1996 CHRYSLER VOYAGER clutch

CAUTION: Compress return spring just enough to
remove or install snap ring.
Fig. 158 Underdrive Clutch Pack
Fig. 159 UD Spring Retainer Snap Ring
Fig. 160 UD Return Spring and Retainer
Fig. 161 Underdrive Clutch Piston
Fig. 162 Input Hub Tapered Snap Ring
Fig. 163 Tap on Input Hub
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 113
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: The OD/UD Reaction Plate, Snap Rings, and
Input Clutches Retainer is not interchangeable with
previous year 41TE components. The snap rings
are thicker and the position of the ring lands have
changed.
Fig. 175 Install Input Shaft Hub Assembly
Fig. 176 Install Input Hub Tapered Snap Ring
Fig. 177 Underdrive Clutch Piston
Fig. 178 Seal Compressor Special Tool 5067
Fig. 179 UD Return Spring and Retainer
21 - 116 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: Compress return spring just enough to
remove or install snap ring.
The OD/UD clutches reaction plate has a step on
both sides. Install the OD/UD clutches reaction plate
tapered step side up.
Fig. 180 Install UD Spring Retainer and Snap Ring
Fig. 181 Underdrive Clutch Pack
Fig. 182 UD Clutch Flat Snap Ring
Fig. 183 Install Last UD Clutch Disc
Fig. 184 OD/UD Reaction Plate
Fig. 185 Tapered Snap Ring
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 117
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Snap ring ends must be located within one
finger of the input clutch hub. Be sure that snap
ring is fully seated, by pushing with screwdriver,
into snap ring groove all the way around.
Underdrive clutch pack clearance must be
0.91 to 1.47 mm (.036 to .058 inch).Select the
proper reaction plate to achieve specifications:
Fig. 186 Seating Tapered Snap Ring
Fig. 187 Set Up Dial Indicator for Clutch Clearance
Fig. 188 Use Hook Tool to Raise One Clutch Disc
UNDERDRIVE REACTION PLATE CHART
Fig. 189 Install OD Clutch Pack
21 - 118 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 190 Install Waved Snap Ring
Fig. 191 OD/Reverse Pressure Plate
Fig. 192 Pressure Plate Installed
Fig. 193 Install Flat Snap Ring
Fig. 194 Check OD Clutch Pack Clearance
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 119
DISASSEMBLY AND ASSEMBLY (Continued)

The overdrive (OD) clutch pack clearance is
1.07 to 2.44 mm (.042 to .096 inch).If not within
specifications, the clutch is not assembled properly.
There is no adjustment for the OD clutch clearance.
Fig. 195 Install Reverse Clutch Pack
Fig. 196 Install Reaction Plate
Fig. 197 Install Reverse Clutch Snap Ring
Fig. 198 Seating Snap Ring to Determine Reverse
Clutch Clearance
Fig. 199 Check Reverse Clutch Pack Clearance
21 - 120 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

The reverse clutch pack clearance is 0.76 to
1.24 mm (.030 to .049 inch).Select the proper
reverse clutch snap ring to achieve specifications:
All clutch clearances in the input clutch retainer
have now been checked and approved.
To complete the assembly of the input clutch
retainer, the reverse clutch and the overdrive clutch
must be removed from the retainer.
CAUTION: Do not intermix clutch parts. Keep in
exact same order.
Now proceed with the next phase of the assembly:
REVERSE CLUTCH SNAP RING CHART
Fig. 200 Install No. 2 Needle Bearing
Fig. 201 Install Underdrive Shaft Assembly
Fig. 202 Install No. 3 Thrust Washer
Fig. 203 Install No. 3 Thrust Plate
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 121
DISASSEMBLY AND ASSEMBLY (Continued)

Reinstall overdrive clutch and reverse clutch as
shown.Rechecking these clutch clearances is
not necessary, as they were set and approved
previously.
TRANSAXLE ASSEMBLE
To assemble the transaxle centerline, refer to the
following procedures.
Fig. 204 Install Overdrive Shaft Assembly
Fig. 205 Input Clutch Assembly
Fig. 206 Install Both Output Bearing Cups
Fig. 207 Install Piston Retainer Gasket
Fig. 208 Install Piston Retainer
21 - 122 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)