS31TH AUTOMATIC TRANSAXLE21 - 157
VALVE BODY (Continued)
ProCarManuals.com

INSTALLATION
(1) Install valve body to transaxle. Position gover-
nor tubes into case (Fig. 331).
(2) Install valve body-to-case bolts (Fig. 332) and
torque to 12 N´m (105 in. lbs.).(3) Install cooler bypass valve and seal (Fig. 333).
(4) Install park rod to valve body and install e-clip
(Fig. 334) (Fig. 335).
Fig. 331 Valve Body and Governor Tubes
1 - VALVE BODY ASSEMBLY
2 - GOVERNOR TUBES
Fig. 332 Valve Body Attaching Bolts
1 - VALVE BODY
2 - VALVE BODY ATTACHING BOLTS (7)
3 - GOVERNOR TUBES
Fig. 333 Cooler Bypass Valve and Seal
1 - TRANSFER PLATE
2 - BYPASS VALVE
3 - SEAL
Fig. 334 Parking Rod
1 - VALVE BODY
2 - PARKING ROD
21 - 158 31TH AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
ProCarManuals.com