differential CHRYSLER VOYAGER 2004 Repair Manual

CHRYSLER VOYAGER 2004 Repair Manual VOYAGER 2004 CHRYSLER CHRYSLER https://www.carmanualsonline.info/img/25/56870/w960_56870-0.png CHRYSLER VOYAGER 2004 Repair Manual

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CHRYSLER VOYAGER 2004 Repair Manual (4) Remove side gear thrust washer (Fig. 103).(5) Remove side gear (Fig. 104).
(6) Remove long pinion shaft (Fig. 105).
Fig. 102 Differential Support Plate
1 - DIFFERENTIAL SUPPORT PLATE
2 - DIFFERENT

Page 1662 of 2585

CHRYSLER VOYAGER 2004 Repair Manual (7) Remove both short pinion shafts (Fig. 106).
(8) Remove pinion shaft retainer (Fig. 107).(9) Remove four pinion gears and thrust washers
(Fig. 108).
(10) Remove side gear (Fig. 109).
Fig. 106 Short

Page 1663 of 2585

CHRYSLER VOYAGER 2004 Repair Manual (11) Remove side gear thrust washer (Fig. 110).
ASSEMBLY
(1) Install side gear thrust washer (Fig. 111).(2) Install differential side gear (Fig. 112).
(3) Install four (4) pinion gears and thrust wash

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CHRYSLER VOYAGER 2004 Repair Manual (4) Install pinion shaft retaining ring (Fig. 114).
(5) Install two (2) short pinion shafts (Fig. 115).(6) Install one (1) long pinion shaft (Fig. 116).
(7) Install differential side gear.
(8) Install

Page 1665 of 2585

CHRYSLER VOYAGER 2004 Repair Manual (9) Install differential support plate. Align support
plate to differential case with alignment pins 8470
(Fig. 118).
(10) Install thrust buttons 8491 to both bearing
journals and press halves togethe

Page 1666 of 2585

CHRYSLER VOYAGER 2004 Repair Manual (13) Install tapered roller bearings using installer
8473 and an arbor press (Fig. 122). Insert button
8491 on opposite journal to protect journal and/or
bearing during press operation. Repeat the sam

Page 1667 of 2585

CHRYSLER VOYAGER 2004 Repair Manual DIFFERENTIAL BEARING SHIM CHART
PART NUMBERSHIM THICKNESS
METRIC (MM) STANDARD (STD)
4659242 0.50 0.0197
4659243 0.54 0.0213
4659247 0.58 0.0228
4659248 0.62 0.0244
4659249 0.66 0.0260
4659250 0.70 0.

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CHRYSLER VOYAGER 2004 Repair Manual If end play measurement indicates a thrust washer
change is necessary, the differential must be disas-
sembled. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/MANUAL/DIFFERENTIAL - DISASSEMBLY)FLUID
STANDARD

Page 1669 of 2585

CHRYSLER VOYAGER 2004 Repair Manual FLUID DRAIN
(1) Raise vehicle on hoist.
(2) Remove transaxle drain plug (Fig. 127) and
drain fluid into suitable container.
(3) Install drain plug and torque to 23 N´m (17 ft.
lbs.).
FLUID FILL
(1) R

Page 1697 of 2585

CHRYSLER VOYAGER 2004 Repair Manual INTERMEDIATE SHAFT
DESCRIPTION
The intermediate shaft assembly (Fig. 227) is part
of the transaxle geartrain, meshes with and is driven
by the input shaft, drives the differential via an inte-
grated