DODGE TOWN AND COUNTRY 2001 Service Manual

TRANSFER SYSTEM -
TRANSFER SHAFT/GEAR/
BEARING
REMOVAL
(1) Remove transfer gear cover bolts (Fig. 265).
(2) Separate transfer gear cover from transaxle
(Fig. 266). Repair any cover imperfections. Clean
cover and case of old adhesive sealant.(3) Using a suitable punch, bend retaining strap
tabs to facilitate bolt removal.
(4) Remove stirrup and retaining strap-to-transfer
gear bolts.
(5) Remove stirrup and retaining strap.
(6) Using Tool L-4434 (Fig. 267), remove transfer
shaft gear retaining nut and washer (Fig. 268).
Fig. 265 Rear Cover Bolts
1 - REAR COVER
2 - REAR COVER BOLTS (10)
Fig. 266 Remove Rear Cover
1 - OUTPUT SHAFT GEAR
2 - USE MOPAR SILICONE RUBBER ADHESIVE SEALER
3 - REAR COVER
4 - TRANSFER SHAFT GEAR
Fig. 267 Remove Transfer Shaft Gear Retaining Nut
1 - TRANSFER SHAFT GEAR
2 - SCREW (2)
3 - OUTPUT SHAFT GEAR
4 - SPECIAL TOOL L-4434
Fig. 268 Transfer Shaft Gear Nut and Washer
1 - OUTPUT SHAFT GEAR
2 - TRANSFER SHAFT GEAR
3 - WASHER
4 - NUT
21 - 134 AUTOMATIC - 31THRS
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(7) Using Tool L-4407A, remove transfer shaft gear
and select shim (Fig. 269).
(8) Using Tool L-4406-1 and adapter L-4406-3,
remove transfer shaft gear bearing cone (Fig. 270).(9) Remove governor support retainer (Fig. 271).
(10) Remove governor support retainer bearing cup
(Fig. 272).
Fig. 269 Remove Transfer Shaft Gear using L-4407A
1 - TRANSFER GEAR
2 - TOOL L-4407A
Fig. 270 Using Tool L-4406-1 with Adapter L-4406-3,
Remove Transfer Shaft Gear Bearing Cone
1 - SPECIAL TOOL L-4406-1
2 - TRANSFER SHAFT GEAR
Fig. 271 Governor Support Retainer
1 - TRANSFER SHAFT
2 - OUTPUT SHAFT GEAR
3 - BEARING CUP
4 - GOVERNOR SUPPORT RETAINER
Fig. 272 Remove Governor Support Retainer
Bearing Cup
1 - PRESS
2 - HANDLE C-4171 (WITH SPECIAL TOOL L-4517)
3 - GOVERNOR SUPPORT RETAINER
RSAUTOMATIC - 31TH21 - 135
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)
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(11) If necessary, remove low/reverse band anchor
pin (Fig. 273).
(12) Remove governor assembly (Fig. 274).(13) Remove transfer shaft bearing retainer snap
ring (Fig. 275).
(14) Set up tools as shown in (Fig. 276).
Fig. 273 Low/Reverse Band Anchor Pin
1 - LOW-REVERSE BAND ANCHOR PIN
2 - OUTPUT SHAFT GEAR
Fig. 274 Governor Assembly
1 - TRANSFER SHAFT
2 - OUTPUT SHAFT GEAR
3 - GOVERNOR ASSEMBLY
Fig. 275 Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS
2 - SNAP RING
3 - OUTPUT SHAFT GEAR
4 - TRANSFER SHAFT
Fig. 276 Remove Transfer Shaft and Bearing
Retainer Assembly
1 - SPECIAL TOOL L-4512
2 - SPECIAL TOOL L-4437
3 - SPECIAL TOOL C-3752
21 - 136 AUTOMATIC - 31THRS
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)
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(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)
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(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)
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(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)
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(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)
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(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)
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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)
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(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)
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